Maintenance Lubrication Points MaintenanceSchedule (NormalConditions) MaintenanceSchedule (SevereGonditions)

............4-z ......4-4 ......4-6

LubricationPoints Forthe detailsof lubricationpointsand type of lubricantsto be applied,referto the illustratedindexand variouswork Drocedure(suchas Assembly/Reassembly, Replacement, Overhaul,Installation. etc.)containedin eachsection,

No.

LUBRICAnON POINTS

1

E^g,ne

2

Transmission

LUBRICANT API ServiceGrade:UseSJ "EnergyConserving"or SH "EnergyConservingll" gradeoil, The oil containermay alsodisplaythe API Certification mark shownbelow.Makesure it savs"For Gasoline " Engines. SAEViscositv:Seechartbelow.

Manual

HondaGenuineMTF*1

Automatic

GenuineHondaPremiumFormulaAutomatic TransmissionFluid(ATF)*,

Brakeline (lncludesAnti-lockbrakeline)

GenuineHondaDOT3BrakeFluid13

Clutchline

GenuineHondaDOT3BrakeFluid*3 Steering greaseP/N 08733- 8070E

Powersteeringgearbox 1 8 o

10 11

14

Release fork lManualtransmission) Throttlewire end (Dashboardlower oanelhole) Cruisecontrolactuatorwire end (Dashboardlower Danelhole) Throttlecableend (Throttlelink) Cruisecontrolactuatorcableend (Actuatorlink) Brakemastercvlinderoushrod Clutchmastercylinderpushrod Batteryterminals Fuelfill lid

Sup€rHighTemp UreaGrease(P/N08798- 9002) Siliconegrease

Multi-purposegrease

L

17 18

Engin6hood hingesand enginehood latch Hatchhinges8od latchor trunk hingesand latch Door hjnges,upperand lower Door ooen detent

HondaWhite LithiumGrease

to

19

Rearb.akecalipers

Siliconegrease

20

Power steeringsystem

21

Ai|'conditioningcompressor

GenuineHondaPowerSteeringFluid-Vor S*. - PR7- A01AHor Refrigerant oii ND-O|L8{P/N38897 38899-PR7-A01) (ForRefrigerant: (R-134a)) HFC-134a

API SERVICELABEL

r (

(

API CERTIFICATION SEAL

Recommended engineoil Engin€oil viscositylor ambrentlemperatureranges

*1: Always use GenuineHonda ManualTransmissionFluid (MTF). Using motor oil can causestiffershifting becauseit does not containthe properaddtuves. *2: Always use GenuineHondaPremiumFormulaAutomaticTransmissionFluid(ATF). Usinga non-HondaATF can affect shift quality. *3: Always use GenuineHondaDOT3 B.akeFluid,Usinga non-Hondabrakefluid can causecorrosionand decreasethe life of the system. '4: Always use GenuineHondaPower SteeringFluid-Vor S. Using any other type of power steeringfluid or automatic transmissionfluid can causeincreasev,/earand poor steeringin cold weather.

4-2

{

at at

@

@ @

@

I

qfl-j__,n til

* \-_-.-

il/

.

_

NOTE: Lubricateall hinges.latches,and locksonce a year. ln corrosiveareas,more frequent lubricationis necessary. We recommendHondaWhiteLithiumGrease.

4-3 )

Maintenance Schedule(NormalConditions) : z

o_4 o ; g

9+

- N N

E

^

€

E .

E

3 3 e

: !

+? F o ts3A ;

F

o z

'6

! .:

1:A o.:;

.! i

I

-

6q:

'-Eg

E'?

. ! ;

- 9 ?

.9

i d E-vi: E.a.E.X;

He8 I

.E

!2

I

z.;

::e-3:3

22

i "2.:!

s-

I

! 53i.8 3

-'E

X : ! : o a

6-

zl2

- . 9 .9 .9 g E ;

a

69 or-66

a

a

a

a

S

=6:s' .9{F:.e{

;.3::lFi

: 9

E

-o

E"r

. EF , i *

a g

g E

6 : i

I

i i 9

:

;

-g o, b

E ;;

E>

iE

6 !

:';

(9-

56i t

:..j

e

ijq

E =*i

9 9 9 0 9

Ei E:5

.9

o !

s3

i a

a

a

a

E

a a

a

a

a

a

a

E

a

a

a

o a 3 a

E

= ;

:;9.no

a

a o

E

.: ;

9 :

'6

.9

E

n ! v== :.=

jco*;;

! 3 6 6mcoco5r o-

.9

srE

r5: r =

$

gESggE ' E @ ? . ^ . E*o 6P ;o c ng56E.9; :

>

z0

;+:: oo,:F.g

;; fi i s g .g

E q

o :

65S

; 6 * ^ o - F

tr

;:E

r E:; si PElcd,)

€"jo

E P

a

a

a E

a

a

O

a

a

a

a

a

a

a

a

a

a

a

a

a

a

E

a

a

a

a

a .9

6

u ;i-.i - - t > I

(4l--

E

..:

E

E . ;

'6

ri 3 6

= E -9

;

,E -!

dt 3

4-4

E

.E

.E

3 l

:

a

.5

z

; a

i ;

i

!

!

E .9

p

.

.g ! 2

9 b

g x

EE \. p,E6 >

t

a ' 6 q

z

9. )i

gET

3Pj

E;* .9 ;

o i " t S

; : E '

9

' ; -

_ !

'o

i . 3 ;i .9

o o)e

d)

9 q )

9 3

h

! R

o ' ; j

!6

,E-.

.:' ; g

F

s ?c E * Y*

o z

; o

t t x d i ;

E : :

g* r ! E

g o 9 c

'

a

o

6 ( J ;

* !

o

:

i E

z

Eo o'o orE

ti o) o

a

':

!,

c

a

. E l

o

a

c3

,9

o

+ c

;

a

o . E

!

a

er

g

. ! ;

z

{ E i'E

" =

l;;

I

;93= E . EE -

H i H ; i P i :

;

N

lp i

{- E;656 e ;

! !

o E i E

a o

t

G= : ;

E

;

E

.E

€:

a

sa

z

;:9 E 3

.9 I

p {

E :

E

E

b :

'6

q 3 i 6 6 3

tr

': o

-

E

!E; i H : . !

igE

:

,?

4-5

MaintenanceSchedule(SevereConditions)

t z

9Err

o @ 9

p F"
f

=

E E -

F

o z

;;!;;

= . q

,: o

ta

HeB

Ee

c

!

4

: t s

Fbieci

EE6

!

5

a

(

J

5

E

^t

.

9

5

tr:. z0

9P9:

;+ I =P

d i- . : ;

;

P E ct

o

*

-;.

o !

o ti

* 0 3 i : b i :€ x -i:

- ;

I i o

S q F o

o c

; : ;

I

o E o

E

t j *

* 9

1 : - ; - -

l:i5i;

3 3 X < o - : l 1 EI F E

565. i

(9

i

A

t >
= ';

a

.2

a a

=

E

a

.z

a

E

z

o E E

a

a a

a

a

a

:

a

E

a

=

sE 6

o

a

a

o

-

o

a a a

>

a

o

I

a r

i

be

6

E

5

! c

o u

E

EF:€;

o

@ e e a .

p ; 6 d t

4-6

q 3

6

a o l l

g 6

€ : ; 9 5

:E

.gFE

2 9 o : =

q : .

3

a

-9 .E

E

p

;

?€

;E

. s a ; . ? 1 6 d E ;;- |

; d |

u

- ?6 a ; ' 1

E ( / )

-90

6

9

E

E E

!

.i

o

.9

t

.a_

i b

a

o

5iT

F

t6 s E d:

:

z

, i oc

z P

3

E

l f , f

I

o a

:

g: H i ! 5 8 3 ; ; oe 5:! : E r::::= &6 E g ; ; z l ! ; 9 ! l & :e ee i tt6--;-.+ l - e aE q . i ;;;:3 IEZZ'-E EE .EE IHi:R,E E EEFEE F r t : . i i ,9 .p ;ii:aF : E

E

TE,

-ei E

xd'5

6,; q,o

!,t

a:P 9 8 3a--

.i; F

F

g

a

H€g 5 a

'a

E

E

e E; €t g

E

. : P P E ; P

sd; !i:E*::

6

9 F

.z o

.9 @

- = t f , c = !

o q q u J F o

u ! . 9 ; . . . . . < t Y

t h

!!$

z a

4-7

r a Engine E n g i n eR e m o v a l / l n s t a l l a t i o. .n. . . . . . . . . . .5 - 1 C y l i n d eH r e a d / V a l vTer a i n . . . . . . . . . . . . . 6 . .- 1 E n g i n eB l o c k. . . . . . . . . ........7-1 E n g i n eL u b r i c a t i o n .........8-1 I n t a k eM a n i f o l d / E x h a u S s ty s t e m . . . . . . 9 - 1 . . . . . . .1 0 - 1 Cooling

\-a EngineRemoval/lnstallation Tools.......... ...........5-2 Speciaf ................ EngineRemovaUlnstallation 5-3 Mount/Bracket Torque ....5-17

)

SpecialTools

Rel.No. I

o

Tool Number 07MAC- SL00200

Description BallJoint Remover,28 mm

Oty ,l

I

PageReterence 5 10

L

EngineRemoval/lnstallation 2.

Removethe strut brace.

Make sure iacks and safety stands ate placed plopelly and hoist brackets are attached to the correct positionson the engine{see section 11, Makesurethe car will not rollolt standsand latl while you are wgrking under it.

8 x 1.25mm 24 N.m {2.4 kgf.m, 17 tbf.tt)

CAUTION: . Use fender covers to avoid damaging painted surfaces. Unplugthe wiring connectorscarelullywhile holding the couplerand the connectorportionto avoid d8mage. Mark all wiring and hosesto avoid misconnection. Also. be sure that they do not contact other wiring or hoses,or intedere with other parts. NOTE:Anti-theftradioshavea codedtheft protectioncircuit.Be sureto get the customer'scodenumberbetore - Disconnecting the battery. - R e m o v i n gt h e N o . 3 2 ( 7 . 5A ) f u s e f r o m t h e u n d e r hood fuse/relaybox. Removingthe radio After service,reconnectpower to the radio and turn it on. When the word "CODE"is displayed,enterthe cus tomer's5-digitcodeto restoreradiooperation. 1.

Removethe hood (seesection20).

STRUTBRACE

3.

Disconnectthe batterynegativeterminalfirst, then t h e p o s i t i v et e r m i n a l . Disconnectthe batterycablesIrom the under-hood Iuse/relaybox and under hood ABS {use/relaybox.

BAITERY CABLES

6x1.0mm 9.8 N.'4 (1.0 kgf.m, 7.2 rbf.ft)

(cont'dl

5-3

Engine Removal/l nstallation (cont'dl R e m o v et h e i n t a k ea i r d u c t , a i r c l e a n e rh o u s i n g assemblyand the bracket.

7.

Removethe brake boostervacuum hose,evaporative emission(EVAP)controlcanisterhose and tuel returnhose(818C5engine).

6 r 't.0 mm 9.8 N.m (1.0 kgt.m,7.2 lbf.ft)

R e m o v et h e e v a p o r a t i v e m i s s i o n{ E V A P c) o n t r o l c a n i s t ehr o s e( B1 8 B 1B , ' 1 8 Ce1n g ; n e s ) .

Removethe enginewire harnessconnectorson the right side of enginecompartment.

6 x 1.0 mm 9 . 8 N . m l 1 . Ok g l . m ,

\

5-4

EngineRamoval/lnstallation (cont'dl 13. Removethe enginewire harnessconnectors,terminal and clampson the left side ot enginecompanmenr,

6 x 1.0 mm 9.8 N.m 11.0 kgl.m, 7.2 tbt.ttl

1 5 . Removethe enginegroundcableat the body end. to.

l.

Removethe adjustingbolt and mountingbolts,then r e m o v et h e p o w e r s t e e r i n g( P / S )p u m p b e l t a n d pump. . Do not disconnectthe P/Shoses.

I I

MOUNTING BOLTS I x 1.25mm 24 N.m 12.4 kgt'm, 17 lbl.ft)

14. Removethe cruisecontrolactuator.

't7. Loosen the

idler pulley bolt and adjusting bolt, then remove the air conditioning (Ay'C)compressor belt.

I x 1.25mm 24 N.m 12.4 kgt.m, 17 tbt.ft)

IDLERPULLEYBOLT 10 x 1.25mm /14 N'm 14.5 kgf.m, 33 lbt'frl

A/C COMPRESSOREELT

\

5-6

EngineRemoval/lnstallation (cont'd) 26. Removethe upperand lower radiatorhosesand the heaterhoses.

27. lAutomatic transmission)Removethe ATF cooler hoses.

81881,B18C5engines: UPPERRADIATOR

..f.

c

,1 i r

HOSES

LOWCRRADIATOR HOSE

24. Removethe radiatorassembly(seepage10-5). HEATER HOSE

29. Removethe A,/Ccompressor. . Do not disconnectAy'Choses.

HEATER HOSE LOWERRADIATOR HOSE ,

5-8

UPPER RADIAToR HOSE

8 x 1.25mm 24 N.rn 12.4 kgl.m, 17 lbf.ft)

t

7

30. D i s c o n n e ctth e p r i m a r yh e a t e do x y g e n s e n s o r ( P r i m a r yH O 2 S )c o n n e c t o rt,h e n r e m o v ee x h a u s t pipeA.

31. Remove the shift rod and extension rod {Mff).

PRIMARY HO2S

818C1engine:

8 x 1.25mm 22 N'm 12.2 kgl.m, '16 lbt.ttl

SHIFTROD

8 x 1.25mm 24 N.m 12.4 kgl.m. t7 rbt.ftt Replace.

GASKET Replace.

RETAINER

Replace.

SELF-LOCKING I{UT 8 r 1.25mm 1 6 N . m ( 1. 6 k g f. m , 12 tbt.frt Beplace.

EXHAUST PIPEA NUT 10 x 1.25mm 54 N.m {5.5 kgt'.n, tlo lbt.ft} Replace.

32. Remove the shift cable (A,/T).

I x 1.25mm 22 N-l'. 12.2 kgl.m, 16 lbf.frl

81881,818C5engines:

SHIFT CABLE

PRIMARY HO25 CONNECTOF 8 x 1.25mm 24 N.m (2.4 kgt.m, 17 lbf.frl Replace.

GASKET Replace.

CONTROL LEVER

GASKET Replace. NUT S€LF.LOCKING 8 x 1.25mm 16 N.m (1.6kgf'm, 12 tbt.fr) Replace.

f{UT 10 x 1.25 mm 54 N.m {5.5 kgf'm, 40 lbf.ftl Replace.

SHIFT CABLE COVER LOCK WASHER

6 x 'l.O mm 14 N.m {1.4 kgf.m, 10 lbt.ft}

{cont'd)

5-9

EngineRemoval/lnstallation (cont'dl Removethe damper{ork. 34. D i s c o n n e ctth e s u s p e n s i o nl o w e r a r m b a l l j o i n t s '18 u s i n gt h e s p e c i a tl o o l . R e f e rt o s e c t i o n f o r t h e properprocedure. N O T E :A d j u s tt h e t o o l s o t h e j a w s a r e p a r a l l etl o eachother.

35. Removethe driveshafts. CAUTION: . Do not pull on the driveshaft,the CV joint may come aoart. . Use care when prying out the assembly. Pull it straight to avoid damaging the differential oil seal or intermediate shaft dust seal. N O T E :C o a t a l l p r e c i s i o nI i n i s h e ds u r f a c e sw i t h c l e a ne n o i n eo i l .

DRIVESHAFT

/.-:

/

,{:

12 x 1.25mm

\

5-jl0

EngineRemoval/lnstallation (cont'dl Enginelnstallation Installtheenginein the reverseorderof removal R e i n s t a l lt h e m o u n t b o l t s / n u t si n t h e f o l l o w i n g sequence.Failureto follow theseproceduresmay cause excessivenoiseand vibration,and reducebushinglife

2.

I n s t a l tl h e e n g i n es i d e m o u n t , t h e n t i g h t e n t h e bolvnutson the engtneside.Leavethe mount bolt toose. 1 0 x 1 . 2 5m m 52 N.m 15.3 kgf.m, 38 tbf.ft, Replace.

1 . 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 , t h e n t i g h t e n t h e bolvnutson the tfansmlssionside.Leavethe mount bolt loose. AIT: ' 1 2x 1 . 2 5 m m g N.m (6.5 kgl'm. 47 thl.ftl

o

/

llf

3,

Tightenthe mount bolt on the transmissionmount.

AIf l MOUNT EOLT

L 1 2 x 1 . 2 5m m 64 N.m {6.5 kgf.m, 47 lbf.fr|

12 x 1.25mm 74 N.m 17.5 kgl.m, 54 rbf.ftl

M/T:

I

1 2 x 1 . 2 5m m 74 N.m (7.5 kgl.m, 54 rbf.ftl

I

5- 1 4

\

{

EngineRemoval/lnstallation {cont'dl 7.

Installthe left front mount,then tightenthe bolts in the numberedsequenceshown (O - @).

.

C h e c kt h a t t h e s p r i n g c l i p o n t h e e n d o f e a c h driveshaftclicksinto place.

CAUTION: Use new spring clips. . ' 1 . 2 5m m O t2 x 83 N.m 18.5kgt.m,61 lbl.ft) Fleplace.

. . . .

@ 12 x 1.25mm 59 N.m 16.0 kgf.m, 43 lbf.frl Replace.

O 1 0 x 1 . 2 5m m

il4 N.m 14.5 kgt'm,33 lbt.ft)

,5-16

!

Bleed air {rom the cooling system at the heater valveopen (seepage10-6). Adjustthe throttlecable(seesection11). Checkthe clutchpedalfreeplay (seesection12). C h e c kt h a t t h e t r a n s m i s s i o ns h i f t s i n t o g e a r smoothlY. Adjust the tension of the following drive belts. Alternatorbelt {seesection23). P/Spump belt (seesection171. A/CcomDressor belt (seesection22). Inspectfor tuel leakage(seesection1ll. . After assemblingfuel line parts,turn on the ignitionswitch (do not operatethe staner)so that the fuel pump operatesfor approximately t w o s e c o n d sa n d t h e f u e l l i n e p r e s s u r i z e s . Repeatthis operationtwo or three times and checkfor tuel leakageat any point in the {uel line.

I Mount/BracketTorque (cont'dl ( 818C5engine: ALTERNATORBRACKET

REARSTIFFENER

1 0 r 1 . 2 5m m

--q;;/44N'mtr.5kst'm'

v=ahp /

12 x 1.25mm 57 N.m {5.8 kgf.m, 42 tbt'trt

w# q7 24 N.m 12.4 kgl.m, 17 rbf'ftt

t: ltri rH {ir \

I

10 x 1.25mm 54 N.m 15.5 kgf.m. 40 rbt.frl

P/S PUMP BRACKET 10x 1.25mm

;

/r/rN.m {4.5 kgf.m, 33 lbtftl

FRONTSTIFFENER A/C COMPRESSORBRACKET

HEAr

6\---

d'1N

^rNsuLAroR

I "--H Gh\ \

sxrlomm

*o-r$l/ v

12 N.m 11.2kgf.m. 8.7 tbf.ftt I x'1.25mm 24 N.m (2.4 kgf'm, 17 rbf.ft)

12 x 1.25mm 57 N.m 15.8kgt.m, 42 lbf.ftt

ValveClearance Adjustment

r.lJ

NOTE: . V a l v e ss h o u l db e a d j u s t e dc o l d ; a t a c y l i n d e rh e a d temperatureof lessthan 100'F(38"C). Adjustmentis the same for both intakeand exhaust valves. . After adjusting,retorquethe crankshaftpulleybolt to 177N.m (18.0kgf.m,130lbf'ft).

2.

1.

Number1 pistonat TDC:

Removecylinderheadcover.

Set the No. 1 piston at top dead center(TDC)(see p a g e6 - 1 2 ) ". U P " m a r k o n t h e p u l l e ys h o u l db e a t the top, and the TDC grooveson the pulley should align with the TDCgroove on timing belt back cover.TDC mark (paintedwhite) on the crankshaft pulley should align with pointeron the timing belt lower cover.

ADJUSTINGSCREWLOCATIONS:

"UP" MARKS

TDCGBOOVES

( EXHAUST

POINTERON LOWER

TDC MAFK (P.inted whh.l

(cont'd)

6-3

ValveClearance Adjustment (cont'dl Adjustvalveclearances on No. 1 cylinder.

7.

Intske: 0.08- 0.12mm (0.003- 0.005inl Exhaust:0.15- 0.20mm (0.006- 0.008inl L o o s e nt h e l o c k n u ta n d t u r n t h e a d j u s t i n gs c r e w until feelergaugeslidesbackand forth with a slight amountof drag.

R o t a t et h e c r a n k s h a f t1 8 0 ' c o u n t e r c l o c k w i s teo bring No. 4 piston to TDC.The "UP" mark should be pointing straightdown. Adjust valveson No. 4 cylinder.

Number 4 piston at TDC:

LOCKNUT9x0.75mm 25 N.m {2.5kgl.m,18lbtft}

"UP" MARKS

Tightenthe locknutand recheckclearanceagain, Repeatadjustmentif necessary. R o t a t et h e c r a n k s h a f t1 8 0 ' c o u n t e r c l o c k w i s e (camshaftpulleyturns 90'). The "UP" mark should be on the exhaustside.Adjustvalveson No,3 cylinder. Number 3 Diston at TDC:

8.

R o t a t et h e c r a n k s h a f t1 8 0 ' c o u n t e r c l o c k w i s teo bring No. 2 piston to TDC.The "UP" mark should be on the intakeside.Adjustvalveson No. 2 cylinder.

Number 2 piston at TDC:

"UP" MARKS

"UP" MARKS

NOTE: Refer to page 6-31 when installing cylinder head cover.

Valve Seals Replacement(cylinderhead removal not required) The procedureshown below applieswhen usingthe inc a r v a l v e s p r i n g c o m p r e s s o r( S n a p - o nY A 8 8 4 5w i t h Y AAA45-2A 1/8" attachment).

8. Selectthe 7/8 in. diameterlong compressorattachment and fastenthe attachmentto the No. 4 hole of the leverarm with the speedpin supplied.

When using this tool, as with any tool, !@@ always use approved eye protection. Using the fight tool tor each job helps increase productivity while safeguardingtools, equipment and ihe user.

9 . Positionthe pistonat TDCand insen an air adaptor into the spark plug hole. Pump air into the cylinder to keepthe valveclosedwhile compressingsprings and removingthe valvekeepers.

Turn the crankshaftso that the No. 1 and the No. 4 pistonsare at top deadcenter(TDC).

1 0 . Positionthe lever arm under the crossshaft so the lever is perpendicular to the shaft and the compressor attachmentrests on top of the retainerfor the spring being compressed.Use the rear positionslot on the leveras shown.

Removethe cylinderheadcover. Removethe distributor.

N O T E :P u t s h o p t o w e l s o v e r t h e o i l p a s s a g e st o preventthe valve keepersfrom fallinginto the cylinderhead.

L o o s e na n d d i s c o n n e c t h e t i m i n q b e l t f r o m t h e camshaftoullevs. 5.

Removethe camshaftholderbolts,then removethe camshaftholders,the camshaftsand rockerarms.

OIL PASSAGE

Intake Valve Seals 6. Usingthe 6 mm bolts suppliedwith the tool, mount t h e t w o u p r i g h t st o t h e c y l i n d e rh e a d a t t h e e n d camshaftholders.The uprightsfit as shown. 7.

I n s e r t h e c r o s ss h a f tt h r o u g ht h e b o t t o m h o l e o f the two uprights.

OIL PASSAGES

(cont'd)

,'.itil

'6-b-' i,

TimingBelt

-1,

lllustrated lndex

NOTE: . Referto page6-12for positioningcrankshaftand pulleybeforeinstallingbelt. . Markthe directionof rotationon the beh beforeremoving. . Replacethe rubbersealsif there is oil leakagebetweenthe cylinderheadand cover. . Do not usethe middlecover and lower coverfor storingremoveditems. . Cleanthe middlecoverand lower coverbeforeinstallation. CAPNUT 6x1.0mm 9.8 N.m {'1.0kgi.m, 7.2 tbftll

WASHER Replacewhen damaged or deteriorated. CYLINDERHEADCOVER Referto page6-33when installing. RUBBERSEALS

TIMINGBELT page6 9 Inspection, Adjustment,page6 9 page6,10 Replacement,

B e p l a c ew h e n d a m a g e d or deteriorated,

8 x 1.25mm 37 N.m (3.8 kgf.m,27 lbf.ft) ADJUSTINGBOLT 10 x 1.25mm 54 N.m {5.5kgt.m, 40 lbf.ltl

BACKCOVER

MIDDLECOV€R 6x1.0mm 9.8 N.m {1.0kgf.m, 7.2lbl.ftl

!

LOWER COVER

6x 1.0mm 9.8 N.m 11.0kgl.m, 7.2lbf.ftl

CRANKSHAFT PULLEY Removeany oil and cleanthe timing belt guide plateside.

TIMINGBELT DRIVEPULLEY Removeany oil ano ctean. Installwith concave s u r f a c ef a c i n g o u t . Remove any oil and clean,

6x1.0mm '11N.m (1.1 kgf.m, 8.0 lbI.ft) SPEED

{cKF) ItEi:lufrroN

PULLEYEOLT 14 x 1.25mm 177 N.m (18.0kgf.m, 130 bnftl page6-8 Replacement,

NOTE:When installinga new crankshaftand/ornew bolt: O tightenthe crankshaftpulleybott to 196N.m (20.0kgf.m,145tbf.ft), @ loosenbolt, @ retightenit to 177N.m (18.0kgnm,130tbnft).

6-7

GrankshaftPulleyBolt Replacement NOTE: o Crankshaftpulleybolt sizeand torquevalue: ' 1 4x 1 . 2 5m m 1 7 7N . m( 1 8 . 0k g fm , 1 3 0l b t f t ) a When installinga new crankshaftand/or new pulley bolt:

W h e n i n s t a l l i n gt h e b o l t , l u b r i c a t et h e t h r e a d sa n d flangewith engineoil, but don't lubricatethe washer a n dD U l l e v .

O tightenthe pulley bolt to 196 N.m (20.0kgim, 145 lbf.ft), @ loosenthe bolt, o retightenit to 177N.m (18.0kgf.m,130lbift).

Don'tlubricatewasher.

PULLEYHOLDEBATTACHMENI, HEX50 mm, OFFSET OTMAB- PY3O1OA

SOCKET,19 mm 07JAA- @1020A COMMERCIALLY AVAILABLE

\-

TimingBelt

\-a

Inspection 1 . Removethe cylinderheadcover.

I

CAUTION: Always adiust iiming belt lension with the engin€ cold.

o Referto page6-33when installing. 2.

Inspectthe timing belt for cracksand oil or coolant soal(n9. NOTE: . Replacethe belt if oil or coolantsoaked. . Removeany oil or solventthat gets on the belt.

NOTE: . The tensioneris spring-loadedto apply proper tenafter makingthe followsion to the belt automatically ing adjustment. . Alwavs rotate the crankshaftcounterclockwisewhen viewed from the pulley side. Rotating it clockwise may result in improper adjustmentof the belt tenston.

1.

R e m o v et h e c y l i n d e rh e a d c o v e r . ( R e f e rt o p a g e 6-33when installing.)

2.

Setthe No. I pistonat TDC(seepage6-12). Rotatethe crankshaftfive to six revolutionsto set the belt. Setthe No. 1 pistonat TDC.

I ADJUSTINGBOLT 54 N.m (5.5kgf.m,

{0 rbr.ftt

Foradjustmentonly, do not remove,

Direction of rotation.

Rotatepulley and inspectbelt.

Loosenthe adjustingbolt 1/2turn (180')only. 3-teethon Rotatethe crankshaftcounterclockwiFe the camshaftpulley After inspecting.retorquethe crankshaftpulley bolt to 177N'm (18.0kgf.m,130lbnft).

7.

Tightenthe adjustingbolt to the qdebifiedtorque.

8.

After adjusting.retorquethe crankshaftpulley bolt to 177N.m {18.0kgf.m,130lbf.ftl.

{

.

6-9

GylinderHead lllustrated Index (cont'd) {

CAUTION: When handling a mstal ga€kot,take care not to fold it o. damagethe contact surfac6 ol the gasket.

VALVEKEEPERS

\ SPRTNG

[\

RETaTNER\_>6

VALVEKEEP€NS I /l / |

/\

EXHAUSTVAL SPRING EXHAUSTVALVE-----------rg SIEM SEAL

,@

VALVESPRING SEAT

CYLINDERIIEAO AOLT 1 1x ' 1 . 5m m 85 N.m (8.7 kgtm, 63 lbf.ft) Apply engineoilto the threads.

ENO PIVOTBOLT 63 N.m {6.4 kgf.m, 46 tbt.ftl

{e

SPRINGAEIAINER

s------.--INTAKEVALVESPRING

r

€.-=---

INTAKEVALVESTEMSEAL VALVESPRINGSEAT

€

M.DULE rRANsMrssroN coNTRoL rrcMr

-fu

I

=.

= g

J:*

f-

r r p p rl o + r l o l r u

lrrpn

I

tflt ti]t lrrezlerer

ASSEMBTY GAUGE AiT GEARPOSITION INOICATOR

LTGRN/BLK GRNI/VHT GRN/RED GRN

GBN/BI"K GRN/8LU

F-

GRN/BLU

GRN/YET

l---

GRN/YEL

LTGRN,M/HT

l--

NoTE: I

:To5v

T

t"TGRN,aWHT

: 1 o1 2 v

\,

14-46

'v

'.J

THROTTLE ENGINE rcsm0N COOLANT SENSOR TEMPERATURE SENSOR BLK/RED WHT/BLK 424

OBN

820

84

VREF IATCHKIBASOSS IAFSAIAFSB IFAS

----T;-

t-T-*

l+

J

REO/BLK

|

*

r--rr!\.1

J

ISCS

+.. |.i{-'1M-l +..,L-{-lr^/t-lt't'/!-? I + ,+

l/vt-l \

:

-r!\./

lt =t Et = l tt ?n NMSG INC

MAINSHAFI SPEED SENSOR

: rartsurssrot coNTFoL M'DULE tTcMr

\

r'

t= I N C S G I S HA

I S HB

-rr I L CA

I L CB

COUNTERSHAFI SPfEDSENSOR

CONTROL I SHIFT

-UP CONTBOL I LOCK

+135Eil,?1o'uo'u' 4i85El,o''P'uo'u' TCMT6nninallocations

J

5

15 16 17

,/1,/

TCM-A (26P1 Connector

7 20

6

I

10 11 1 2 25

5

12

14

,/1,/ 1 7

7

8

I

1 9 20

10

,/1,/

TCM-B l22P)Conn€ctor

14-47

TCM Terminal Voltage/MeasuringConditions TCM TerminalLocations

5

2 11

6

,/l/

7

8

9

20

'10

11

24

26

Signal

11

20

10

,/1,/

Description

MeasuringConditions/T€rminalVoltag€

In 1stand 2nd gear in E anOE positionsand E position: Battery voltage ln E position,3rdand 4th gear in E anOE p o s i t i o n s :V 0

SHA

Shift controlsolenoidvalveA control

In E, E positions,2ndand 3rd gear in E and E positions: Batteryjloltage In lst gear in !d and -qtlpositonsand 4th gear i n E o o s i t i o n0 :V

Not used

NE

Enginespeedsignalinput

When engineis rotating:Pulsingsignal

ATPl

A,/Tgear position switch E positioninput

In L!-lposition: 0 V In other than I position: Batteryvoltage

A7

ATP2

Ay'Tgear position switch E positioninput

I n 1 3 p o s i t i o n : 0V In other than E position: Batteryvoltage

A8

ATPD3

In E position:0V In otherthan @ position:Batteryvoltage

A9

ATP D4

A,/Tgear position switch E positioninput A,/Tgear position switch E positioninput

410

ATP PN

411

ATP R

A,/Tgear position switch E and E positionsinput A/T gear position switch E positioninput

InEorEpositions:OV In otherthanE or N position:Batteryvottage l n E p o s i t i o no :V ln otherthanE position: 8atteryvoltage

412

tGl

Power supply system

With ignitionswitchON (lll: Batteryvoltage

413

LG1

Ground

A5

I

,/l/

I

Shift controlsolenoidvalveB control

A4

I

14

I

SHB A2

l

1

5

Not used

A'I

I

12

3

B (22PlConnector

A l26Pl Connector

T6rminal Number

2

13

A14

InEposition;0V In other than El position: Batteryvoltage

Not used

A15

LCB

Lock-up control solenoid valve B control

Duringhall and full lock-upand duringdeceleration:Batteryvoltage V D u r i n gn o l o c k - u p : 0

A16

LCA

Lock-upcontrolsolenoidvalveA control

When lock-upis ON; Batteryvoltage With no lock-up:0 V

417

D4 IND

D4 Indicator light control

A18

Not used

A19

Not used

420

AT CHK

421 422

423

14-44

Upshifvdownshift comparative signaloutput

When ignitionswitchis first turnedON (ll): Batteryvoltage for two seconds In E position:Batteryvoltsge

With ignitionswitchON (ll):Pulsingsignal

Not used ILU

VBU

Interlockcontrol

Back-uppower system

When ignitionswitchis ON (ll),brakepedal deoressedand accelerator oedalreleased: Batteryvoltage Always Batteryvoltage

\/

Terminal Number

Signal

Description

424

ACCL

Air conditioning(Ay'C) clutchrelay control

With A,/CcomDressorON: 0 V With Ay'CcompressorOFF:Battery voltage

A25

tG1

Power supply system

With ignitionswitchON (ll)r12 V

426

LG1

Ground

B1

MaasuringConditlons/TarminalVoliage

Not used

82

BAROSS

Barometricpressuresensorsignal input

With ignitionswitchON (ll) and dependingon barometricpressure:Approx.3 V

B3

ECT

Enginecoolanttemperaturesensor signalinput

B4

TPS

Throttlepositionsensorsignal input

With ignitionswitchON (ll)and dependingon enginecoolanttemperature:Approx.0.1- 4.8V With ignitionswitchON (ll) 8nd throttlefully open:4.14- 4.82V With ignitionswitchON (ll) and throttlefully closed:0.44- 0.56V

B5

VSS

Vehiclespeedsensorsignalinput

With ignitionswitchON (ll) and front wheels rotating;Pulsingsignal

B6

AFSB

Upshifvdownshiftcomparative signaloutput

With engineidling:0 V At uDshiftor downshift: 5 V for an instant

B7

AFSA

Upshifvdownshiftcom parative srgnaloutput

With engineidling:0 V At upshiftor downshift:5 V for an instant

NCSG

Countershaft speedsensorsignal ground

Always: 0 V

B9

NC

Countershaft speedsensorsignal Input

Dependingon vehiclespeed:Pulsingsignal Whenvehicleis stopped:0V

B10

NM

Mainshaftspeedsensorsignal input

Dependingon vehiclespeed:Pulsingsignal When vehicle is stoDoed:0 V

B8

811 812

Not used

STOPSW

813 814

Brakeswitchsignalinput

Not used

scs

Timing adjustment servicechecksignal

815

Not used

816

Not used

817

NMSG

818

Mainshaftspeedsensorsignal ground

With ignitionswitchON (ll) and servicecheck connectoroDen:5V With ignitionswitchON (ll) and servicecheck connectorconnectedwith specialtool: 0 V

Always: 0 V

Not used

819

FAS

820

VBEF

82'l

With ignitionswitchON {ll) and b.akepedal depressed:Batteryvoltage With ignitionswitchON (lll and brakepedal released:0V

Shift acknowledgeinput

With engineidling:5 V At upshiftor downshift:0 V for an instant

+5 V reference

With ignitionswitchON {lll: Approx.5 V

Not used Not used

14-49

TroubleshootingProcedures

uJ trr

Checkingthe DiagnosticTrouble Code (DTC) with an OBD ll Scan Tool or th€ Honda PGM Tester When the TCM sensesan abnormalityin the input or output systems,the lD,]indicatorlight in the gauge assemblywill blink.When the 16p DataLinkConnector(DLC)(locatedunderthe dash on the passengerside)is connectedto the OBD ll (DTC)when ScanTool or HondaPGMTasteras shown,the scantool or testerwill indicatethe DiagnosticTroubleCode the ignitionswitchis turnedON {ll}. Whenthe !r indicatorlight has been reportedon, connectthe OBD ll ScanTool confirmingto SAEJ1978or HondaPGM Testerto the DLC(16P)behindthe ashtray.Turn the ignitionswitchON (ll) and observethe DTCon the screenofthe OBD ll Scan Tool or Honda PGM Tester.After determiningthe DTC,refer to the electricalsystem Symptom-to-Component Charton pages14-54and 14-55. NOTE:SeetheOBDll ScanToolorHonda PGMTesteruser'smanualfor specificinstructions.

(16P) DATALINKCONNECTOR

I

il

lt

ai

ulu

OBD-IlSCAN TOOL or HONDA PGM TESTER

Some PGM-Flproblemswill also makethe lol indicatorlight come on. After repairingthe PGM-Flsystem.disconnectthe BACKUp fuse (7.5A) in the under-hoodfuse/relaybox for more than 10 secondsto resetthe TCM memory,then recheck. the BACKUP fuse also cancelsthe radio anti-theftcode, presetstationsand the clocksetting.Get NOTE:Disconnecting the customer'scode number,and makenoteof the radiopresetsbeforeremovingthe fuse so you can resetthem

14-50 L

rJq

L . /

Checkingth€ DiagnosticTrouble Codo (DTC) with the Sowica CheckConnectorand SpecialTool When the TCM sensesan abnormalityin the input or output systems,the [D;lindicatorlight in the gaugeassemblywill blink. When the ServiceCheckConnector(locatedunderthe dash on the passengerside) is connectedwith the specialtool as shown,the E1Tindicatorlight will indicate(blink)the DiagnosticTroubteCode(DTC)when the ignitionswitchis turnedON { }. Whenthe @ indicatorlight has beenreportedon, connectthe ServiceCheckConnectorwith the specialtoot. GAUGEASSEMEI.Y

\

- F ;

ii^r

\) ,J Thenturn ON (ll)the ignitionswitchand observethe E indicatorlight. Codes1 through9 are indicatedby individualshort blinks.Codes1Oand aboveare indicatedby a seriesof long and short blinks.One long blink equals10 short blinks.Add the long and short blinkstogetherto determinethe code.After determiningthe code,referto the electricalsystemSymptom-to-Component Charton pages14-S4and 55. Short blink loncsl

Se. OTCI

Soo DTC2 Long blink

Short blinb lfive timcsl

Soe DTCl5

Some PGM-FIproblemswill also makethe E indicatorlight come on. After repairingthe PGM-FIsystem,dasconnect the BACKUP fuse No. 47 (7.5A) in the under-hoodtuse/relaybox for more than 1Osecondsto resetthe TCM memory,then recnecK.

\-/

\i,

NOTE; Disconnecting the BACKUP fuse alsocancelsthe radioanti-theftcode,presetstationsand the clocksetting(cont,d)

14-51

TroubleshootingProcedures (cont'd) \) l.Removethetwoc|ipssecuringthekickpane|,thenremovethe|eftsidekickpane|onthedriver,sside. 2. Removethe TCM,and turn it over.

3.

flowchanwith the specialtool and a digitalmultimeInspectthe circuiton the TCM accordingto the troubleshooting as shown. ler How to uss the Blckprobr Sat Connect the backprobeadapters to the st8cking patch cords, and connect the cord to a multimeter. Using the wire insulationas a guide for the contouredtip of the backprobeadapter,g€ntlyslidethe tip into the connectorfrom the wire until it comesin contactwith the terminalend oJthe wire.

(

SET BACKPROBE 07sAz- 001000A (tworequired) DIGITALMULTIMETER lcomm.rci.lly .v!ilablol KS-AHM-32-003, or oquivalont

ADAPTER

{

,

14-52

TCM Reset Procodure 1.

Turn the ignitionswitchOFF.

2.

Removethe No. 47 BACKUP fuse {7.8A) from the under-hoodfuse/relaybox for lO secondsto resetthe TCM.

NOTE: . Disconnecting the No, 47 BACKUP fuse alsocancelsthe radioanti-theftcode,presetstationsand clocksetting,Getthe customer's code number, and make note of the rsdio presetsbefore removing the fuse so you can resetthem. o The TCM memorycannotbe clearedby usingthe OBDll ScanTool or HondapGM Tester;be sureto removethe BACK UP fuse to resetthe TCM. BACKUP (7.5A) FUSE

J

UNDER.HOOD FUSE/RELAY BOX .

Final Procodurs

NOTE:This proceduremust be done afterany troubleshooting. 1.

Turnthe ignitionswitchOFF.

2.

Resetthe TCM.

3.

Disconnect the OBD ll ScanTool or HondaPGMTesterfrom the DataLinkConnector,or removethe sDecialtool from the ServiceCheckConnector.

4.

Turn the ignitionswitchON (ll),and set the radiopresetsand clocksetting.

14-53

Chart Symptom-to-ComPonent ElectricalSystem Diagnostic TroubleCode

(Drc)* P1153 (1)

,94 lndicator Light

B l i nk s

Symptom

Lock-upclutchdoes not engage, Lock-upclutchdoes not disengage. . Lock-upclutchdoes not engage.

P1758

t2l

Blinks

. Lock-upclutchdoesnot engage. P1790 (3)

Blinks . Lock-upclutchdoes not engage.

P1191 (4)

P1705 (5)

P1706 (6)

P0753 (71

P0758 (8)

Blinks

Blinks

OFF

Blinks

. Failsto shiftotherthan 2nd - 4th gears. . Lock-upclutchdoes not engage. ' Failsto shift otherthan 2nd 3rd - 4th gears. . Lock-upclutchdoes not engage.

. Failsto shift (between 1st - 4th or 2nd - 3rd gear only). . Failsto shift (stuckin 4th gear). . Failsto shift (stuckin 1stor 4th gears).

Blinks

Lock-upclutchdoes not engage. P0120 (9)

Blinks

. Lock-upclutchdoesnot engage, P1192

00) P0725 { 11 )

Blinks Lock-upclutchdoes not engage. OFF

PossibleCause

Referto Page

lock-upcontrolsolenoid Disconnected valveA connector Shortor open in lock-uPcontrol solenoidvalveA wire Faultylock-upcontrolsolenoidvalveA

14-56

lock-upcontrolsolenoid Disconnected valveB connector Shortor open in lock-uPcontrol solenoidvalveB wire Faultylock-upcontrolsolenoidvalveB

14-58

throttleposition(TP) Disconnected sensorconnector Shortor open in TP seflsorwire FaultyTP sensor

14-60

vehiclespeedsensor Disconnected {VSS}connector Shon or open in VSSwire FaultyVSS

14-61

. Shod in AvTgear positionswitchwire . Faulty A,/Tgear position switch A/T gear positionswitch Disconnected connector Openin A/f gear positionswitchwire FaultyA/f gear positionswitch

14-62

14-64

shiftcontrolsolenoid Disconnected valveA connector Shortor open in shiftcontrolsolenoid valveA wire Faultyshift controlsolenoidvalveA

14-66

shift controlsolenoid Disconnected valveB connector Shortor open in shift controlsolenoid valveB wire Faultyshift controlsolenoidvalveB

14-68

speedsencountershaft Disconnected sor connector speed Shortor open in countershaft sensorwrre speedsensor Faultycountershaft

1+10

enginecoolanttemperaDisconnected ture (ECT)sensorconnector Shortor open in ECTsensorwire FaultyECTsensor

14-72

ignitioncoil connector Disconnected Shortor open in ignitioncoil wire Faultyignitioncoil

14-73

(DTC)*:The DTCSin the parentheses are the codesthe E indicatorlight indicates{blinks)when the servicecheckconnector is connectedto the specialtool (SCSserviceconnector)

4-54

J

Diagnostic TroubleCode (DTC).

Ej lndicator Light

Symptom . No specificsymptom appears.

P1794 (131

Blinks

P1786 (14)

Blinks

. Transmission jerkshardwhen shifting.

PossibleCause . Shortor open in LT GRNwire between 82 terminaland ECM . Faultybarometricpressure(BARO) sensor NOTE:BAROsensoris built into ECM. Shortor open in FAS(YEL)wire between819 terminaland ECM FaultyECM Disconnected mainshaftspeedsensor connector Shortor open in mainshaftspeedsensor wrre Faultymainshaftspeedsenso.

. Lock-upclutchdoesnot engage,

J

P0715 (15)

Blinks

P0740 {n o n e ,

OFF

. Lock-upclutchdoes not engage.

Faulty lock-upcontrol system

P0730 In o n e ,

. Failsto shift (betweenlst - 2nd, 2nd - 3rd, 1st- 4th.3rd - 4th, 1st- 2nd - 3rd, 1st- 2nd - 4th, 1st- 3rd - 4th, or 2nd - 3rd - 4th gearsonry). . Failsto shift (stuckin 1stgears).

P0700 (none)

. Otherautomatictransmissionproblem(s) (s)accordingto problem Inspeclthe automatic transmission theDTC(s)indicated withcodem700.

Referto Page

't 4-7 4

14-76

14-74

14-80

. Faulty shift control system 14-81

(DTC)*:The DTCSin the parentheses are the codesthe E indicatorlight indicates(blinks)when the servicecnecKconnector is connectedwith the sDecialtool{SCSserviceconnector). NOTE:WhentheOBDll ScanTool orHonda PGMTesterindicatesthe DTC(S) for the automatictransmissioncontrolsystem, the scan tool or testeralso indicatescode P0700simultaneously. Code P0700meansdetectionof some automatic transmissionproblemon the PGM-Flcontrolsystem. lf the self-diagnostic E indicatorlight does not blink.performan inspectionaccordingto the table below. Symptom

Inspection

E indicatorlight does not come on for two secondsafter ignitionis firstturnedon (ll). (notblinking)whenevertheignitionis on {ll). E indicatorlightis on constantly Lock-upclutchdoes not haveduty operation(ON - OFF). Lock-upclutchdoes not engage. Shift levercannotbe movedfrom E positionwith the brakepedal oeDresseo.

J

R€f.page 14-42 14-84

CheckA,/Csignal with Ay'C on.

14-85

Checkbrakeswitchsignal.

14-86

NOTE: . lf a custombrdescribesthe symptomfor code P1706(6),P0725(11)or P0715(15),it will be necessaryto recreatethe symptomby test-driving, then recheckthe DTC, . Sometimesthe E indicatorlight and the MalfunctionIndicatorLamp (MlL)may come on simultaneously. lf so, check the PGM-Flsystemaccordingto the DTC,then resetthe memory by removingthe BACKUP fuse in the under-dash f u s e / r e l a y b o x f o r m o r e t h a n l 0 s e c o n d s .D r i v e t h e v e h i c l e f o r s e v e r a l m i n u t e s a t a s p e e d o v e r 3 0 m p h (50km/h).then recheckthe DTC. . Disconnecting the BACKUP fuse also cancelsthe radio anti-theftcode, presetstationsand the clock setting.Get the customer'scode number,and makenoteof the radiopresetsbeforeremovingthe fuseso you can resetthem.

14-55

ElectricalTroubleshooting

TroubleshootingFlowchart- Lock-upControlSolenoidValveA . OBD ll Scrn Tool indic|t.3 Cod. P17!i:t. . Self-Dirgnoii! E indic.tor light blinkr onco.

Po+tible Cauta ' Diaconnac'tad lock-upcontrol lolanoid valva A connac'toa . Shon or opan in lod(-up co|ltrol 3olonoidvalva A wire . Faulty lock-upcont?ollolanoid TCM CONNECTORS

M.Nur. VREFVoh.go: 't. Disconnectthe A (26P)and B ( 2 2P ) c o n n € c t o r sl r o m t h € TCM. 2. Turn tho ignitionswitchON (ll). 3. Nleasuretho voltage betwson the 820 and A13 or A26torminals.

lsthereapprox.5 V?

Raplir opan or 3hort in tha wi.a b.twa.n th. B20 t.lmin!l .nd th€ EcM.

WIRE SIOEOF FEMAI."ETERMINALS

Checktor a Short to Powa.i Measuretho voltag€ botwoenthe A16and A13 or A26terminals.

Rap!fu ahorl to Pow.t in tha wlra b!tw..n th. A16 t rmln.l rnd tho lock-up c!filtol lolaooid valvo A.

Moaaurc Lock-uP Contlol Solenoid Vrlvo A Be3bianco: 1. Ttrrn the ignition switch OFF. 2. Measure the rssistance betweenthe A16 and A13 or A26 terminals.

ls the rosistanco12- 25 O?

To page 14-57

\

14 -5 6

Chack tor loolc TCM conncctora. lf naca!3!ry, rub3tftuta a known' good rolcnold v.lva a$amblY ol TCM .nd r.ch.ck.

WIRE SIDE OF FEMA.E TEBMINAIS

L/

F.om page 14-56

TCMCONNECTOR A I26PI

Chack Lock-up Control Sol.nold V.lv. A tor . Short Circuit: 1. Disconnoctth€ 2P connoctor trom thg lock-uocontrol sole noid v6lv6 assembly. 2. Ch€ckfor continuity between the A'16and 413 or A26 tErmi nals.

Raprir ahori to grosnd in tha wira botwaan tha 416 tormin.l .nd th. lock-up control rol.noid Yalva A.

WIRESIDEOF FEMALETENMNALS

LOCK-UPCONTROL SOLENOIOCONNECIOR

Mqltura Lock-up Control Sol.noid Vrlv. A R.3i.t.nc. .t tha Solonoid Connactor: Msasurg th6 resistancebetween terminalNo. 2 otthe lock-upcontrol solonoid connectorand body grouno.

r

,

Itr-t-r1l -l*. I L____L__Fr I

@

ls the resistance12- 25 0?

Chack for opln In tha wira b.tw..n th. A16 tormin.l .nd th. lock-up control .ol.noid valva A,

+

TERMINALSIDEOF MALETERMINALS

Raplaca thc locl-up control rolanoid Yrlv. .3lambly.

14-57

ng ElectricalTroubleshooti TroubleshootingFlowchart- Lock-upControlSolenoidValveB . OBD ll Scrn Tool indicrt.3 Cod. P1758. . Self-Oiagnosis E indicato. light blink3 twics.

Poitibl. Cau3o

u,

*d

. Dbconn.stsd lock-up control solenoidvalv6 B connectol . Short or open in lock-upcont.ol 3olonoidvalva B wiro . Faulty lock-upconttol solcnoid valva B TCM CONNECTORS

MoasuroVREFVohago: 1. Disconnect the A (26P)and B ( 2 2 P )c o n n e c t o r sf r o m t h e TCM. 2. Turn the ignitionswitchON (ll). 3. Measuretho voltage between the 820 and A13or 426 terminats. WIRESIDEOF FEMALETERMINALS ls there approx. 5 V?

Rapair opan or lhort in iho wiro batwaan tho 820 terminal and th. ECM.

Checkfor a Shon to Powar: Measurethe voltage betweenth€ A15 and A13or A26terminals.

Rapair .hort to powar in tha wirc batr.,aon tha A15 ta.mlnal and tha lock.up control rol.noid valva B.

wlRE SIDEOF FEMAIETERMINALS

Moa3ure Lock-up Control Sol.noid Vrlv. B R$btanco: 1. Turnthe ignitionswitchOFF. 2. Measure the reslstance botweenthe A15 and A13 or 426 terminals.

..

12-25A? ls the r€sistance NO

To page14-59

14-5 8

Chack for loo.. TCM connactoB. It necassrry, 3ub3thuta ! knowngood 3olcnoid valve .ir€mbly ol TCM .nd r6ch.ck.

*,

From page 14-58

TCM CONNECTOR A I26PI

Chock Lock-up Contlol Solonoid Valv6 8 tor ! Short Circuit: 1. Disconnectthe 2P connector Irom the lock-rrpcontrol solenoid vaive assembly. 2. Checkfor continuitybetween the A15 and A13 or 426 terminals.

Rspsir rhort to ground in tho wirg bgtwoen tho A15 torminal and the lock-uDcontrol 3ol6noid valva B.

WIRESIDEOF fEMALE TERMINALS

LOCK.UPCONTBOL

Maasuro Lock-up Control Solanoid V.lvo B Rosist.nc6 at the SolonoidConnactor: Measurethe resistancebetween terminal No. 'l of the lock-uocontrol solenoidconnectorand body grouno.

sotf Noto coNNEcToB

r

'

lIr_e_rtjl l' | , l l

\/

cnrurefiT/Or ls the resistance 12- 25 O?

Chack tor open in tho wir6 botwe.n th€ A15 to.minal and tha lock-up conlrol aolenoid v.lv. B.

-L --= TERMINAI SIDEOF MALETERMINALS

Roplacelhe lock-up codrol rolenoid vrlvo a$embly.

J 14-59

ElectricalTroubleshooting TroubleshootingFlowchart- ThrottlePositionITP}Sensor ' OBD ll Sc.n Tool indlclto3 Codc P1790. . Soll-di.gnosi. E indic.tol lighi blinks tht.e tim*,

U

.d

\./

{

\"/

4

Po3Cblc C!us. . Dirc.nn.c.t d throttlo pothion lTPl ranaor connac'tor . Shon of opan in TP aanror wiro . Faulty TP ianror

Check tor Anoth.r Code or MIL Blinking: 1. Turn the ignitionswitchoN (ll). 2 . C h e c kw h e t h e r r h e O B D l l scan tool indicatss another code or the Malfunctionlndicator Lamp (MlL) blinks (seo soctionl1).

Ooesthe OBD ll scantool indicate the anothorcode or is the MIL blinking?

TCMCONNECTORS

Morrur. VBEFVohag.: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e A ( 2 6 P )a n d B (22P)connectorstrom the TCM. 3. Turn the ignitionswitchON (ll). 4. Measurethe voltage b6twson the 820 and A13 or 426 terminats.

ls there approx.5 V?

t26Pl

WIRE SII'E OF FEMAI.I TERMI'TALS

RcpaiJ opon or thort in tha wlJa b.tt r..n lho 840 t rlnlnal md lh. ECM.

Mer3uroTPsvohrg.: Measureth€ voltagebetweenth6 84andA13or A26terminals.

ls there 0.4- 0.6V?

Rapair opon oa rhoat in thr wlra b.tw.cn th. B4 t.rmln.l .nd th. TP aansor.

Ch.ck lor loosa TcM connactorr. ll nocassary, rubditut. r knowngood TCM and r.chock.

14-60

TroubleshootingFlowchart- VehicleSpeedSensor{VSS) IJ . OBD ll Sc.n Tool indlcrt . Cod. Pl791. . s.lt-dl.gno.i. E indicrtor llghi blinkr four tirn.r.

Pos.ibl. C.u3o . D|""."-"t"d .r"hl"L 3p*d aanaor (VSSI connactol . Short or opan in VSS wira . F.ulty VSS

Ch.d( tho Sp..dom.t r Op.r.don: Checkthatthe spoedometgropeF at€scorrsctlv.

R.t.r io ..ctlon 23 lor v.hlcl. !p.!d tlnto. IVSSI t rt.

v

Ch.ck thr VSS Voh.g.: 1. Baiseth6 car. 2. Shift the transmissionto E position. 3. Disconn€cttho A (26P)and B (22P1conn€ctorsfrom the TCM. 4. Turnthe ignitionswitchON (ll). 5. Rotate the front wheel snd checkfor th6 voltage botws€n the 95 and A'13or 426 terminals. Blockth€ oth6r wheel so it does not turn.

@

. M.k. .ur. 11ft3,l.cl(., .nd ilt ty .l.nds .r. pl.c.d prop€rly (t€a .cction 11. . Srt th. p!.king b..ko rlcur.ly, lnd block thr r..r wh..b. . J.ck up th. t?ont ol ih. yohlcl., lnd .upport it whh rdlty rt.ndr.

TCM CONNECTORS

Chack tor ahorl or opan in iha wlra batwaan tha 85 tarmin.l and tha vahicla tpaad tanror {VSSI. ll wirc i! OK, ch.ck th. VSSk ot ction 23).

WIRESIDEOF FEMAI.CTERMINALS

Chack io. loo.c TCM conn.ctors. It nacasaary. rubditut . knowngood TCM .nd r.ch.ck.

14-61

ElectricalTroubleshooting TroubleshootingFlowchart - A/T Gear Position Switch (Short)

L l u . OBOll ScanTool indicatesCode P1705. . S6lt-diagnosis Pr-,.. indicator light blinks five times.

Observethe A/T gear position indicator: 1. Turnthe ignitionswitchON {ll). 2. Observethe A/T gear position indicator,and shift eachPosition separately.

Do any indicatorsstayon when the shift leveris not in that position?

Po$ible Cause ' Shon in A/T gea. position switch wire . F.ulty A/T g€at position switch NOTE:Code P1705(5) is set when the TCM receivestwo gear positioninputs at the same time.

The syslem is OK at this time. Ch€ckthe wite hotn€ssfor dama9e,

MeasureATP R Voltage: 1. Turnthe ignitionswitchON (lli. 2 . s h i t t t o a l l p o s i t i o n so t h e r than E. 3. Measurethe voltagebetween the A11 and 413 or 426 terminals.

ls there battery voltageT

TCM CONNECTOR A {26FI

WIRESIDEOF FEMALETERMINALS Check for short in ihe wire betwe€nthe 411 termin.l and the A/T gear position switch or A/T g6ar position indicator. lf wire is OK, check tor lo6e TCM connectors. lf necessary,substitute a known-goodTCM and rech€ck.

{

MeasureATP PN Volt.go: 1 . S h i f tt o a l l p o s i t i o n so t h e r than E or E. 2. Measurethe voltage between the 410 and A13 or 426 termi nals. Check for 3hort in the wire between the A10 tetminal and the A/T gear position indicator, or a short in the wir63 between the A/T gear position indicator and A/T g€ar position switch. lf wires are oK, check for loose TCM connecto13.lf necessarv, 3ubslitute a known-good TCM and recheck. MeasureATP D. Voltagel 1. Shiftto all positionsotherthan

o;.

2. Measurethe voltagebetween the Ag and 413 or A26 termi' nals. Check for 3hort in the wire between the Ag terminal and tho A/T gear po3ition switch. lf wire is OK, check tor loose TCM conneclors. ll necessary,substitute a known-goodTCM and recheck.

{ To page14 63

14-62

TCM CONNECIOR A {26P) MeasureATP D3Voltrg.: 1. Shift to all positionsother than

BRN/BLK

E.

2. Moasurethe voltago botwg€n the A8 and A13 or A26 terminals.

ls there batteryvoltage?

Chock for shori in the wirs botwoon tho A8 torminal snd tfie A/T goai position switch or the A/T ge.r po.idon indicaioi, It wiro is OX, ch6ck for loore TCM conn€cto]s. lf n.ceacary, aub6tftrjt6 a known.good TC.M.nd Jocicck.

BFN/BLK WIRESIDEOF FEMALETERMINALS

GRN/YEL

Me.suro ATP2Volt6go: 1. Shiltto all positionsotherthan

A.

2. Measurethe voltage betlveen the A7 and A13 or A26 terminals. Check fo? 3hort in tho wire bstwaon tha At torminal and tho A/T goar position switch or tho A/T ge.r po.ldon indlcltor. lf wiro is OK. ch.ck for looso TCM connoctors. lf nocoalary, lubctiiuto a known-good TCM rnd rech.ck. LT GRN/WHT

M6a.urc ATPI Voltagc: 1. Shift to all positionsotherthan

tr.

2. Measurethe voltag€ betweon the 46 and Al3 or 426 terminals,

ls there batteryvoltage?

Chock for 3holt in the wiro b6two6n tho AO torminal and tho A/T gear po3ition .witch or tho A/T ger. po.ition indicator. I wir6 is OK. ch.ck tor looso TCM connocto6. lf noca3srry, sub6titut6 a known-good TCIVI.nd r.ch€ck.

BRN/BLK

Chack for looaa TCM connocioF. ll n6ce$ary, iubstitute a knowngood TCM .nd rech.ck.

14-63

ElectricalTroubleshooting TroubleshootingFlowchart- A/T GearPositionSwitch (Openl . OBD ll Scsn Tool indicate. Code P1706. . S e l f - d i a g n o s i sE i n d i c a t o r light blinks six times.

Po3.ible Cause . Di"""."."i"d A/T ,"". p""iti switch connoctor . Open in A/T ge.r position switch wire . Faulty A/T gear position switch TCM CONN€CTORA (26PI

MeasuroATP R Voltago: 1. Turnthe ignitionswitchON (ll). 2. Shiftto E position. 3. Nleasurethe voltage between the 411 and 413 or 426 termi nals.

BRN/ BLK

Repairopen in the wire bctwean the A11 te.minal and the A/T gear position switch. WIRESIDEOF FEMAI.ETERMINALS

MoasureATP PN Volt.ge: 1. Shiftto E or E position. 2. Measurethe voltagebetween the 410 and A13 or 426 terminals.

Ropai. open in the wirs between t h o A 1 0 t e r m i n a ls n d t h e A / T gear position indicator.

MeasuroATP D. Voltage: 1. Shiftto E position. 2, Measurethe voltagebetween the Ag and A13 or 426 terminals.

ls there voltage?

Repairopen in the wire between the Ag terminal end the A/T g€ar po3ition switch.

NO

To page14-65

14-64

V J

Frompage14.64 TCM CONNECTOR A I26P} Mearuro ATP D3Vohage: '1. Shift to E position. 2. Measurethe voltage between the A8 and A13 or A2Oterminals.

Repair opan in tho wire bstwoGn tho A8 to?min.l rnd th€ A/T g6a. po.ition 3whch.

WIRESIDEOFFEMA1IIERMINALS

Me.ruro ATP 2 Voltrgo: 1. Shift to E position. 2. Nleasureth€ voltage b€tween the A7 and A13 or A26 terminals.

Raprir opon in tha wir. lratwaan lh. A? t.rminal .nd tho A/T gear position 3witch.

Mea3u.. ATP 1 Vohage: 1. Shiftto E position. 2. Measurethe voltage between the A6 and A13 or A26 termi' nats.

Raplir opon in tho wiro bdtw.on the A6 tarminal lnd thc A/T goal position swhch.

Ch€ck lor loora TCM connactoa3. It ncccsa!ry, sub3titutc 6 knowngood TCM and roch6ck.

14-65

g ElectricalTroubleshootin TroubleshootingFlowchart- Shift GontrolSolenoidValveA \r, . OBD ll Scan Tool Indicat . Code m7$. . S e l f - D i a g n o s i sE i n d i c a t o r ligln blinb sovontimes.

PossiblcCause . Dbconnoctodshift control solonoidvrlv€ A conneclot . Short or oDenin 3hift control solenoidvalve A wire . Faulw 3hift control solanoid

Morsure VREFVohag6: 1 . D i s c o n n e ctth e A ( 2 6 P )a n d B (22P)connectorstrom the TCM, 2. Turn the ignitionswitchON (ll). 3. Measurethe voltage between the 820 and A13 or 426 terminals.

ls thereapprox.5 V?

TCM CONNECTORS

Repair open or 3hort in the wiro betwoon tho 820 terminal 3nd the ECM.

WIRESIDEOF FEMALETERMINALS

A (26PI TCM CONNECTOR

Chocklol a Short to Power: Measurethe voltage betweenthe 43 and Al3 or 426terminals.

Repail short to powgr in the wire belwoon the A3 termin.l and th6 shift control solonoidvalvo A.

Measure Shift Contlol Solenoid Valvo A R63btenc.: 1. Turnthe ignitionswitchOFF. 2 . M e a s u r e t h e r e s i s t an c e between the 43 and A13 or 426 torminals.

12- 25 O? ls the resistance

To page14-67

14 -6 6

Chockfor loo3. TCM connectors. ll nec€ssary, 3ubsthute a knowngood solenoid v.lve sssombly or TCM and r6check.

WIRESIDEOF FEMALETERMINALS

Frompege14-66 A I26PI TCM CONNECTOR Chock Shitt Control Solonoid Valvo Alor a Short Circuit: 1. Disconnectthe 3P connector trom lhe shift control solenoid valve assembly, 2. Checklor continuity betwoen the A3 and A13 or A26 terminals, WIRESIDEOF FEMALETERMINALS Rapair sho.t to ground in ths wi.c batwocn tha A3 torminal ind th6 shift control 3olanoid

SHIFTCONTROLSOLENOID CONNECTOR Mearur. Shitt Control Sol.noid Valv. A Re3istsnceat th. Sol€noid Connactor: Measur€the rosistancebetween terminal No. 1 of the shift control s o l e n o i d c o n n e c t o ra n d b o d y oround.

L l/ i 3 t L

ar-urvelf-

@ I L --

ls the rosistsnce 12- 250?

Chcck tor ooen in th6 wir6 betwocn the A3 tclminll .nd tho .hift control 3ol6noidvrlvo A.

TERMINALSIDEOF MALETERMINALS

Repl.c6 th. .hltt control .016noid valvo aarcmbly.

14-67

g ElectricalTroubleshootin TroubleshootingFlowchart- Shift ControlSolenoidValveB

J . OBD ll Scan Tool Indicrt.3 Code m758. . sell"Diagnosi3 [Q indicator light blink3.igl|ttlm.!.

Po3sibl. Cauao ' Diaconncctad ahift control solanoidvalve B connoc'tor . Short ol op.n in shift contlol solanoidvalvo B wiro . Faulty lhift control solonoid valvo B

Moasur. VREFVoh.go: 1 . D i s c o n n e ctth e A ( 2 6 P )a n d B (22P)connectorsfrom tho TCM. 2. Turn the ignitionswitchON (lll. 3. Measurethe voltage between the 820 and Al3 or A26terminals.

ls there approx. 5 V?

TCM CONNECTORS

R.pair opan or 3hort in thc wira b.twrqn th. 820 tormin.l and th. ECM.

WIR€ SIDEOF FEMALETERMINALS

A (26PI TCM CONNECTON

Checkfor . Short to Powor: Measurethe voltage bstween the A2 and A13 or 426termin8ls.

U g RapairBhortto power in tho wilo botwecn thr 42 laiminal and th. 3hift control solanoidvalvo B.

TERMII{ALS WIRESIDEOF FEMAI."E

Me.sure Shift Control Solenoid valvo B Raliatanco: l. Turnthe ignitionswitchOFF. 2. Measure the resistance between the 42 and A'13or A26terminals.

ls the resistance 12- 25 O?

To page 14-69

Chacklor loos. TCM connactoB. lf n.ceasary, subsiituto a knowngood sol.noid valv6 tasambly ol TCM rnd rech.ck.

U g

From pag€ 14-68

Chock Shitt Control Sol.noid V.lv! B tor r Short Circuit: 1. Disconngctth6 3P connoctor trom the shift control solenoid valve sssombly. 2. Checkfor continuitv betwo€n th€ A2 and 413 or 426 torminals.

A I26PI TCM CONNECTON

Rapalr lhort to ground in iho wirc batwoan lhc A2 tarminal and th6 ihlft control 30lcnoid valva B.

WIRESIDEOF FEMALETERMINALS

SHIFTCONTROLSOLENOID CONN€CTOR M...ur. Shift Control Sol.noid Valv. B R.rid.[c. rt tha Sol.noid Connactor: Measurethe resistanc6between terminal No, 3 of th€ shitt control s o l e n o i d c o n n e c t o ra n d b o d y ground,

ls the resistancel2 - 25 0?

GRN/WHT

Ch.ck for open in lh. wi.. batwaon th6 42 torminrl rnd tho ahitt control lolanoid valva B.

TERMINALSIDEOF MALETERMINALS

u 14-69

g ElectricalTroubleshootin TroubleshootingFlowchart- CountershaftSpeedSensor

\ I J . OBD ll Scrn Tool Indlcat ! Cod. m720. . Self-diagnosis E indicatol lighl blinks nine tim6.

PosalblaCruae . Loora or faulty connaction b.tw.$ tho TCM and 61 h!1. na33 . Dbconnactad couniaBhaft locad lantot oonnac{ot . Shorl or opan in counta6hatt tDaad $naor wha . F.ultv coufiaEh.ft apaad acnaol

ls the countershaftspeedsensor installedproperly?

SPEED COUNTERSHAFT SENSORCONNECTOR

.-_

Moas{ra Cour 6Ghaft Sp€od Sen60r R6Btanca gt iha SaGol Conn€c'tor: 1. Disconnectthe 2P connector trom the countershafl spgod sensorconnectof. 2. Measurethe resistanceol the countershaftspeedsensor.

lfr-trtl -r-TL+l

tt @ l

U\lO

L__l

TENMINALSIDEOF MAIE TERMINALS

ls the rosistance400- 600 O?

B (22PI TCM CONNECTON

Check Countorrhcft Spe.d Son3ol for r Shon Circuit: 1 . D i s c o n n e ctth e 8 { 2 2 P )c o n nectorlrom the TCM. 2. Ch€cklor continuity between body ground and the 88 t€rminaland Bg terminalindividually. WIBESIDEOF FEMALETERMINALS

Rapair rhon In th6 wiro! hwaan tho E8 rnd Bg te.min.l. .nd th. countaFhaft !D..d aanaol.

\, To page'14-71

L

14- 7 0

a,

From page 14-70

TCM CONNECTORB I22P)

Mgasuro CountoFhaft Spo€d Sensor Re3btancg: 1 . C o nn e c t t h e c o u n t e r s h a f t speedsensor2P connedor, 2. Measure the resistance betweenthe 88 and gg terminals.

WIRESIDEOF FEMALETERMINALS

ls the resistance400- 600 0?

Ropair looto torminsl or opgn in the wires b.twoon th6 88 .nd 89 torminals and tho countor3haft spoad s€nsor.

Chock for loo3o TCM connodor. lf neceatary, substitute a known. good TCM and rochock.

14-71

ElectricalTroubleshooting TroubleshootingFlowchart- EngineCoolantTemperature (EGTISensor ' OBD ll Scsn Tool Indicat6 Code P1792. . S e t t ' d i a g n o 3 i 3E i n d i c a t o l light indicatesCode 10.

U

Polribl. Cluta . Dirconnoct.d Engin. Coollnt Tampaolur€ IECTI aanaor con. noctot . Short or opcn In ECT..n.or . F.ulty ECTr.n.or

Chock tor Anothor Codo or MIL Blinking: 1. Turn the ignitionswitch ON (ll). 2 . C h e c kw h € t h e r r h e O B D l l s c a n t o o l i n d i c a t e sa n o t h e r code or the MalfunctionIndicator Lamp (MlL) blinks (see section11).

Doesthe OBDll scantool indicateanothercodeor is the MIL blinking?

Tctrrtoot{NEcToRs MoasureVREFVoh.go: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e A { 2 6 P )a n d B (22P)conneotorsfrom the TCM. 3. Turn the ignitionswitch ON (ll). 4. Measu.e the voltage between the 820 and A13 or A26torminals.

ls thereapprox.5 V?

I i

:

WIRE SIDE OF FEMAII TERi'IINAIS

Bap|ir open or thort in tha wirc b.two.r th. B:m t.rminll .nd tho ECM.

M6esur. ECTVoh.ge: 1. Turnthe ignitionswitchOFF. 2. Connect the A (26P) and B (22P)connectorsto the TCM. 3. Start the engineand w6rm it uP to normal operatingtemp er a t ur e ( t h e r a d i a t o r f a n comeson), 4, Measurethe voltage between the 83 and A13 or A26 terminats.

rt

.f

ls therelessthan 1 V?

Ch.cl fo. looso TCM connac{or3, t nacaasary, substituto a known" good TCM rnd r.chock.

napalr opln in iha wlra brtwaan the lB t.rminrl lnd th. ECTr.nao1.

{

- TroubleshootingFlowchart- lgnitionCoil

U

J . OBD ll Sc.n Tool Indicrt$ cod. m725. . S.lf.di.gnosi3 E indicetot light indicet$ Cod. 'l 1.

PoaaibleCau3€ ' Di.conn€c{od ignition coil con. nactot . Short or opcn ignition coil wira . Frulty ignition coil

Motsure NE Vohago: 1 . D i s c o n n e ctth e A { 2 6 P )c o n nectorfrom the TcM. 2. Stantha €ngine. 3. Measurgthe voltage betwegn the A5 and Al3 or 426 terminals.

BRN/BLK WIRESIDEOF FEMAI,TTEBMINALS

ls there banery voltage?

t

t

t

t

Rapair opan or lhort in tho wira bctwo6n tho AS tarminal and tho lgnhion coil.

Chack tor loose TCM connector. lf necasllry, 3ub3titule a knowngood TCM snd recheck.

14-73

ElectricalTroubleshooting

TroubleshootingFlowchart- BarometricPressure(BARO)Sensor

t

\l, . OBD ll ScanTool lndicatosCode P1794. . S e l f - d i a g n o s i sE l i n d i c a t o r light indicatosCode 13.

PGsible cau3€ ' Short ot oDen in LT GRN wite betwoen the 82 lcrminal and ihe ECM . Faulty baromotric Prelsure IBAROIignsol NOTE: Tho BAFO sensor is built intothe ECM.

MeasureVREFVolttge: 1. Turnthe ignitionswitchOFF. the A (26P)and B 2. Disconnect ( 2 2P ) c o n n e c t o r sf r o m t h e TCM. 3. Turnthe ignitionswitchON {ll}. 4. Measurethe voltage between the 820 and 413 or 426 terminals, WIRESIDEOF FEMALETERMINALS

ls thereapprox.5V?

l

Repair shon or oPen in the wite betwcon the 820 tsrminal and tho EcM.

V q J

CheckBAROSS Wire ContinuitY: 1. Turn the ignitionswitchOFF. the 22Pconnedor 2. Disconnect trom the ECM. 3. Check for continuity between t h e 8 2 t e r m i n a lo t t h e T C M connectorand C21terminalof the ECMconnector.

'|

ls therecontinuity?

Repairopen in the wiro betwoon the TcM and ECM.

V To page14-75

14-74

!

v

Frompage17-74

CheckBAROSS Wiro tor a Short Circuh: Checkfor continuity between the 82 terminalofthe TCMor the C21 t e r m i n a lo t t h e E C M a n d b o d y ground. WIRESIDEOF FEMALETERMINALS

TCM CONNECTOR B {22PI

u Ch.ck {or loose TCM and ECM connoctots. lf n€cessary,sub3titut6 a known-good TCM and rochock.

WIRESIDEOF FEMALETERMINALS

14-75

ElectricalTroubleshooting Troubleshooting Flowchart - FAS Signal . OBD ll Scan Tool indicatcs Code P1786. . Soff-diagnGisE indicrtor light indicat6 Codo'1,0.

U

. Short o. opon FAS wira . Feoltv ECM

M6a3ureFASVottago: 1. Start the engineand warm it temPer_ up to normaloperatang 6ture (the radiatorfan comes on). 2. shift to E position. 3. Turnthe ignitionswitchOFF. 4. Turn the ignition switch ON (ll) and wait lor at least two seconds. 5. Measlre the voltage between the 819 and A13 or A26terminals.

ls thereapprox.5 V?

v

PG.iblo Cru!.

TCM CONNECTORS

WIRESIDEOF FEMALETERMINALS

Chsckfor loo3r TCM connactot!. lf necoslary, lubsihuto a known. good TCM rnd r.chrck, ECMCONNECTORS

M6asuroFAs vohagoIECM sidol: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe B (22P)connector lrom the TCM. 3. Turn the ignitionswitchON (ll). 4. Measurethe voltage Ag and C9 terminalsof tho ECMconnectors.

a WIRESIDEOF FEMAI.TTEBMINAI-S

ls thereapprox.5 V?

,i

,I

To page14-75

ChockFAS Wiro Continuity: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe C (31P)connectorlrom the ECM. 3. Checklor continuity between the C9 terminalof the ECMC (31P)connectorand the 819 terminal of the TCM B (22P) C I31P} ECMCONNECTOR

Chockfor loore TCM connectoE. lf noceilary, subrtitula a knowngood ICM rnd rcchock. WIRESIDEOF FEMALETERMINALS Repairopon in the FASwirc b€(we€n the TCM snd ths ECM.

14-76

From pag€ 14-76

Ch.ck FAS Wir! for I Shoit Clrc!hr 1. Turn th6 ignition swilch OFF. 2. Disconnectthe C (31P)conn€ctorfrom tho ECM. 3. Chockfor continuiv b€tweon th€ c9 torminal of th6 EcM c ( 3 ' l P )c o n n 6 c t o ro r t h e 8 1 9 torminal of th€ fcM B l22Pl connoctorand body ground,

B {22P} TCM CONNECTOR

WIRESIDEOF FEMALETERMINALS

C {31PI ECMCONNECTOR

B.pllr rhort in th. FAS wiro b.tw..n th. TCM .nd th. ECM.

WIRESIDEOF FEMALETERMINALS

Chack tor looaa TCM connactora. lf nacaaary, aubatltuta I known. good TCM .nd rach..k.

14-77

ElectricalTroubleshooting TroubleshootingFlowchart- MainshaftSpeedSensor ' OBD ll Sc.n Tool indicrt6 Codo P0715 ' s e l f - d i a g n o s i sE l i n d i c a l o r light indicatosCode 15.

Po3aiblocauso ' Diaconnoctedmrin3haft spocd 30nsorconnoctot . Short or open in mainshstt soeodsenSotwito . Faulty main3haltspood3€n3ol

'15)on the TCM NOTE:CodeP0715(code doesn't always mean there's an electrical oroblemin the mainshaftor countershaft speedsensorcircuit;codeP0715(codel5) may also indicatesa mechanicalproblem in the lransmission.

v

Checkthe mainshattand counlershaftsoeedsensorinstallation.

Are the mainshaftand countershalt speedsensorinstalledproperly? MAINSHAFTSPEED SENSORCONNECTOR

M6asure Mainshtft Spood Son' sor Rgsi5tancoat ths Sonsol Connec'tor: 't. Disconnectthe 3P connector I r o m t h 6 m a i n s h a t ts p e e d sensorconnedor, 2. Measurethe rcsistanceof the mainshaftspeedsensor.

TERMINALSIDEOF MALETERMINALS

\4 ls the resistance400 - 600 o?

B (22P) TCM CONNECTOR

Chock Mainshaft Speed Son3or for a Short Circuh: l. Disconnectthe B (22P)connectorlrom the TCM. 2. Checklor continuity betlveen body groundand the 810 ter' m i n a la n d 8 1 7 t e r m i n a li n d i vidually. WIRESIDEOF FEMALETERMINALS Repair 3hort in tha wi?es bttwo€n tho 810 lnd Bt? terminal3.nd tha mainshltt spaed sonaot.

To page14-79

V J ,

14-7 4

Frompage17-78

Mo!3urc Mrinahaft Spced Sonsor Rosistrnco: 1. Connoctthe mainshaftspeed sensor3P conn6ctor. 2 . M e a s u r e t h e r e s i s t an c 6 betweenthe 810 and 817 terminals.

ls the resistance400- 600 0?

TCMCONNECTOR B I22PI

Run th. ELcticrl TlouH..hooting Holrrdrart lor cod. m720 (codo 91. Chock lor looaa TCM connactor3. lf nacllg!ry, $badtuta a knowngood TCM rnd i.ch.ck.

Ch.ck NM Wiro Continuity: 1, Disconnectthe 3P connector {rom the mainshaftsp6edsensor connector, 2. Checkfor continujty between the B10terminalandtheNo.3 terminal of the mainshatt speedsensorconnector.

WIBESIDEOF FEMALETERMINALS

MAINSHAFTSPEEO SENSORCONNECTOR

R€paiaopon in tha wir. bctwoan th. 810 t.rmin.l lnd th. m.in3hrft apaad sanaor.

WIRESID€OFFEMAI"E TERMINALS CheckNMSG Wl.e Continuity: Checkfor continuity b€twoenthe B'17terminaland the No. 1 t6rmi, nal oI the mainshaftspeeds6nsor connector.

Rapairopan in thc wiia batwacn th6 Bl7 t.rmin.l .nd th. m.ln. 3hdt rDaad aansor,

Chock lor loo3e TCM connactor. It n.cGslry, $bititutc ! knowngood TCM lnd r.chock.

14-79

g ElectricalTroubleshootin TroubleshootingFlowchart- LCControlSystem Poeribl. C.ua.

\.r.

control

Chocklor Anothor Cod6: Checkwhether the OBD ll tool indicatesanothercodo.

Doesthe OBDll scantool indicate anothercode?

P6rform tha Troublorhooting Flowcha for tho indicrlad Codolsl. R.ch.ck fof codo P0740 !ft.t t.oublo3hooting. NOTE: Do not continue with this troubleshooting until thg caus€s ot any other DTCShave beeo corrected.

Tost Line Proisurg: Measurethe line pressure(see pag614-98).

ls the line prsssurewithinthe servic€limit?

t, I

Repl!c6 th6 Lock-upControl Solenoid Velva As3ambly .nd Rschock: 1 . R e p l a c et h e l o c k - u pc o n t r o l solenoidvalve y'y'Bassembly (seepage '!4-87). 2. Turn the ignitionswitch OFF and reset the TCM memory b y r e m o v i n gt h e B A C KU P fuse in the und€r-hoodfuse/ rolaybox tor more than 10 seconos. 3 . U s i n gt h e O B D l l s c a nt o o l , checkthat the enginecoolant temperaturesis 176'F (80'C)

'I

4. Drive the vehicle at 55 mph (88 km/h) constantlylor rnore than one mrnute, 5. Recheckfor code P0740.

Doesthe OBDll scantool indicate codo P0740?

R.prir tho hydraulic syltcm !! n.cGsary (soc pago 1+98).

v

I

Tha iy3t6m ir OK .t thi! timc.

V J 14-80

TroubleshootingFlowchart- ShaftControlSystem Poitible C.uBe F""lty

"hlft ".^t..t

",/"t".

Chockfoi Another Code: Checkwhether the OBD ll scan tool indicatesanothercode.

Doesthe OBD ll scantool indicateanothorcode?

Psrtorm tho Tioubla3hooting Flowch.rt fo. th. indicatod Codcl.l. Rechsck tor code P0730 attol troublolhooting. NOTE: Do not continue with this troubleshootlng until the causes of any other DTCShave been corrected.

Tost 1st, 2nd, 3rd, and 4th Clutch Prossuro: M e a s u r et h e 1 s t , 2 n d , 3 r d ,a n d 4th clutch pressure(see page 14-

ls eachclutchpressurewithin the servicelimit?

R.p!ir lhG hydraulic ry3t.m ra nac.3!.ry l3€e pago 1+991.

Roplace the Shilt Contiol Solonoid Valve A/B Assombly, thon Recheck: 1. Turn the ignition switch OFF and reset the TCM memory b y r e m o v i n g t h e B A C KU P fuse in the under-hoodfuse/ r e l a yb o x f o r m o r e t h a n ' 1 0 seconds. 2. Orive the vehicle at over 12 m p h ( 2 0 k m / h )i n l s t , 2 n d , 3rd, and 4th gearfor more than 30 secondsin E position. 3, Recheck for codeP730(41).

Doesthe OBDllscantoolor the E indicatorlight indicate codeP0730(4'1)?

Tho systom is OX etthi3 timo.

ElectricalTroubleshooting Troubleshooting Flowchart - lDnlIndicator Light DoesNot ComeOn

\ / J The iDalIndic.tor light does not coma on whgn the ignhion switch is tirst tulnod ON {ll). (lt should come on tor about two s€conds.)

Checkthe Sowice ChockConneclol:

Make sure the specialtool {SCS Sorvice Connector)is not connectedto the servicecheckconnector.

ls the specialtool(SCSService Connedor)connectedto the servicecheckconnector?

Disconnect the 3pocisl tool from tho sgrvice chock connlc'tor and rachock.

Ch.ck tho [O! Indicator Light: Shiftto E position.

\/ Doesthe E indicatorlight comeon?

J

Chock tor loos. TCM conn.ctoi3. lf nece3s!ry, subttitute a knowngood TCM and r.ch.ck,

A I26PI TCM CONNECTOR

Ch.ck the Ground Circuit: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe A 126P)connectorfrom the TCM. 3. Checklor continuity botween t h e A 1 3 t e r m i n a la n d b o d y ground and tho 426 terminal and body ground.

Reprir opan in the wir.3 betwoon th6 A13 or A26 t..minil. and G101. Repairpoor ground (G101).

To page14-83

14-a2 t-

V J

\.

Frompage14-82

TCM CONNECTOR A I26PI

Measure Power Supply Circuit Voltage: 1. Turnthe ignitionswitchON (ll). 2. Measurethe voltagebetween the A12andA13terminalsand betweenthe A25 and 426 ter

BI-K/YEL

BRN/BLK

BLK/YEL

BRN/BLK

wlRE SIDEOF FEMALETERMINALS

ls there batteryvoltage?

\.

Repeir open or short in tha wire bgtwoon th6 A12 .nd/or A25 torminrls and under-dashfu3e/r6lay Dox.

MeasureO. IND Vohag.: 1- Turnthe ignitionswitchOFF. 2. Connectthe A (26P)connec tor to the TCIL 3. Connecta digital multimeter to the A17 and A13or 426 terminals. 4. Turnthe ignitionswitchON (ll) and makesure that the voltage is available for 2 seconds.

BRN/BLK

GRN/BLK

BRN/BLK

Checkfor open or short in tho wire betweon the A17 torminal tnd the gauge as3emblv.ll the wire is OK, chock tor a faulty Eli indicator light bulb or a f.ulty gauge assgmbly printgd circuit board. Ch€ckD. IND for an OpenCircuitr 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ct th e A { 2 6 P }c o n , nectorfrom the TCM. 3. Checktor continuitybetween the A17 terminaland the teF minal of the gaugeassembly connector(seesection23).

ls thereconlinuity?

Rap.ir open in tho wire between th. A17 tgrminaland the gsuge assembly.

Checklor loose TCM connectoB. C h e c kt h e A / T g o a r p o s i t i o n switch. lf necessary,substitute e known-good TCM and.echock.

14-83

ElectricalTroubleshooting TroubleshootingFlowchart- E IndicatorLight On Gonstantly

v

!

\4

{

Th. E indicltor ligM i! on cor. .t.ntly Inoi blinllng) wh.n.Y.l th. lgrhior lwftch l. ON {ll). ICM CONNECTORA I26PI M...ur. D. INO Vohtg.: 1. Turn tho ignition switch OFF. 2. Disconnectth€ A (26P)connoctorfrom the TCM. 3. Turn the ignitionswitchON (ll). 4. Measurethg voltag€ bstwegn t h e A 1 7 t 6 r m i n a la n d b o d y ground. WIRESIDEOF FEMAI.I TERMINALS

Rapalr ahort to powar In tha wiru b.tw..n th. A17 l.rmin.l lnd tha gaug. .cr.mbly.

M.a3ur. ATP D. voh.g.: 1. Turn the ignition switch OFF. 2. Conn€ctth€ A (26P)conn€ctor to the TCM. 3. Turn th€ ignitionswitchON (ll). 4 , S h i f t t o a n y p o s i t i o no t h e r than E position. 5. Moasurethe vohag€ b€tween the A9 tormin.l and body ground.

Ch.ck tor r rhort to ground in tha wir. b!tw..n th. Ag tarmin.l .nd th. A/T g..r potfion lwltch. f wi.e b OK r.pllca th. A/T g.|r polition Indacrtor.

I i

rl

Iti

u

J Inspsctionof tho A/C aign.l

Symp(om ' Lock-uD clutch dog3 not have duty opor.tion ION*OFF). . Lock-up clutch doe3 not ongago.

Ch.ck A/C Op.ration: 1. Start the engine. 2. Turnthe blowerswitchON. 3. Pushthe r'y'Cswitch ON.

TCM CONNECIORA (26PI Moaluro ACCLVoltdg.: 1. Stopthe engine. 2. Disconnectthe A {26P)connectorfrom the TCM. 3. Startthe engine. 4. Measurothe voltage betwoon tho A24 and A13 or 426 terminals with the Ay'Ccompressor OFF.

fj

BLK

J

WIRESIDEOF FEMALETERMINALS ls therc batteryvoltage?

Ropairopen in tho wira batwaen th. A24 termin.l and rhc A/C comprclsor clulch ralay.

. A/C aignal is OK. . Chgck for loo3e TCM connoc1013.lf neces3ary,3ub3tituto d known-goodTCM rnd rcchock. .Inspect tho A/C sy.tem lso. lection 221.

\*

J 14-85

ng I Troubleshooti Electrica Troubleshooting Flowchart - Brake Switch Signal

v

Symptom Shift lovar clnnot bo moved Itom E pGition with the brske pod.l dsoressod.

CheckBrako Light Oporation: Deoressthe brakeDedal.

Are the brakelightsON?

i

Repairtaulty brako switch circuit {soo3€qtion231.

TCM CONNECTORS

Mea.ur6 STOPsw voh.ge: 1. Turnthe ignitionswitchOFF. 2. Disconnect the A (26P)and B ( 2 2 P )c o n n e c t o r sl r o m t h e TCM. 3. Moasurethe voltage botween the 812 and A13 or 426 terminals with the brake podal depressed.

v

{

v

{

WIRESIDEOF FEMALETERMINALS

R€plir opon in the wire Itstwoon th€ 8'l2 torminal and bi.ke svtidt.

. 8rak6 switch signal b OK. . check lor loose TcM connocto]s, lf nsce$ary, sub3tituts a known-goodTcM and rochock. . lnsooct tho brake swilch circuit (sooscction 231.

lr

,

14-86

Lock-upControlSolenoidValveA/B Assembly Replacement (.

NOTE:Lock-upcontrolsolenoidvalvesA and B must be removed/replaced as an assembly. L

Disconnect2P connectorfrom the lock-upcontrol solenoidvalveAy'Bassembly.

2.

Measurethe resistancebetweenthe No. 2 terminal {solenoidvalve A) of the lock-upcontrol solenoid valveconnectorand body ground,and betweenthe No. 1 terminal{solenoidvalveB) and body ground.

1.

R e m o v et h e m o u n t i n g b o l t s a n d l o c k - u pc o n t r o l solenoidvalveA/B assemblv. Checkthe lock-upcontrol solenoidvalve fluid passagesfor dust or dirt. and replaceas an assembly,if necessary.

STANDARD:12 - 25 O 6x1.0mm 12 N.m (1.2kgtm,8.7 lbf.ftl

L Cleanthe mountingsurface and tluid passages.

LOCK.UP CONTROL SOLENOID VALVEA/B ASSEMBLY Replacethe lock-uocontrol solenoidvalve assembly if the resistance is out of specification. lf the resistanceis within the standard,connectthe No. 1 terminalof the lock-uDcontrolsolenoidvalve connectorto the battery positiveterminal. A clicking soundshouldbe hea.d.Connectthe No. 2 terminalto the batterypositiveterminal.A clickingsoundshould be heard.Replacethe lock-upcontrolsolenoidvalve assemblyif no clickingsoundis heard.

Cleanthe mounting surfaceand fluid passagesof the lock-upcontrol solenoid valve assembly,and installa new lock-upcontrolsolenoidvalveAy'Bwith a new filter/gasket. Checkthe connectorfor rust, din or oil, and reconnectit securelv.

l-

14-87

Shift ControlSolenoidValveA/B Assembly Test

Replacement

NOTE: Shift control solenoidvalves A and B must be as an assembly. removed/replaced

Removethe mounting bolts and shift control solenoid valvely'Bassemblv.

l.

D i s c o n n e c3 t P c o n n e c t o rf r o m t h e s h i f t c o n t r o l solenoidvalveA,/Bassembly.

NOTE:Be sure to removeor replacethe shift control solenoidvalvesA and B as an assemblY.

2.

Measurethe resistancebetweenthe No. 1 terminal (solenoidvalveA) of the shift controlsolenoidvalve connectorand body ground,and betweenthe No. 3 terminal(solenoidvalveB) and body ground.

Checkthe shift control solenoid valve fluid passagesfor dust or dirt, and replsceas an assembly,if necessarv.

J

STANDARD:12 - 25 o 6 x 1.0mm 't2 N.m {1.2kgf m, 8.7 lbf'ft)

BRACKET

\ \

^

,,

..,'

UYM a

SHIFTCONTROL SOLENOIDVALV€ A/B ASSEMBLY

Replacethe shift controlsolenoidvalve assemblyif is out of sDecification. the resistance lf the resistanceis within the standard,connectthe No. 1 terminalof the shiftcontrolsolenoidvalveconnector to the battery positiveterminal. A clicking soundshouldbe heard.Connectthe No.3 terminalto the batterypositiveterminal.A clickingsoundshould be heard. Replacethe shift control solenoid valve assemblyif no clickingsoundis heard.

14-88

Cleanthe mountingsurface SOLENOID and tluid passages. VALVEA/B ASSEMBLY FILTER/GASKET Replace.

Cleanthe mounting surfsceand fluid passagesof t h e s h i f t c o n t r o l s o l e n o i d v a l v e a s s e m b l y ,a n d installa new shift controlsolenoidvalveAy'Bwith a new filter/gasket. Checkthe connector for rust, dirt or oil, and reconnectatsecurely.

v.

Mai nshaft/Countershaft Speed Sensors Replacement l.

Disconnect the speedsensorconnectors.

2.

Removethe 6 mm boltssecuringthe mainshaftand countershaftspeed sensorsfrom the transmission housing.

TransmissionControl Module(TCM) Replacement 1.

Removethe two clips socuringthe kick panel,then removethe oanel.

2,

Disconnect the connectorsand removethe TCM.

Removethe mainshaftand countershaftspeedsensors. Installthemainshaftand countershaft speedsensors in the reverseorderof the removal.

6x1.0mm 12N.rn11.2kgtm, 8.7 tbttrt

6 x 1.0 rnm 12 N.m {1,2 kgt.m, 8.7 tbt.ft)

CONNECTORS

u

J 14-89

Symptom-to-ComponentChart HydraulicSystem Checktheseitemson the PROBABLE CAUSEList

SYMPTOM

1 , 2 , 3 , 5 , 6 , 7 , 3472, Engineruns,but car does not move in any gear. D. position. 6, 8, 9, 10,59 not in or moves in and but Vehicle lD,l, , E E E, 6,11,12,21 Vehiclemovesin E, o.-,E, E, but not in E position. Vehiclemovesin 9r, 9. , E, E, but not in E position. Vehiclemovesin E position.

4 , 6 ,1 3 , 3 2

idle vibration. Excessive

2,33, 31, 44,49

flareson startingoff in D! position Pooracceleration; Stallrpm high in lQ|.E, E, E position.

K,L,R

Stallrpm high in B position.

32

N

'15,33,48,49

R

No shift

44,51,52

G,L

Failsto shift in ql position;from 1stto 3rd gear. Failsto shift in E position;from lst to 4th gear. Erraticupshifting.

19

1-2upshift, 2-3upshift,3-4 upshift

64

19,20

52 5 l

Harshupshift{1-2). Harshupshift(2-3).

1 2 ,1 6 ,1 1 , 2 1 , 6 3 , 6 4

C,D,E,V

16,17,22,24,31,63,64

Harshupshift(3-4). Harshdownshift(2-1). Harshdownshift(3-2).

16,' tl. 23,28,32, 63,64

C,D,E.H,L,V C , D , E .I , L . V

o

Harshdownshift(4'3).

1 6 ,1 7 , 2 1 , 2 7 , 3 4 , 6 3 , 6 4 1 6 ,1 1, 2 2 , 2 A , 3 9 , 5,76 3 , 6 4 16,17,23.40,56,63. 64

Flareson 2-3 upshift.

1 6 ,1 7, 2 2 , 2 4 ,2 5 , 2 9 , 3 1

E,L,V

Flareson 3-4 upshift, Excessive shockon 2-3 uDshift.

1 6 ,1 1, 2 3 , 2 5 , 2 4 , 3 0 , 3 2

E,L,V,N

16, 11,22,24, 29,38, 46,64 16, 11, 23,2a,29, 40, 46,64

E,L.N

10,26 4, 18,32,55

Shift leverdoes not operatesmoothly. Failsto shifu stuckin 4th gear. Transmission will not shiftinto parkinggearin JII position. Stallrpm high;all clutchpressuresare in specification.

6, 43 5'1,52 6, 43,62

P

Lock-upclutchdoes not disengage.

16,17,47,48,49,50,53,54,64

Lock-upclutchdoes not operatesmoothly. Lock-upclutchdoes not engage. shockwhen shiftinginto E position. Excessive N o e n g i n eb r a k i n gi n E p o s i t i o n .

16, 17, 45,47, 48, 49,50,53.54,64 16,17,45,47,48,49,50,53,54,63,64 E , L , V

-

-

-

v

J

o K,L,O

14-9 0

J

E,L,N M

2,41

Positionindicatorlight does not come on.

\4

C ,D ,E ,I

Noisefrom transmissionin all shift leverDositions. Vehicledoes not acceleratemorethan 31 mDh(50 km/h).

P

D,K,O

60 58,50

Vibration in all positions.

-

B,K,L

c.D

Excessive shockon 3-4 upshift. Lateshiftfrom E positionto d or E position. Lateshiftfrom M positionto L!!lposition.

-

c,L,o

10,12,14,31,32,34,35,36

1 , 2 , 3 , 6 , 4 2 ,4 5

Ia-+upstrifi

-

K,L.R,S

6 ,8 , 1 0

fiz upshift ETupshift

\ . J

c,M,o c.L

stall rpm high in lo.tl.ld, E position. Stallrpm high in E position.

tat"tkp,ril"*

L

Checktheseitems on the NoTESList

6, 43,61

E,L,V

C,D.L

L

J PROBABLE CAUSE 1

Low ATF.

40

2

ATF pump worn or binding.

4'l

3

Regulatorvalvestuckor springworr..

42

4

Servovalvestuck.

43

Mainshaft worn/damaged.

44 45 46 47 4A 49 50 5l 52

Modulatorvalvestuck. Torqueconvertercheckvalvestuck. Foreignmaterialin separatorplateorifice. Lock-uptiming B valvestuck. Lock-upshift valvestuck. Lock-uppistondefective. Lock-upcontrolvalvestuck. Shift controlsolenoidvalveA defective.

53

Lockup controlsolenoidvalveA defective, Lock-upcontrolsolenoidvalveB defective. Servocontrolvalvestuck. 4-3 kick-downvalve stuck. 3-2 kick-downvalvestuck. lst-holdclutchdefective. '|st accumulatordefective. 'lst-hold accumulatordefective, A,rf gear position switch defective, Parkingmechanismdefective. Mainshaftspeedsensordefective. Countershaft speedsensordefective.

5 6 7

8 9 10 11

12 14

't5 16 11 18 '19

20

\a

al

22 24

Shift cablebroken/outof adiustment Finalgearsworn/damaged(2 gears). One.way{sprag)clutchworn/damaged. 1stgearsworn/damaged{2 gears). lst clutchdefective. 2nd gearsworn/damaged(2 gears). 2nd clutchdefective. Reversegearsworn/damaged(2 gears). Excessive ATF. Torqueconverterone-wavclutchdefective. ThrottlevalveB stuck. Throttlecontrolcableout of adiustment. 1-2shiftvalvestuck. 2 3 shiftvalvestuck. 3-4 shift valvestuck. 2nd accumulatordefective. 3rd accumulatordelective, 4th accumulatordefective. Orificecontrolvalvestuck. Foreign material in main orifice.

26

54 55 56

59

60 o l

62 63 64

4th checkball stuck. Torqueconverterhousingor transmission housingball bearingworn/damageo. ATF strainerclogged. Joint in shift cableand transmissionor body

Shift control solenoid valve B defectrve.

Foreignmaterialin lst orifice. Foreign material in 2nd orifice.

2A 30

2-3orificecontrolvalvestuck. Foreignmaterialin 3rd orifice. Foreignmaterialin 4th orifice.

J I

3rd clutch defective.

29

4th clutch defective.

33

34 35 36 37 38 39

\.

Engineoutputlow. Needlebearingworn/damaged. Thrustwasherworn/damaged. Clutchclearanceincorrect. Driveplatedefectiveor transmissionmisassemory. 2nd checkball stuck. 3rd checkball stuck.

"tl (cont'd)

14-91

Symptom-to-GomponentGhart HydraulicSystem(cont'd)

\ . J The followingsymptomscan be caused by improperrepairor assembly

itemson the Checkthese PROBABLE CAUSEDUETO Llst IMPROPER REPAIR

Vehiclecreepsin E] position.

R1,R2

Vehicledoes not move in l&l or Lql position. Transmittionlocksup in E] position.

R4

Excessive drag in transmission.

R6

ExcessiveVibration, rpm related.

R7

Noisewith wheelsmoving only.

R5

Msin soalpopsout,

R8

Variousshiftingproblems.

R 9 ,R 1 O

Harshupshifts.

Rll

Itemson the NOTESList

R 3 ,R 1 2

K,R

REPAIR PROBABLE CAUSEDUETO IMPROPER R1

lmproperclutch clearance.

R2.

lmpropergear clearance.

R3.

Parkingbrake lever installedupsidedown.

R4.

One-way (sprag)clutch installedupsidedown.

R5.

Reverseselectorhub installeduosidedown.

R6.

ATF pump binding.

R7.

Torque converternot fully seatedin ATF pump.

R8.

Main seal improperlyinstalled.

R9.

Springsimproperlyinstalled.

R10.

Valves improperlyinstalled.

R11

Ball check valves not installed.

R12.

Shift tork bolt not installed.

v.4

\/J 14-92

NOTES B.

c. D. E.

H.

J.

See flushingprocedure,page 14-172 and 173. Set idle rpm in gearto speciliedidle speed.lf still no good, adjust motor mounts as outlinedin engine sectionof servicemanual. lf the large clutch piston O-.ing is broken,inspect the piston groove for rough machining. lf the clutch pack is seizedor is excessivelyworn, inspectthe other clutcheslor wear, and check the orifice control valves and throttle valves for free mov€ment. lf throttle valve B is stuck. insDectthe clutchesfor wear. lf the 1 - 2 shift valveis stuck closed,the transmissionwill not upshitt.lf stuck open,the transmission hasno lst gear. lf the 2-3 orilice control valve is stuck, inspectthe 2nd and 3rd clutch packs for wear. lf the orifice control valve is stuck. inspectthe 3rd and 4th clutch packs for wear. lf the clutch pressurecontrol valve is stuck closed, the transmissionwill not shift out oI 1st gear. lmproper alignment or main valve body and torque converter housing may cause ATF pump seizure. The symptoms are mostly an rpm-related ticking noise or a high-pitched squeak.

M.

N.

P.

lf the ATF straineris cloggedwith particlesof steelor aluminum,inspectthe ATF pump and differential pinionshaft. lf both are OK and no causefor the contaminationis found, replacethe torque converter. lf the 1st clutch feed pipeguidein the right sidecover is scoredby the mainshaft,inspectthe ball bearing lor excessivemovementin the transmissionhousing.lf OK, replacethe right sidecoveras it is dented. The O-ringunder the guide is probablyworn. Replacethe mainshaftif the bushingfor the 4th feed pipe is loose or damaged. lf the 4th feed pipe is damagedor out of round, replacethe right side cover. Replacethe sub-shaftil the bushingfor the 1st-holdteed pipe is loose or damaged. lf the 1st-holdteed pipe is damagedor out of round, replaceit. Replacethe mainshaftiI the bushingfor the lst feed pipe is loose or damaged. lf the 1st leed pipe is damagedor out of round, replaceit. A worn or damagedsprag clutch is mostly a result of shiftingthe transmissionin El or LDllposition while the wheelsrotatein reverse,suchas rockingthe vehiclein snow. Inspect the trame for collision damage.

Inspectlor damageand wear: 1. Reverseselectorgear teeth chamfers. 2. Engagementteeth chamfersof countershaft4th and reversegear. 3. Shift fork for scuff marks in center. 4. Differentialpinionshaft tor wear under pinion gears. 5. Bottom of 3rd clutch for swirl marks. Replaceitems 1. 2, 3 and 4 iI worn or damaged.lf transmissionmakesclicking,grindingor whirring '1, noise,also replacemainshaft4th gear, reverseidler gear, and countershatt4th gear in additionto 2,3or4. pinionshalt is worn, overhauldifferential It differential assembly,and replaceATF strainer,andthoroughly clean transmission,tlush torque conveder, cooler and lines. lf bottom ot 3rd clutch is swirledand transmissionmakesgearnoise,replacethe countershaftand final onven qear. R.

S.

T.

Be very carefulnot to damagethe torque converterhousingwhen replacingthe main ball bearing.You may also damagethe ATF pump when you torque down the main valve body. This will result in ATF pump seizureif not detected.Use propertools. Installthe main seal llush with the torque converterhousing.lf you push it into the torque converter housinguntil it bottoms out. it will block the fluid return passageand result in damage. Harshdownshiftswhen coastingto a stop with zerothrottle may be causedby a bent-inthrottlevalve retainer/camstopper.Throttle cable adjustmentmay clear this problem. Throttlecableadjustmentis essentialtor properoperationol the transmission.Not only does it affect the shift points if misadjusted,but also the shift quality and lock up clutch operation. A cableadjustedtoo long will resultin throttle pressurebeingtoo low for the amountof enginetorque input into the transmissionand may causeclutch slippage.A cableadjustedtoo short will resultin too hiqh throttle pressurewhich may cause harsh shifts, erraticshifts and torque converterhunting.

RoadTest i

NOTE:Warm up the engineto operatingtemperature(the radiatorfan comeson). 1. Apply parkingbrakeand blockthe wheels.Startthe engine,then shiftto @ positionwhile depressing the brakepedalpedal,and releaseit suddenly.The engineshouldnot stall. Depressthe accelerator 2.

Repeatsametest in E position.

3.

Test drive the vehicle on a flat road in the @ position. Checkthat the shift points occur at approximatespeedsshown. Also checkfor abnormalnoiseand clutchslippage.

NOTE:Throttlepositionsensorvoltagerepresents the throttleopening. -1. Removethe TCM (seepage14-52). -2. Set the digitalmultimeterto checkvoltagebetween84 (+)terminaland A13 or A26 (-) terminalfor the throttleposition sensor.

84 Terminal

DIGITALMULTIMETER (Commerciallyavailablel KS- AHM -32 - 003 oa oquivalent

TCM CONNECTORS

WIRESIDEOF FEMALETERMINALS

,

14-94

J

.

Upshift: E Position Throttle Opening Throttlepositionsensor voltage:1.0V

.

Unit of spead

lst + 2nd

2nd r 3rd

3rd + 4th

mpn

8 . 0- 1 0 . 0

20.0- 23.0

2 7 . 0- 3 1 . 0

km/h

1 3 . 5- 1 6 . 1

32.2- 31.0

mpn

38.0- 43.0

43.5- 49.9 58.0- 64.0

61.2 - 69.2 63.0- 71.0 1 0 1 . -4 1 1 4 . 3

93.3- 103.0 97.0- 108_0 1 5 6 . 1- 1 7 3 . 8

Throttlepositionsensor voltage:2.5V

km/h

Fully-opened throttle

mph

21.0- 25.O 33.8- 40.2 3 1 . 0- 3 6 . 0

km/h

49.9- 57.9

Unit of speed

lst -, 2nd

2nd -r 3rd

mpn

8 . 0- 1 0 . 0

km/h

I J.C -

20.0- 23.0 32.2- 37.O 38.0- 43.0

Upshift: [d Po3ition Throftle Opening

Throttlepositionsensor voltage;1.0V Throttlepositionsensor voltage:2.5V Fully-opened throttle

mph km/h mph km/h

V

tO. I

21.0- 25.O 33.8- 40.2 3 1 . 0- 3 6 . 0 49.9- 57.9

6 1 . 2- 6 9 . 2 6 3 . 0- 7 1 . 0 1 0 1 . -4 1 1 4 . 3

o Downshift: E Position Throttle Opening

.

Unit ol spced

itth -+ 3.d

Throttlepositionsensor voltage:0.5V

km/h

Fully-opened throttle

mph

1 7 . 5- 2 0 . 5 24.2 - 33.0 85.0- 95.0

km/h

- 1s2.9 137.0

mpn

3rd r znd

2nd r lst

6.0- 9.0 (3rdr1st) 9.7- 14.5(3rd-r1stl 54.0- 61.0 86.9- 98.2

23.0- 24.0 37.0- 45.1

Downshift E Position Throttle Opening

Unit of speed

Throttlepositionsensor voltage:0.5V

km/h

Fully-opened throttle

mpn

mpn

km/h

3rd J znd

znd + 13t

6.0-9.0 (3rd-r1st) 9.7- 14.5(3rd-+1st) 54.0- 61.0 86.9- 98.2

23.0- 28.0 37.0- 45.1

14-95

RoadTest (cont'dl Lock-up:E Position Throttle Opening

Unit of spoed

Lock-upcontrol solenoid valve A: ON

Lock-upcontlol solenoid valve B: ON

17.0 - 20.0 27.4 - 32.2

Throttlepositionsensor voltage:1.0V

mph

1 4 . 0- 1 7 . 0

km/h

22.5- 27.4

throftle Fully-opened

mph km/h

.

92.0- 96.0 - 154.5 148.1

92.0- 96.0 1 4 8 . 1 -1 5 4 . 5

Lock-up:Ell Position Throttle Opening

Unit of speed

Throttlepositionsensor voltage:1.0V

km/h

Fully-opened throttle

mpn

mph

km/h 4.

Lock-upcontrol solonoid valvs B: ON

61.0- 68.0 98.2- 109.4

60.0- 67.0 96.6- 107.8

85.0- 94.0 1 3 6 . 8- 1 5 1 . 3

' 1 3 6 .-81 5 1 . 3

85.0- 94.0

Accelerate to about35 mph (57 km/h)so the transmissionis in 4th,then shitt from E positionto E position. The vehicleshouldimmediatelybeginslowingdown from enginebraking. CAUTION: Do noi shitt lrom I damage the transmission.

5.

Lock-upconirol 3olenoid valve A: ON

or $

position to E or E position 8t speeds over l0o mph (160 km/h); you may

Checkfor abnormalnoiseand clutchslippagein the followingpositions, E {1stGear}Position -1. Accelerate from a stop at fullthrottle.Checkthat thereis no abnormalnoiseor clutchslippage. -2. Upshiftsshouldnot occurwith the shift leverin this position. E (2ndGear)Position -1. Accelerate from a stop atfull throttle.Checkthat there is noabnormalnoiseorclutchslippage. -2. Upshiftsand downshiftsshouldnot occurwith the shift leverin this position. Position E (Reverse) Accelerate from a stop at tull throttle,and checkfor abnormalnoiseand clutchslippage.

6.

Testin E (Parking)Position Parkvehicleon slope{app.ox.16'},applythe parkingbrake,and shift into E position.Releasethe brake;the vehicle shouldnot move.

14-96 -

Stall Speed V

CAUTION: a To prev€nt €nt transmission damage, do not tost stall speod for mol€ than 10 soconds at a time. a Do not shitt tho lever while raising the engina speed, a Be suro to remove tho plossule gaugo bolore testing st8ll spe€d. 1. 2. 3. 4. 5. 6.

Engagethe parkingbrake.and block all lour wheels. Connectthe tachometer,and start the engine, Make sure the A/C switch is OFF. After the enginehas warmedup to normaloperatingtemperature{the radiatorfan comeson), shift into g Fully depressthe brake pedal and acceleratorfor 6 to I seconds.and note enginespeed. Allow two minutesfor cooling,then repeatthe test in [, [Dll and @ oositions.

position.

NOTE: a Stall speed tests should be used tor diagnosticpurposesonly. . Stall speed should be the same in E, tr, tr and @ Fositions. Stall Speed FPM: rpm Specification: Bl88l €ngine 2,5q) rpm Bl8Cl engine 2.i|{10.pm SorviceLimit: 81881 engins 2,350- 2,650rpm Bl8Ct ongine 2,250- 2,550rpm

L

TROUBLE Stallrpm hish in E, position

PROBABLE CAUSE and@

E, I

Low tluid level or ATF pump output CloggedATF strainer Pressureregulatorvalve stuck closed Slippingclutch

Stall rpm high in I

position

Slippageof 1st clutch, 1st-holdclutch or 1st gear one-way clutch

Stall rpm high in E

position

Slippageof 2nd clutch

Stall rpm high in ldnl posirion

Slippageof 1st clutch. 1st gear one-way clutch

Stall rpm high in [!l position

Slippageof 4th clutch

Stallrpm low in E, position

Engineoutput low Torque convener one-way clutch slipping

E. I

and@

14-97

FluidLevel Checking/Changing Insertthe dipstickback into the transmissionin the directionshown.

Checking NOTE:Checkthe fluid level with the engine at normal operatingtemperature(the radiatorfan comeson).

V*Y

FRONT

1 . P a r kt h e v e h i c l eo n l e v e l g r o u n d .T u r n o f f t h e e n gIn e .

2. Removethe dipstick(yellow loopl from the transmission,and wipe it with a cleancloth. Insertthe dipstickinto the transmission.

DIPSTICK

Installthedipstickin the extent of the directionshown.

Changing 1.

Bringthe transmissionup to operatingtemperature b y d r i v i n g t h e v e h i c l e .P a r kt h e v e h i c l eo n l e v e l ground,turn the engineoff, then removedrain plug and drainthe automatictransmissionfluid (ATF). Reinstallthe drain plug with a new sealingwasher, then refill the transmissionwith the recommended fluid* to the uppermark on the dipstick.

DIPSTICK

R e m o v et h e d i p s t i c ka n d c h e c kt h e f l u i d l e v e l . shouldbe betweenthe u9Derand lower marks.

\& J

Automatic TransmissionFluid Capacity: 2.7 t 12.9US qr,2.1lmp qt) at change 5.9 / 16.2US $. 5.2 lmp qt) at overhaul RecommendedAutomatic TransmisgionFluid: Genuine Honda Premium Formula Automatic TransmissionFluid (ATE* * A l w a y s u s e G e n u i n eH o n d a P r e m i u mF o r m u l a AutomaticTransmissionFluid(ATF).Usinga nonHondaATF can affectshift qualitv

UPPER LOWER

lf the levelis belowthe lower mark.pour the recommendedfluid* into the tube to bring it to the upper mark. DRAIN 18 x 1.5mm 49 N.m 15.0 kgt.m, 36 lbf.ftl

,

14-98

v WASHER Replace.

I

PressureTesting 4.

Start the engine,and measurethe respectivepres s u r e sa s f o l l o w s . a Line Pressure a Clutch Pressure a Clutch Low/High Pressure a Throttle B Pressure

5.

Installa new sealingwasherand the sealingbolt in the inspectionhole and tighten to the specified torque. T O R O U E : 1 8N . m ( 1 . 8 k g f . m , 1 3 l b f . f t )

a Whiletesting,be careJulotthe rotatingfront wheels. a Make sule litts, iacks, and safety stands are placed properly(see section 1). CAUTION: Befoie testing, be sure the transmissionfluid is filled to the properlevel. '1. Raise 'll. the vehicle{seesection 2.

Warm up the engine (the radiatorfan comes on), then stop the engineand connecta tachometer.

3.

Connectthe specialtool to eachinspectionhole(s).

NOTE: Do not reuse old sealingwashers;always replacewashers. Line PressureMeasurement

T O R O U E1: 8 N . m l 1 - 8 k g t . m , 1 3 l b f . f t l

-1.

S e tt h e p a r k i n gb r a k e a , n d b l o c kb o t h r e a rw h e e l s securely.

CAUTION: Connectthe A/T pressuregaugesecurely, be surenot to allow dust and olher foreignpanicles to enter the inspectionhole.

-2.

R u nt h e e n g i n ea t 2 , 0 0 0 r p m

A/T PRESSURE GAUGE SET W/PANEL 07406 -0020400

3. Shift to S

or @ position.

4. lMeasureline pressure. LINEPRESSURE INSPECTION HOLE

A/T LOW PRESSURE GAUGE W/PANEI. 07406-OO70300

A/T PRESSURE HOSE, 2210 mm OTMAJ_PY4O11A {4 Required} HOSE A/T PRESSURE ADAPTER 07MAJ -PY40120 l4 Requiredl

LOCK-UPCONTROL SOLENOIDVALVE ASSEMBLY

NOTE: Use the A/T PressureGauge Set (07406OO2O0O3)or A/T Low Pressure Gauge (07406OOTOOOO), and the A/T pressuregaugehosesand adapters shown above.

SHIFTLEVER SYMPTOM PRESSURE POST ON Line

No,B

FLUIDPRESSURE PROBABLE CAUSE Standard

Torque converter, 830 88o kPa No (orlow) Irnepressure ATF pump, pressure ( 8 . 5 9 . O k g f / c m ' , 12 0 1 3 0 p s i ) regulator,torque convertercheck

Service Limit

78O kPa ( 8 . Ok g f / c m ' ,1 1 0 p s i )

are madein shitt leverpositionsotherthan S or f, position. NOTE: Higherpressuresmay be indicatedif measurements { c o n t ' d)

14-99

PressureTesting .Y Clutch P.6ssureMeasuremgnt

wnirc testing.be caretulot the roratingtront wheels.

@ -

1. 2. 3. 4. 5.

Setthe parkingbrake,and blockboth rearwheelssecurely. Raisethe front of the vehicle,and supportit with safetystands. Allow the front wheelsto rotatefreelv. Runthe engineat 2.000rpm. Measureeachclutchoressure. lST-HOLDCLUTCH PRESSUREIiISPECTION HOLE

LOCK"UPCONTROLSOLENOID VALVE ASSEMBLY

4TH CLUTCHPRESSURE INSPECTION HOLE 1ST CLUTCHPRESSURE INSPECTIONHOLE

t DRAINP

PfiESSURE

STIIFTLEV€R SYMPTOM POStTtON

11 o' D;l

lst Clutch

1

F L U I DP R E S S U R E PROAAALECAUSE S€rvico Limit lst Clurch

No or low

lsr hold C utch

830- 880kPa (8.5- 9.0 kgflcm, 120- 130psi)

780kPa (8.0kgflcm,,110psi)

420- 440kPa 14.3- 4.9kg?cm,, 61- 70 psi) throttlecontroldrum tully-closed 8:|0- 880 kPa 18.5- 9.0kgflcm', 120- 130psi) throttlecontroldrum morethan1/4ooened 440- 480kPa (4.5- 4.9kgtcm,, 64- 70psi) throttlecontroldrum fully-closed 830- 880kPa {8.5- 9.0ksf/cm', 120- 130psi) throttlecontroldrum rn9l9!q l/4 olqg 830- 880kPa (8.5- 9.0kgtcm?, 120- 130psi)

400 kPa ( 4 . 1k g ? c m , , 5 8p s i ) throttle control drum

Clutch

lr,

znocruiltr

2nd C ltch 2nd Clutch

3rd Clulch

l,i

No or ow

I 4th Clutch

, !,q !le"** No or Low 4th pressufe

3rd Clurch

a,ril","r,

Clulch

14-100

780 kPa ( 8 . 0k g f l c m , ,1 1 0p s i ) t h r o t t l ec o n t r o l d r u m m o r e t h a n 1 / 4o p e n e d

400 kPa 1 4 . 1k g v c m , , 5 8 p s i ) throttle control drum fully-closed 780 kPa (8.0 kgflcm' , 110 psi) throttle control drum more th6n 1/4 opened

zeorpi ( 8 . 0k g t c m ' , 1 1 0P s a ,

I

\a

Clutch LoWHigh ProssuroMoasursment wnire t6sting, be carelul of the rotating @ front whaols.

6. With the engineidling.lift the throttlecontroldrum 'l12 up approximately of its possibletravel and increasethe enginerpm until pressureis indicated on the gauge,then measurethe highestpressure readingobtained.

- 1. Allow the front wheels to rotate freelv. 2. Removethe cableend of the throttlecontrolcable trom the throttle control drum. NOTE: Do not loosenthe locknuts,simplyunhook the cable end.

t

THROTTLE CONTROL DRUM -3.

Start the engineand let it idle.

-4.

Shitt to @

- 7. Repeatsteps 5 and 6 for each clutch pressurebeing inspected.

d

Q^--,'.-

THROTTLECONTROLDRUM

position.

5. Slowlymovethe throttlelinkageto increaseengine rpm until pressureis indicatedon the A/T pressure gauge. Then releasethe throttle linkage,allowingthe engineto returnto an idle,and measurethe pressure reading.

(conr'd)

14-101

PressureTesting {cont'dl \.

t,

LOCK-UPCONTROL VALVE SOLENOID

4TH CLUTCH PRESSURE INSPECTION HOLE

INSPECTION HOLE

u

INSPECTION HOLE

PRESSURE 2 n dC l u t c h

L

SHIFTLEVER POStTtON ior

FLUIDPRESSURE SYMPTOM

PBOBABLECAUSE Siandard

No or low 2nd Clutch 2nd pressure

3rd Clutch

No or low 3rd pressure

3rd Clutch

4th clutch

Noor low 4th pressure

4th Clutch

14-102

420 - 880 kPa (4.3- 9.0 kgf/cm,, 6 1 - 1 3 0p s i ) varieswith throttle openrng 440- 880 kPa (4.5- 9.0 kgf/cm,, 64 - 130psi) varieswith throttle opening

ServiceLimit 400 kPa (4.1kgflcm',58 psi) with throttle control drum released 780 kPa (8.0kgflcm' ,110psi) with throttlecontrol drum more than 1/4 openeo

v

{

lr

while testing, be careful of the rotating @ front wheels.

- 3. - 4. - 5. -6.

- 1. Allow the front wheelsto rotatefreely.

- 7.

Throttle B pressureM€asurement

- 2.

Shift to E!] or Oll position. Runthe engineat 2.000rpm. Measurefully-closedthrottleB pressure. M o v e t h e t h r o t t l ec o n t r o l d r u m t o f u l l y - o p e n e d throttleDosition. Measurefully-openedthrottleB pressure.

Removethe cableend of the throttlecontrolcable trom the throttlecontroldrum. NOTE:Do not loosenthe locknuts,simply unhook the cableend.

THROTTLECONIBOL DRUM

INSPECTION HOLE THROTTLEB PRESSURE

SHIFTLEVER SYMPTOM PRESSURE POStnON Throttle B

[6ll or JDi] Pressuretoo high

No or low Throttle B pressure

FLUIDPRESSURE PROBABLE CAUSE Standard Throttle Valve B

Service Limit

0 15 kPa ( O O . 15 k g l / c m ' , 0 2.1 psi) throttle control drum fully closed 830-88O kPa ( 8 . 5- 9 . O k g f / c m ' , 12 0 1 3 0 p s i ) throttle control drum tully open

780 kPa ( 8 . 0 k g f / c m ' ,1 1 O p s i ) throttle control drum fully open

14-103

Transmission Removal Make sure lifts, iacks and salety stands are placed properly, and hoist brackets are attached to lhe correct position on the engine (seesection 11. Apply parking brake and block real wheels, so vehicle will nol roll off stands and fall on you while working underit.

.

.

Removethe transmissionground cable from the transmissionhanger.

-

5 . Disconnectthe lock-upcontrolsolenoidvalve connectorand the shift controlsolenoidvalve connector, then removethe harnessclamp on the lock-up control solenoidharnessfrom the harnesss1ay.

CAUTION: Usefendercoversto avoiddamagingpainted surtaces. 1.

Disconnect the batterynegative(- ) and positive{ + ) cablesfrom the battery.

2.

Removethe intakeair duct and air cleanerhousing assemoty.

HARNESSCLAMP

AIR CLEANER HOUSINGASSEMBLY

{ TRANSMISSIOI GROUND CABLE 6.

Removethe starter motor cablesand cable holder from the starter motor.

Disconnectthe vehiclespeed sensor(VSS),mainshalt speedsensorand countershaltspeedsensor connecrors. VEHICLE SPEED VEHICLESPEED

ll

t2tor coNNEcroR

V

MOTORCABLE CABLEHOLDER

MAINSHAFT SPEED SENSORCONNECTOR

STARTERMOTOR

'/,/

\

STARTERMOTOR CABI-E

14-104

MAINSHAFT SPEED SENSOR

COUNTERSHAFT SPEEDSENSOR

{

7.

Removethe transmissionhousingmountingbolts.

9. Removethe splashshield.

SPLASH SHIELD

6 x 10 mm BOLT CLIP 5 pcs. 8.

Removethe drain plug, and drain the automatic transmission fluid {ATF).Reinstallthe drainplugwith a new sealingwasher.

10. Remove the cotter pins and castle nuts, then separatethe balljointsfrom the lower arm (seesection 18). 1 1. Removethe rightdamperfork boltanddamperpinch bolt, then separateright dampertork and damper.

PINCH BOLT

SELF.LOCKING NUT Replace.

a COTTERPIN Replace.

DAMPEB FORK 18 x 1.5mm 49 N.m {5.O kgt-m,36 lbf-fr)

V.

14-105

Transmission Removal(cont'd) '12.

Pry the right driveshaftout of the differential,and pry the lelt driveshaftout ol the intermediateshaft.

J

'17. Removethe intermediateshaft.

13. Pullon the inboardjoint, and removethe right and lelt driveshatts(see section l6). 14. Tie plastic bags over the driveshaltends. NOTE: Coat all precisionfinished surlaces with c l e a ne n g i n eo i l .

INTERMEDIATE SHAFT

1 8 . Removethe shitt cablecover,then removethe shilt cable by removingthe control lever.

| 5.

to.

Disconnect the primary heated oxygen sensor ( H O 2 S )c o n n e c t o r .

CAUTION: Take care not to bend the shifr cable while removingit.

J

Removethe exhaustpipe A. SHIFTCABLE

PRIMARY HEATEOOXYGEN SENSOR{HO25l CONNECTOR

CONTROLLEVER SELF-LOCKING NUT Replace.

.l

14-106

u

1 9 .Removethe right front mount/bracket, then remove the end of the throltle controlcablefrom the thrott l e c o n t r o ld r u m . 2 0 . R e m o v et h e A T F c o o l e r h o s e sa t t h e A T F c o o l e r lines.Turn the ends of the cooler hosesup to prevent ATFfrom flowing out,then plug the ATFcooler lines. NOTE: Check for any sign ol leakageat the hose jornrs.

23. Placea jack underthe transmission.raisethe transmission just enough to take weight off of the mounts, then removethe transmtssionmount.

TRANSMISSION MOUNT

THROTTLECONTROLCABLE

f

RIGHTFRONTMOUNT/BRACKETEOLTS ATF COOLER Replace. HOSES 21. Remove the engine stiftener and torque converter cover, 22. Remove the eight drive plate bolts one at a time while rotating the crankshaft pulley.

24. Removethe transmissionhousingmounting bolts and rear enginemountingbolts. 25. Pullthe transmissionaway trom the engineuntil it clearsthe 14 mm dowel pins, then lower it on the transmissionjack.

REARENGINE MOUNTING BOLTS Replace.

WASHERS

COVER

ENGINE STIFFENER

\

TRANSMISSIONJACK

14-107

lllustratedlndex Side Cover Transmission/Right

3

lt

6A

12J

J 14-108

L

(t RtcHTsroEcovER sPEEosENsoR @ MAINSHAFT (O O-RINGSReptace.

spEEosENsoR @ couNTERSHAFT BRACKET @ HARNESS @ RoLLER O coLLAR Replace. @ O-RING @ FEEoPIPEFLANGE @ o-RtNGReptace. O) SNAPRING @ 3RDcLUTcHFEEDPIPE LocKNUT(FLANGE NUT)RepIace, @ COUNTERSHAFT CONtcAL spRtNGwAsHERReptace. @ couNTERSHAFT GEAR @ PARKING G) ONE-WAYcLUTcH lST GEAR @ COUNTERSHAFT BEARTNG @ NEEoLE 1STGEARCOLLAR @ COUNTERSHAFT €0 o-RINGReprace. ptsTok @ 1sT-HoLDAccUMULAToR spRtNG @ 1sr-HoLDAccUMULAToR @ o-RINGReptace. covER @ rsr-HoLDAccUMULAToR @ SNAPRING BRAKEPAWL @ PARKING BRAKEPAWLSPRING @ PARKING BRAKEPAWLSHAFT €0 PARKTNG BRAKEpawl sroppER @ PARKTNG LOCK WASHEF Replace. €0 BRAKESTOPSetecriveoart @ PARKTNG BRAKELEVER @ PARKING ERAKELEVERSPRING @ PARKING @ DowEL PrN @ o-RlNGsReptace. GASKET Reptace. @ RtcHTStOECOVER @ 1sr cLUTcHFEEDptpE Reptace. @ O-R|NGS @ FEEOP|PEGUTOE

@ SNAPR|NG LocKNUT(FLANGE NUT)Replace @ MAINSHAFT coNtcALspRtNGwAsHERReptace. @ MAtNSHAFT @ 1sT clurcH ASSEMBLY Reptace. @ O-RINGS (4DTHRUSTwASHEB NEEDLE EEARING @ THRUST EEARING @)NEEDLE 1sT GEAB @ MAINSHAFT ,IsT @ MAINSHAFT GEARcoLLAR @ ROLLER €) coLLAR @ o-R|NGReptace. @ FEEDPIPEFLANGE @ o-RtNGReptace. @ SNAPRING @ 1sT-HoLDcLUTcHFE€DptpE LOCKNUT NUT)Reptace. TFLANGE @ SUB-SHAFT suB-SHAFT CONTCAL SpRtNG WASHER Reptace. @ 1sT GEAR @ SUB-SHAFT Reptace. @ LocK WASHER coNTRoLDRUM @ THRoTTLE coNTRoLDRUMSPRING 6, THRoTTLE @ OILSEALReplace. @ THRoTTLEcoNTRoL cAELEBRAGKET @ sHtFTcoNTRoLsoLENotoHARNESS G0)JOINTBOLT LINE @ ATFCOOLER wASHERS Reptace. @ SEAL|NG @ ATFcooLERLINE @ ATF DrPsflcK @ JOINTBoLT sENsoR @ vEHrcLESPEED @ o-RINGReptace. (, DRAINPLUG wasHERReplace. @ SEAL|NG

TOROUESPECIFICATIONS BoltiNut No.

Torque Value

5A 6A 6B 8A 12J 18D

8 N.m (0.8 kgf.m, 6 lbf'ft) 1 2 N . m ( 1 . 2 k g f . m , 8 . 7l b f . f t ) 1 4 N . m { 1. 4 k g f. m , 10 l b f. f t ) 2 2 N ' m 1 2 . 2k g f' m , 1 6 l b f. f t ) 2 8 N . m ( 2 . 9 k g f . m . 2 ' 1l b l . I t ) 4 9 N . m { 5 . Ok g l . m , 3 6 l b f . t t ) 9 3 N . m ( 9 . 5 k g t . m ,6 9 l b f . t t ) 7 8 N . m ( 8 . 0 k g t . m , 5 8 l b f. f t ) - O - 1 0 . 5k g f . m . 103-O- 103N.m(1O.5 7 5 . 9- O - 7 5 . 9 t b t . f t )

r9s 21M 23C

Size

Remarks

5xO.8mm 6 x 1 . Om m 6 x 1 . Om m 8 x 1 . 2 5m m 1 2 x 1 . 2 5 m m Joint bolt 1 8 x 1 . 5m m Drain plug 1 9 x 1 . 2 5m m Sub-shaft locknut 2t x

|.25 mm

2 3 x 1 . 2 5m m

Mainshaft locknut: Left-hand threads Countershaft locknut: Left hand threads

{l 14-109

lllustratedIndex TransmissionHousing

" '

ui',

. . ' .:=''...

14 -1 1 0

:

!

(

f

REVERSE O) COUNTERSHAFT GEARCOLLAR (, NEEDLEBEARING @ couNTERSHAFTREVEBsEGEAR (4 LOCKwaSHER Replace. sHtFr FoRK G) REVERSE G) REVERSESELECTOR SELEcToRHUB O REVERSE @ coUNTERSHAFT4TH GEAR O NEEDLEBEARING tE DISTANCECOLLAR,28 mm Setectivepart (} COUNTERSHAFT2ND GEAR [, THBUSTNEEDLEBEARING @ coUNTERSHAFT3RD GEAR [E NEEDI.EBEARING (' COUNTERSHAFT 3RD GEARCOLLAR @ THRUSTNEEDLEBEARING (, SPLINEDWASHER @ 3RD cLUTcH ASSEMBLY t0 O-RINGSReplace. @ couNTERSHAFT (?])SNAP RING @ THRUSTWASHER @ THRUSTNEEDLEBEARING Q} MAINSHAFT4TH GEAR @ NEEDLEBEARINGS @ THRUSTNEEDLEBEARING @ MAINSHAFT4TH GEARcoLLAR €O 2ND/4TH cLUTcH ASSEMBLY @ O-RINGSReptace. @ THRUSTWASHER.36.Sx 55 mm Setectivepart C])THRUST NEEoLE BEARING @ MAINSHAFT2ND GEAR @ NEEDLEBEARING 0t THRUST NEEDLEBEARTNG @ MAINSHAFT

RtNGs,35 mm @ SEALTNG R|NG.29 mm €DSEAL|NG B€ARING @ NEEDLE @ sETRING @ lsT.HoLDcLUTCHASSEMBLY @ o-RtNGsReptace. (, THRUST WASHER NEEDLE BEARING @ THRUST BEARING @ NEEDLE 4TH GEAR @ SUB-SHAFT (O THRUSTNEEDLE BEARING 4TH GEARcoLLAR @ sUB-SHAFT @ SUB-SHAFT NEEDLE EEARING @ SUB-SHAFT BEARTNG sToP @ NEEDLE cAp Reptace. @ ATF GUTDE IDLER GEARsHAFT/HoLDER @ REVERSE BEARING @ NEEDLE (i) sHrFTcoNTRoL soLENotDvALvE A/B @ sHrFTcoNTRoLsoLENotDvALVEFTLTER/GASKET Replace. @ TRANSMISSIoNHANGER .5, TRANSMISSIoN MoUNT BRACKET @) REVERSETDLERGEAR @ otL SEAL Replace. @ THRUSTSHIM, SO mm Setectivepart HOUSTNG @ TRANSMTSSTON GASKETReptace. @ DowEL PtN @ SNAP RING @ SUB-SHAFTTRANSMlsstoNHoustNG BEARTNG @ MA|NSHAFTTRANsMtssroN HoustNG BEARTNG TRANSMIssloNHoUsING BEARING @ CoUNTERSHAFT ASSEMBLY @ DIFFERENTIAL @ oll- SEAL Replace. E9 CONNECTORBRACKET

TOROUESPECIFICATIONS Bolt/NurNo. 6A 6B 10A

12r

Torque Value '12

N . m { 1 . 2 k g f . m ,8 . 7 t b f . f t ) 1 4 N . m ( 1 . 4 k g l . m , 1 Ot b f . f t ) 4 4 N . m { 4 . 5 k g f' m , 3 3 t b f. f t } 4 9 N . m ( 5 . Ok g f . m , 3 6 l b f . t t )

Size

Remarks

6 x 1 . Om m 6 x 1 . 0m m 1 0 x 1 . 2 5m m 12x1.25mm

I 14-111

lllustrated Index Torque Converter Housing/ValveBody \

-

\.,

x

6A

\t

I

14-112

{

I

fD ATF FEEDPIPE

covER O AccUMULAToR @ o-RINGReptace. (O ATF FEEDPIPES (!) ATF FEEDPIPE BASE @ sERvo DETENT Reptace. O LocK WASHER [8)ATFSTRAINER @ sucTroNptpEcoLLAR @ sERVOEODY (, THRoTTLE coNTRoLSHAFT (t E R|NG PLATE Q9SERVOSEPARATOR (D 1STACCUMULAToR cHoKE EALL C' CHECK @ sToP SHAFTSTAY VALVEBODY @)SECONDARY OODOWELPIN (t SEcoNDARYSEPARAToR PLATE PTATE @ LUBRICAToR 8] ATF FEEDPIPE @ LocK-uPvALvE BoDy @ DowEL PrN PLATE @ LocK-uPSEPARAToR cHEcKVALVESPRING E TORoUECoNVERTER cHEcK vALvE €0 ToRouE CoNVERTER CHECKVALVESPRING Q) COOLER @ cooLERcHEcKVALVE

vALvE BoDY @ REGULAToR @ sToP SHAFT @ o-RINGReptace. 6, STATORSHAFT @ ATF FEEDPIPE @ MA|NVALVEBOOY @ cHEcKBALL @ DowEL PrN @ ATF PUMPDRIVEGEAR GEARSHAFT @ ATF PUMPDRIVEN GEAR OOATFPUMPDRIVEN @ MA|N SEPARAToR PLATE 6' DowEL PIN SHAFT @ CONTROL @ DETENTARM SPRING ARM SHAFT @ OETENT @ DETENTARM ToRoUEcoNVERTER HoUSING @ coUNTERSHAFT NEEOLE BEARING @ ATF GUIDEPLATE @ ToRouE coNvERTERHoustNG ToRoUEcoNvERTERHousING BEARING @ MAINSHAFT @ oll SEALReDtace. @ LocK-up coNTRoL soLENotDvALvE A/B ASSEMBLy @ coNNEcToRBRACKET @ LocK-UPcoNTRoL SoLENoIDvALvE FILTER/GASKET Replace.

TOROUESPECIFICATIONS Bolt/Nut No.

TorqueValue

Size

6A

1 2 N . m { 1. 2 k g f . m , 8 . 7l b f . f t )

6 x 1 . 0m m

Remarks

I 14-113

Right Side Cover Removal

J

NOTE: compressedalr' a Cleanall parts thoroughlyin solvent or carburetorcleaner'and dry with a Blowout all Passages. a When removingthe transmissionright side cover, replacethe following: . Right side cover gasket . Lock washers . O rings . E a c hs h a { tl o c k n u t . C o n i c a sl p r i n gw a s h e r s . Sealingwashers 6 x RIGHTSIDECOVER GASKET Beplace.

1 . 0mm BOLTS ,

B

MAINSHAFTLOCKNUT Replace. CONICAL SUB-SHAFTLOCKNUT SPRING Replace. WASHER Replace.

RIGHTSIDECOVER

c

,

CONICALSPRINGWASHER Replace. 1ST CLUTCHASSEMBLY PARKINGBRAKELEVER

COUNTERSHAFT LOCKNUT CONICALSPRING WASHER Replace.

J

PARKINGGEAR

\-_7 SUB-SHAFT1

ONE-WAYCLUTCH

'::-Pf.a

1ST GEAR NEEOLEBEARING

THROTTLECONTROL DRUM 1ST GEAB

1ST GEARCOLLAR SEALING WASHERS Replace.

'. .) JOINT BOLT ATF COOLERLINES

otPsTtcK SEALINGWASHERS Replace.

I

t

14 -1 1 4

I

1 .

Removethe 13 bolts securingthe right side cover, then removethe right side cover.

5. Cut the lock tabs oI the each shaft locknutusing a chiselasshown.Thenremovethe locknutfrom each shatt.

2 . Slip the specialtool onto the mainshaftas shown. NOTE: a lvlainshaftand countershaftlocknutshave left, h a n dt h r e a d s . a Cleanthe old countershaftlocknut, it is used to pressthe parkinggear on the countershaft. a Always wear salety glasses.

MAINSHAFT HOLDER OTGAB PFsO1O1

CAUTION: Keepall of the chiseledpaiticlesout of the transmission.

ll fcH,sEL

Jl{*---,o"*",r

@--.**,o, 6. Removethe lock pin that was installedto hold the sub-shaft.

t

7. Removethe specialtool from the mainshattafter removingthe locknut. Engagethe parkingbrakepawl with the parkinggear. Alignthe holeof the sub-shaft'lst gearwith the hole of the the transmissionhousing,then inserta pin to lock the sub-shaft while removing the sub-shaft locknut.

8. Removethe 'lst clutch and mainshaft'lst gear as sembly from the mainshaft. 9 . R e m o v et h e s u b - s h a f t1 s t g e a r 1 0 . R e m o v et h e p a r k i n gb r a k ep a w l ,

MAINSHAFT COUNTERSHAFTLOCKNUT LOCKNUT Reptace. Replace.

PIN 8 mm pin. commercially available

1 1 . U s i n ga u n i v e r s at lw o j a w p u l l e r r, e m o v et h e p a r k Ing gear,one-wayclutchand countershalt1st gear assemoty.

SUB.SHAFT LOCKNUT Replace.

PARKINGGEAR

Removethe parking brake lever from the control shaft.

Align the holes.

13. Removethe throttle controldrum lrom the throttle control shaft.

I

CONICALSPRING WASHERS Replace.

1 4 . Removethe ATF coolerlines. t5.

Removethe ATF dipstick.

14-115

TransmissionHousing Removal

J HOUSING TRANSMISSION MOUNTING BOLTS

TRANSMISSIONHOUSING

TRANSMISSIONHOUSING GASKET Replace. REVERSEGEAR COLLAB

NEEDLEBEARING GEAR REVERSE MAINSHAFT SU8-ASSEMBLY

LOCXWASITEF Replace.

4 REVERSESELECTOR

COUNTERSHAFT SUB.ASSEMELY DIFFERENTIAL ASSEMBLY

J

,

14-116

f

NOTE: a Clean all parts thoroughly in solvent or carburetor cleanerand dry with compressedair. a Blow out all passages. a Whenremovingthe transmission housing,replacethe tollowing: . Transmissionhousinggasket . Lock washer 1.

5 . Removethe countershaftreversegearwith the collar and needlebearing. 6.

Removethe lock bolt securingthe shilt fork. then removethe fork with the reverseselectorfrom the countershatt.

7 . Remove the countershaft and mainshaft subassemblytogether.

Removethe transmissionmount bracket.

2 . Removethe transmissionhousingmounting bolts andhanger. Align the spring pin of the control shatr wirh the transmissionhousinggrooveby turningthe control shatt. Installthe specialtool on the transmissionhousing, then removethe housingas shown. TRANSMISSTON HOUSING HOUSING PULLER

8.

Removethe differentialassemblv.

14-117

Torque ConverterHousing/ValveBody Removal

t

ATF FEEDPIPE

LUBRICATOR PLATE ATF FEED Bott PIPES

ATF FEEDPIPES COVER ACCUMULATOR ATF FEEOPIPE

DOW€I-PIN Bolrs,3 LOCK-UPSEPARATOR PLATE ,

REGULATORVALVE EODY

ll E

./"o"

LOCK WASHER

SERVODETENT SASE

coNrRoL Sl{AF-r ATF STRAINER

ATOR ATF FEED

-

DOWELPIN ATF PUMPDRIVENGEARSHAFT

ATF PUMP ORIVENGEAR

SEPARATOR PLATE

.a

_ro-rr!_

I

NOTE: a Clean all parts thoroughlyin solvent or carburetor cleanerand dry with compressedair. a Blow out all passages. a Whenremovingthe valvebody replacethe lollowing: . O-rings . Lock washers

14. Cleanthe inletopeningot the ATF st,ainerthoroughly with compressedair, then checkthat it is in good condition.and the inlet openingis not clogged.

1 . Removethe ATF feed pipesfrom the servo body, servo detent base, accumulatorcover, lock-upvalve body and main valve body. 2. Removethe three bolts securingthe ATF strainer and servo detent base, then remove the strainer and detentbase. 3. Removethe three bolts securingthe accumulator cover, then removethe accumulatorcover.

INLETOPENING

4. Removethe six bolts securingthe servobody. then removethe servo body and separatorplate. 5. Removethe one bolt securingthe secondaryvalve body, then removelhe secondaryvalve body and separatorplate.

l"

J

6. Removethe eight boltssecuringthe lubricatorplate and lock-upvalve body, then remov€th€ lubricator plate.Iock-upvalvebody,and separatorplate.

1 5 .Replacethe ATF strainerif it is cloggedor damaged. NOTE: The ATF strainercan be reusedif it is not clogged.

7. Removethe one bolt securingthe regulatorvalve body, then removethe regulatorvalve body. 8. Removethe stator shaft and stop shaft. 9. Removethe detentspringfrom the detentarm,then removethe controlshaft from the torqueconverter housrng. 1O. Removethe detent arm and detent arm shatt from the main valve body. 'l 1 . Removethe four boltssecuringthe mainvalvebody, then removethe main valve body. 'I2. Remove the ATF pump driven gear shatt, then remove the ATF pump gears. 13. Removethe main separatorplate with two dowel pins.

I 14-119

Valve Caps Description I a Caps with one projectedtip and one flat end are installed with the flat end toward the insideoJthe valve body. a Caps with a proiectedtip on each end are installed with the smallertip toward the insideof the valve body. The smalltip is a springguide.

Toward outsid6 ot v6lvo body.

CaDswith hollow ends are installedwith the hollow end away from the insideof the valve body. Capswith notchedends are installedwith the notch toward the insideot the valve body. Capswith tlat ends and a holethroughthe centerare installedwith the smallerholetowardthe insideof the valve body.

Toward ouGida ol valvo body.

Efla Toward insido of valvo bodv.

Toward in.ldo ot valve bodY.

{ Caps with one projectedtip and hollow end are installedwith the tip toward the insideof the valve body. The tip is a spring guide.

Tow6.d outsid€ ot valvo bodY.

Capswith tlat ends and a groovearoundthe cap are installedwith the groovedsidetoward the outsideof the valve bodv.

Toward oulrlda of valve bodv.

"-\"h ,a\

v{9

Sociiohal viow.

Tow6rd in3id6 ol valvo bodv.

,

14-120

Toward insido ot v.lvo body.

Valve Body Repair NOTE: This repairis only necessaryif one or more of the valvesin a valve body do not slidesmoothlyin their bores.You may use this procedureto free the valvesin the valve bodies. 1. Soak a sheet of # 600 abrasiveDaDerin ATF for about 30 minutes. 2.

Removethe #600 paperand tho.oughlywash the entire valve body in solvent, th€n dry with compressedair. Coat the valve with ATF then droD it into its bore. It should droD to the bottom of the bore under its own weight. lf not, repeat step 4 then retest. lf the valve still sticks,replacethe valve body.

Caretullytap the valve body so the stickingvalve drops out of its bore. CAUTION: lt may be necessary to use a small scrawdriv6r to pry the the valve f.66. Bs caloful not to sciatch th€ bole with th6 scrowdriver. InsDectthe valvefor anv scuff marks.Usethe ATFsoaked# 600 paperto polishofl any burrsthat are on the valve.then washthe valvein solventand drV it with compressedair, VALVE BODY Rollup halt a sheetot ATF-soakedpaper,and insert it in the valve bore of the stickingvalve. Twist the paperslightly,so that it unrollsand fits the boretightly.then polishthe boreby twistingthe paper as you push it in and out. CAUTION: The valvs body is aluminumand doesn't require much polishing ro lomovo any bulla.

7 . Removethe valve. and thoroughlyclean it and the valve body with solvent. Dry all parts with compressed air, then reassembleusing ATF as a lubricant.

14-121

Valve Assembly NOTE: Coat all parts with ATF before assembly. a Installthe valve,valvespringandcap in the valvebody and securewith the roller.

a Set the springin the valveand installthemin the valve oooy. Pushthe springin with a screwdriver,then installthe spnng seat.

SPRINGSEAT

VALVE EODY

Install the valve, spring and cap in the valve body. Push the cap, then install the clip. VALVE BODY

VALVE

14-122

I

ATF Pump Inspection ' t . Install the ATF pump gears and ATF pump driven

2.

gear shaft in the main valve body. NOTE: a Lubricateall parts with ATF during inspecting. a InstalltheATF pumpdrivengearwith its grooved and chamferedside facing up as shown.

Measure the side clearance of the ATF pump drive and driven gears. ATF Pump Gears Side {Radial} Clearance: Standald (Newl: Drive geal O.21O 0.265 mm (O.O083 O.O104in) Dfiven geal 0.07O 0.125 mm (O.O028 O.0049 in)

ATF PUMP DRIVENGEAR Groovedand chamferedside facing up.

ATF PUMP DRIVEGEAR

ATF PUMP DRIVENGEAR Inspectteeth for wear and damage,

lnspectteethfor wearanddamage-

3.

Removethe ATF pump drivengearshatt, and measure the thrust clearanceoI the ATF pump driven gear-to-mainvalve body. ATF pump Drive/DrivenGearthlust (Axiall Clearance: StandardlNew): 0.O3-0.05 mm (0.0O1 0.002 in) Selvice Limit: O . O 7m m { 0 . 0 0 3 i n )

STRAIGHTEDGE

14-'|,2 3

Main Valve Body Disassembly/lnspection/Reassembly NOTE: a Cleanall pans thoroughlyin solventor carburetorcleaner,and dry with compressedair. a Blow out all passages. a Replacevalve body as an assemblyif any psrts 8re worn or damaged. a Check all valves tor free movement.It anv fail to slide freely, see Valve Body Repairon page 14-121.

Y

CAUTION: Do not use a magnet to lemove tho check balls; it may magnoliz€ the balls.

2-3 SHIFTVALVE

CHECK BALLS.3 ARM SHAFT

DETENTARM

I

RELIEFVALVE

MAIN VALVE BODY Inspectfor wear. scratches and sconng.

14-124

DETENTARM SHAFT MANUAL VALVE

SPRINGSPECIFICATIONS Unit ot length: mm (in) Stsndard {N€w} No.

o

@ @ \

\9

Spdng Reliefvalve spring 4th exhaustvalve spring 2-3 shift valve spring CPC valve spring 1-2 shift valve spring

Wi.s Dia.

1.1 (O.O43) 1.0 (o.o39) o.9 (o.o35) 1. 3 ( 0 . O 5 1 ) o.9 (o.035)

o.D. 8.6 (O.339) 7.1 (O.280) 7.6 (O.299) 9.4 {0.370) 8.6 (O.339)

Fro€ Lsngth

3 7 . 1( 1. 4 6 1 ) 6 0 . 3( 2 . 3 7 4 ) 57.Ot2.244]. 3 5 . 3 ( 1. 3 9 0 ) 4 0 . 4( 1. 5 9 1 )

No. ot Coils 18 . 5 zo.6

14.5

14-125

RegulatorValve Body /Reassembly Disassembly/lnspection !

NOTE: a Cleanall parts thoroughlyin solvent or carburetorcleaner.and dry with compressedair. a Blow out all passages. a Replacevalve body as an assemblyif any parts are worn or damaged. a Check all valvesfor free movement.lf any fail to slide freely, see Valve Body Repairon page 14-121. 1. Hold the regulatorspring cap in place while removingthe lock bolt. Once the bolt is removed.releasethe spring cap slowly. CAUTION: The regulator sp ng c8p can pop out when the lock bolt is r€moved. 2.

Reassemblyis in the reverseorder of the disassemblyprocedure. NOTE: . Coat all pans with ATF. a Align the hole in the regulatorspringcap with the hole in the valve body, pressthe springcap into the body and tighten the lock bolt.

LOCKBOLT 6 x 1 . Om m 1 2 N . m1 1 . 2

REGULATORSPRINGCAP

COOLERCHECK

DOWEL PINS, 2

oi.

,/ "W_-

REGULATORVALVE BODY Inspectfor wear, scratches and sconng. LOCK-UPCONTROL VALVE

ROLLER

..

/

,/ i>,

ll

@

VALVE SLEEVE

SPRINGSPECIFICATIONS

; m (in) U n i to f l e n g t h m Standard {Newl

Spring

No.

o @ @ @ rA @

RegulatorvalvespringA RegulatorvalvespringB Statorreactionspring Lock-upcontrolvalvesprlng Coolercheckvalvespring Torqueconvertercheckvalvespring

Wiro Dia. 1 . 8( 0 . 0 7 1 ) 1 . 8( 0 . 0 7 1 ) 4.5lO.177l 0.8 (0.031) 1.0(0.039) 1.0(0.039)

o.D. 14.7{0.579} *6.0 (0.236) 2 6 . 4( 1 . 0 3 9 ) 6.6 (0.260) 8 . 4( 0 . 3 3 1 ) 8.4 (0.331) *: lnsideDiameter

,

14-126

FrooLongth 87.8(3.457) 44.0\1.1321 3 0 . 3( 1 . 1 9 3 1 4 1 . 6( 1 . 6 3 8 ) 3 3 . 8( 1 . 3 3 1 ) 3 3 . 8( 1 . 3 3 1 )

No. of Coils to.c

1.92 27.6 8.2 4.2

Lock-upValve Body Disassembly/lnspection/Reassembly

I

J

NOTE: a Cleanall parts thoroughlyin solvent or carburetorcleaner,and dry with compressedair. a Blow out all passages. a Replacevaive body as an assemblyif any parts are worn or damaged. o Check all valves for free movement.lf any fail to slide freely, see Valve Body Repairon page 14-121, a Coat all parts with ATF before reassembly.

LOCK-UPSHIFTVALVE

LOCK-UPVALVE

LOCK-UPTIMINGB VALVE

SPRINGSPECIFICATIONS Unit of length: mm (in) Standard(New) No.

o (r\

Spring Lock-upshift valve spring Lock-uptiming B valve spring

Wire Dia.

o.D.

o.9 (o.o35) 7 . 6 ( O . 2 9 9 ) o . 8( o . o 3 1 ) 6 . 6 ( O . 2 6 0 )

Free Length

7 3 . 7t 2 . 9 0 2 1 6 0 . 8{ 2 . 3 9 4 }

No. of Coils

32.O 22.1

4-127

SecondaryValve Body Disassembly/lnspection/Reassembly i

NOTE: a Cleanall parts thoroughlyin solvent or carburetorcleaner.and dry with compressedair. a Blow out all passages. a Replacevalve body as an assemblyif any parts are worn or damaged. a Check all valvesfor tree movement.lf any fail to slide freely. see Valve Body Repairon page 14-121. a Coat all parts with ATF belore reassembly. CAUTION: Do not use a magnet to remove the check balls; it may magnetize the balls.

@

a/ \.^fl

*..'a

tio.

ORIFICECONTROL VALVE 16

FILTER Replace.

o \

{

2-3 ORIFICECONTROL VALVE 4 SHIFT VALVE

/ i ( /

\ \

DOWELPIN, 2 SECONDARYVALVE BODY Inspectfor wear, scratches and sconng.

)

da ')

a

MODULATORVALVE

@

\n

l"

@

;fl'J'*'

tq, fr

b

\ \ VALVE CAP

14-128

CHECK SALL

CHECKBALLS

SECONDARY VALVEBODY lSectionalView) FILTER

SPRING SPECIFrcANONS

Unit of length:mm (in) Standard {Ncwl

No. \!-/

o @ @

o @ o

Spring 3-2 kick-downvalve spring 4-3 kick-downvalve spring Orificecontrolvalvespring 2-3 orifice control valve spring 3-4 shiftvalvespring Servocontrolvalvespring Modulatorvalvespring

wir€ Dia. 1 . 3( 0 . 0 5 1 ) 1.0{0.039) 0.8(0.031) 0.9(0.035) 0.9(0.03s1 0.9(0.035) 1 . 3( 0 . 0 5 1 )

o.D. 8.6(0.339) 6.6(0.260) 6.6(0.260) 6.6(0.260) 7.6(0.299) 6.4(0.252) 9.4(0.370)

Frcc Lcngth

4s.6(1.795) 24.511.'t221 48.2(1.898) 33.0{1.299) 52.0\2.0471 34.1(1.343) 39.3(1.547)

No. of Coils 1 1. 0 14.7 14.9 26.8 12.4

14-129

Servo Body Disassembly/lnspection/Reassembly NOTE: a Cleanall parts thoroughlyin solvent or carburetorcleaner,and dry with compressedair. a Blow out all passages. a Replacevalve body as an assemblyif any parts are worn or damaged. a Coat all parts with ATF before reassembly. a Replacethe O-rings.

\9 \ l 6 x 1 . Om m 12 N.m {1.2kgf'm, 8.7 tbt.ftl

4TH ACCUMULATOR PISTON

1ST ACCUMULATORCOLLAR O.RING Replace.

l l

PISTON 1ST ACCUMUI.ATOR

Replace. O.RING Replace.

SERVOBODY Inspectfor wear, scratches and sconng. THROTTLEADJUSTINGBOLT CAUTION:Do not loosenor

{

--'-'a@':

l l l VALVE B

li il

Replace.

14-130

{a

I

J

SPRINGSPECIFICATIONS Unit of length: mm (in) Standard{Newl No.

o

Throttle valve B adjustingspring

(r\

Throttle valve B spring

o

@

t

J

t

J

Spring

4th accumulatorspring 1 s t a c c u m u l a t osrp r i n g 3rd accumulatorspring 2nd accumulatorspring

Wire Dia.

I (

o.D.

Free Length

34.0(1.339) 4 1 . 5( 1 . 6 3 4 ) 4 1 . 5( 1 . 6 3 4 ) 4 1 . 6 ( ' 1. 6 3 8 ) (0. I o _ J 1 03.3(4.067) r 2.6 02) lo.642) 2.5(O.098) I o . J lo.6421 10 5 . 4 ( 4 .1 5 0 ) 2 . 8 ( O . 11 0 ) 1 7. 5 1 0 . 698) 105.2 l'4.142) 3 . 6 ( O . 1 4 2 ) 2 2 . O l o . 8 6 6 ) 1 0 8 . 9( 4 . 2 8 7 )

0.7 10.028) 1.4{0.055) 1.4(O.055) 1.4 (0.055)

6 . 2 "o.244\ 8 . 5 1 o . 353) 8 . 5 1 0 . 353) 8 . 5 1 o . 353)

No. of Coils 10.5 11.2 12.4 21.2 16 + 8.6 19.1

14-131

1st-holdAccumulator/RightSide Cover Disassembly/lnspection /Reassembly rl NOTE: a Cleanall parts thoroughlyln solvent or carburetorcleaner,and dry with compressedair. a Blow out all passages. a Coat all parts with ATF before reassembly. SNAPRING

lST.HOLD ACCUMULATORCOVER

O.RING Rephce.

(N1ST-HOLDACCUMULATORSPRING

lST.HOLOACCUMULATORPISTON

RIGHTSIDECOVER

O --l

\

SPRINGSPECIFICATIONS

Unit of length: mm {in) Standard {New}

Spring

No.

o

L

'lst

hold accumulator spring

14-132

Wire Dia.

o.D.

4 . O ( O . 15 7 )

21.5(O.846)

Free Length

7 1 . 7t 2 . a 2 3 l

No. of coils

ra

Mainshaft Disassembly/lnspection/Reassembly \

J

NOTE: a Lubricateall parts with ATF during reassembly. a Inspectthe thrust needlebearingsand the needlebearingsfor gallingand rough movement. a Beforeinstallingthe O-rings,wrap the shatt splineswith tape to preventdamagingthe O-rings. a Locknut has left-handthreads. LOCKNUTIFLANGENUTI 1 9 x 1 . 2 5m m 78 N.m (a.0 kgf.m, 58 lbl'ltl Replace. Left hand threads

CONICALSPRINGWASHER Replace. 1ST CLUTCH ASSEMBLY

THRUSTWASI{€R

O-RINGS Replace. THRUSTWASHER

4TH GEAR

MAINSHAFT Checksplinesfor excessive wear ano oamage, Check bearingsurfacefor scoring, scratchesand excessivewear.

\

NEEDLEBEARINGS

THRUSTNEEDLE EEARING NEEDLEEEARING 1ST GEAB lST GEAR COLLAR

THRUSTNEEDI-E BEARING 4TH GEARCOLLAR

J

2ND/4TH CLUTCH

O-RINGS Replace. THRUSTWASHER,36.5 x 55 mm Selectivepart.

THBUSTNEEDLE BEARING 2ND GEAR BEARING THRUSTNEEDLE BEARING lnstallthe sealingring matinglaces as shown-

\

J

SET FING

NE€DLEBEARING

14-133

Mainshaft Inspection 3 . T o r q u e t h e m a i n s h a t tl o c k n u t t o 2 9 N . m ( 3 . O kgf.m, 22 lbt.tt).

ClgaranceMeasurement NOTE: Lubricateall parts with ATF during assembly,

NOTE: Mainshaftlocknut has left-handthreads. 1.

Removethe mainshaftbearingfrom the transmission h o u s i n g{ s e ep a g e 1 4 - 1 5 6 ) .

2.

Assemblethe pans below on the mainshaft. NOTE: Do not assemblethe O-rings during inspection. CONICAL

WASHER

29 N.m (3.0 ksl'm,22 lbf'ftl

lST CLUTCHASSEMBLY THRUST WASHER lST GEARCOLLAR TRANSMISSION HOUSINGBEARING SNAP RING THRUSTWASHER TH GEARCOLLAR

Hold 2nd gear againstthe 2nd clutch, then measure the clearancebetween 2nd gear and 3rd gear with a feelergauge. NOTE: Takemeasurements in at leastthreeplaces, and use the averageas the actual clearance. S T A N D A R D0: . 0 5 - 0 . 1 3 m m 1 0 . 0 0 2 - 0 . 0 0 5 i n ) 3RD GEAR

2ND GEAR

2ND/4TH CLUTCI{ ASSEMALY THRUST WASHER 36.5 x 55 mm Selective part THRUSTNEEDLE BEARING zND GEAR BEARING THRUSTN€EDLE BEARING THRUSTWASHER, 36.5 x 55 mm

MAINSHAFT

14-134

!

It

5 . It the clearance is out of tolerance,removethe thrust washer and measurethe thickness.

Selectand installa new washer,then recheck.

6.

THRUSTWASHER36.5 x 55 mm No.

Part Number

Thickness

1

4 . 0 O m m ( 0 . 15 7 i n )

2

90441 PG4 010 9 0 4 4 2- P G 4 - O l O

3

90443-PG4-O10

4 . 1 Om m ( O . 1 6 1i n )

4

90444-PG4 010

. 6 3i n ) 4 . 15 m m ( O 1

5

90445 PG4-010

4 . 2 0 m m ( O . 1 6 5i n )

6

90446 PG4 010

4 . 2 5 m m { O . 1 6 7i n )

7

90447,PG4-010

4 . 3 0 m m ( O . 16 9 i n )

I

90448 PG4-0'10

4 . 3 5 m m ( 0 . 17 1 i n )

9

90449-PG4-010 90450 PG4- 000

4 . 4 0 m m { 0 . 17 3 i n ) 4 . 4 5 m m ( 0 . 17 5 i n )

J

10 7.

4 . 0 5 m m ( 0 . 15 9 i n )

After replacingthe thrust washer, make sure the clearanceis within tolerance.

.J 14-135

Countershaft Disassembly/lnspection/Reassembly NOTEI a Lubricateall parts with ATF before reassembly. a Inspectthe thrust needlebearingsand the needlebearingsfor gallingand rough movement. a Beforeinstallingthe O rings, wrap the shaft splineswith tape to preventdamagingthe O-rings. a Locknut has left-handthreads.

REVERSE GEARCOLLAR

NUTI LOCKNUT {FLANGE 2 3 x 1 . 2 5m m 103-0-1O3N.m (10.5-0-lO.5kgf.m, 75.9 - 0 - 75.9 rbf.lrl Replace.

CONICALSPRING WASHER

Left hand threads

BEARING REVERSE SELECTOR REVERSESELECTOR HU8 1ST GEAR COUNTERSHAFT Check splinesfor excessive wear and damage, Check bearing surface for scoring, scratches and excessive wear.

4TH GEAR NEEDLEEEARING DISTANCECOLLAR, 28 mm Selectivepart. 2ND GEAR

THRUSTNEEDLE EEARING

3RD GEAR NEEDLEBEABING

i

3RDGEARCOLI-AR THRUSTNEEDLEBEARING SPLINED WASHER 3RD CLUTCH ASSEMBLY

14-136

TFANSMISSION HOUSINGBEARING

Disassembly/Reassembly 1. Usinga hydrsulicpress,pressout the countershaft while supponing4th gear. NOTE: Placean attachmentbetweenthe oressand the countershaft to prevent damage to the shatt, CAUTION: Do not allow th€ count€rshaftto fall rnd hit the ground.

2.

Assemblethe parts on the countershaftas shown below. NOTE: a Lubricateall parts with ATF during assembly. a Before installingthe O-rings, wrap the shaft splines with tape to prevent damaging the O-rings.

'{EEDLEEEARIIIG DISTANCECOLLAR, 28 mm Selectivo part.

THRUST NEEDLEBEARING

T

BEARING GEAR COLLAR TI{BUST NEEDLEBEARING WASHER CLUTCH ASSEMBLY

T

(cont'd)

14-137

Countershaft (cont'dl Disassembly/Reassembly 3.

Installthe reverseselectorhub on the countershaft sub-assembly,and then pressthe reverseselector hub using the specialtool and a press as shown.

ClearanceMeasurement NOTEr Lubricateall parts with ATF during assembly. 1. Removethe countershaftbearingfrom the transmis s i o n h o u s i n g( s e ep a g e 1 4 1 5 6 ) . 2.

lnstallthepartsbelowon the countershaftusingthe specialtool and a pressas describedon this page. NOTE: Do not assemble the O-rings during anspection.

REVERSESELECTOR HUB 4TH GEAR BEARING DISTANCECOLLAR,28 mm Selectivepart.

2ND GEAR THRUSTNEEDLEBEARING 3RO GEAR BEARING GEARCOLLAR THRUSTNEEDLEBEARING SPLINEDWASHER

CLUTCHASSEMBLY

14-138

I

3 . Install the parts below on the countershaftsub assembly,then torque the locknut to 29 N.m (3.O k g f. m , 2 2 l b l ' f t ) . NOTE: Countershaltlocknuthas left handthreads.

Measurethe clearancebetween the 2nd gear and the 28 mm distancecollar with a feeleroauoe. NOTE: Takemeasurements in at leastthreeplaces, and use the averageas the actual clearance. S T A N D A R DO : . 1 0 - O . 1 8 m m ( O . 0 O 4 - O . O Oi7n l DISTANCECOLLAR,

LOCKNUT Left hand threads CONICALSPRING WASHEB PARKINGGEABiONE.WAY CLUTCH/1STGEAR ASSEMELY NEEEDLE EEARING lST GEARCOLLAR TRANSMISSION HOUSING BEARING REVERSE GEAR COLLAR

DISTANCECOLLAR.

COUNTERSHAFT SUB,ASSEMBLY

2ND GEAR

FEELER GAUGE

14-139

Countershaft Inspection(cont'd) Y 5.

lf the clearanceis out of tolerance.remove the 28 mm distancecollar and measurethe width.

6.

Select and install a new distance collar. then recheck.

DISTANCECOLLAR, 28 mm No.

Part Number

width

1

90503-PC9-OOO

3 9 . 0 0 m m ( 1 . 5 3 5i n )

t

90504-PC9-000

3 9 . 1 0m m ( 1. 5 3 9i n )

90505-PC9-000 90507-PC9-O00

3 9 . 2 0 m m ( 1 . 5 4 3i n ) 3 9 . 3 Om m ( 1 . 5 4 7 i n )

90508-PC9-OOO

3 9 . 0 5 m m ( 1. 5 3 7 i n )

90509-PC9-000

3 9 . 15 m m { ' 1 . 5 4 1i n )

7

90510-PC9-000

3 9 . 2 5m m ( 1 . 5 4 5i n )

I

9 0 5 1 1 - P C g - 0 0 0 3 8 . 9 0 m m ( 1 . 5 3 1i n )

I

90512-PC9-OO0

5

7.

3 8 . 9 5m m ( 1 . 5 3 3i n )

Alter replacingthe distancecollar, make sure the clearanceis within tolerance.

J

./

14-140

One-way Glutch Disassembly/lnspection/Reassembly

I

1.

Separatecountershaftl st gearfrom the parkinggear by turningthe parkinggear in the directionshown.

Inspect the parts as follows:

PARKING GEAR PARKINGGEAR

Inspectthe parkinggear for wear and scoring.

COUNTERSHAFT lST GEAR

ONE-WAY 2.

Removethe one-wayclutchby pryingit up with the end of a screwdriver.

COUNTERSHAFT 1sr GEAR

Inspect the one-way clutch for damages and faully movement,

ONE.WAYCLUTCH ioie, ,n",u',In thrsdrectron. 1ST GEAR

Inspectcountershaft 1st gear Ior wearandscoring,

3.

After the partsare assembled, holdcountershaftl st gearandturn the parkinggearin the directionshown to be sure it turns freely.AIso make sure the park ing gear does not turn in the oppositedirection.

PARKINGGEAR

Of{E-WAY CLUTCH COUNTERSHAFT lST GEAR

COUNTERSHAFT 1ST GEAR SCREWDRIYER

14-141

Sub-shaft Disassembly/lnspection/Reassembly NOTE: a Lubricateall parts with ATF during reassembly. a Inspectthe thrust needlebearingsand the needlebearingsfor gallingand rough movement' a Beforeinstallingthe o-rings, wrap the shaft splineswith tape to preventdamagingthe o-rings.

TRANSMISSION HOUSING

TRANSMISSION HOUSINGBEARING

1ST-HOLOC|-UTCH ASSEMBLY

O-RINGS Replace. 6 x 1.0 mm 12 N.m (1.2 kgf.m, 8.7 lbf.tt)

THRUSTWASHER THRUST NEEDLE BEARING NEEDLEBEARING

SUB-SHAFT Checksplinesfor excessive wear and oamage. Check bearingsurfacefor scoring,scratchesand

4TH GEAR THRUSTNEEDLE AEARING

ATF Replace-

NEEDLEBEARING STOPPEB

4TH GEAR COLLAR

NEEDLEBEARING

14-142

Disassembly/Reassembly Removethe ATF guidecap by pushingthe sub-shaft insidethe transmissionhousing. Removethe 1st-holdclutchassemblyby pullingthe sub-shaft,then removethe sub-shaft. Installnew O-ringson the sub-shaft. NOTE: Wrapthe shaft splineswith tape to prevent damagingthe Orings, Placethe sub-shaftin the transmissionhousingand installthe 1st-holdclutch assembly. Installnew ATF guidecap usingthe specialtoolsas shown. NOTE: Installthe ATF guide cap in the direction shown.

ORIVER

TTACHMENT, 32x35mm 07746-O010100

CLUTCH ASSEMBLY

t 14-143

Sub-shaftBearings Replacement Install the new needle bearing in the transmission housing using the specialtools and a press as shown.

NOTE: Lubricateall partswith ATF beforereassembly. 1 . To removethe sub-shaftballbearingfrom the transmissionhousing,expandthe snapringwith snapring pliers,then push the bearingout using the special tools and a press as shown.

PRESS

ATTACHMENT, 32 x 35 mm 07746-0010roo ATTACHMENT. 62 r 68 mm 07746-0010500 Removethe needlebearingstopper. Removethe needlebearingfrom the transmission housingusing a drift punch.

DRIFTPUNCH

5 . Expandthe snap ring with snap ring pliers,then insert the ball bearingpart-way into the housingusingthe specialtools and a pressas describedin step 1. Installthebearingwith the groovefacingoutside the housing. 6.

Releasethe pliers,then pushthe bearingdown into the housinguntilthe snapringsnapsin placearound rt.

7 . After installingthe ballbearing,veritythe following: a The snap ring is sealedin the bearingand housing grooves. a The snap ring operatesProperly. a The ring end gap is correct. END GAP: 0-7 mm

7A SNAP RING

L

14-144

Clutch lllustratedIndex

I

3RD CLUTCH CLUTCH DRUM

O-RINGS Replace. CLUTCH PISTON DISCSPRING

RETURNSPRING SPRINGRETAINER SNAP RING cLUTcH PLATES

CLUTCHDISCS Standardthickness: 1 . 9 4 m m ( O . 0 7 6i n ) SNAP RING

\

1ST CLUTCH CLUTCHEND

SNAP RING SPRING

Standard thickness: 1 . 6 m m 1 0 . 0 6 3i n l

T

CHECKVALVE {cont'd}

14-145

Glutch lllustratedlndex (cont'd) 2ND/4TH CLUTCH

END PLATE CLUTCHOrSCS 1.94 rr|m {0.076 inl

CLUTCHPLATES Standard thicknoss: 2.00 mm 10.079inl

\

DISC SPRING CLUTCH PISTON

I i l

\2NO CLUTCH DRUM CLUTCTIPISTON DISC SPBING

O-RINGS Replace. CHECKVALVE 4TH CLUTCHDRUM

[*

CLUTCHPLATES Si.ndard thickness: 2.00 mm {0.079 in)

cLuTcHDrscs Slandard thickness: 1.94 mm {0.076 in)

CLUTCHEND PLATE SNAP RING

14-146

\

l ST-HOLDCLUTCH

SNAP RING CLUTCH END PLATE

cLuTcHDrscs Standard thickness: 1.94 mm {0.076 inl

SPRINGRETAINER RETURNSPRING DISC SPRING CLUTCH PISTON O.RINGS Replace.

t Standard thicknoss: 1.6 mm 10.063 in)

l' 14-147

Clutch Disassembly 1.

Removethe snap ring, then removethe clutch end olate, clutch discs and Plates

3.

!

Installthe specialtools as shown. CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE-PX40100

SCREWDRIVER

SNAP RING

2.

Removethe disc spring. CLU'CH SPRING COMPRESSOR BOLTASSEMBLY 07GAE- PG,O200 ol O'GAE - PG4I}2OA

DISC SPRING

CLUTC}I SPRING COMPRESSOR ATTACHMENT 07LAE- PX0100 ot 07HAE- P150100

CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE-PX40100

2ND CLUTCH DISC SPRING

CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX(}Iq)

I I 'tsT, 3RO, 4TH and lST.HOLDCLUTCH

14-148

CI-UTCHSPRING COMPRESSOR BOLTASSEMBLY 07GAE- PG40200 ot OTGAE- PG4O2OA

ol

07HAE- P150100

I

CAUTION: lf either end of the comoressor attachment is set over an area of the spring letainsr which is unsupportod by the retum spring,the retainermay be damaged. Be sur6 the special tool is adiusted to have full contact with the spring ietainel,

5 . Remove the snap ring. Then remove the special tools, spring retainerand return spring.

SNAP RING Do not set here.

T

Wrap a shop towelaroundthe clutch drum, and apply air pressureto the fluid passageto removethe piston.Placea fingertip on the other end while ap, plying air pressure.

COMPRESSED AIR HOSENOZZLE OSHA-approved 30 psi RETAINER

4.

Compressthe return spring.

CLUTCH

)

RETURNSPRING

PISTON

14-149 )

Glutch Reassembly NOTE: a Clean all parts thoroughly in solvent or carburetor cleaner,and dry them with compressedalr. a Blow out all passages. a Lubricateall parts with ATF belore reassembly. 1.

Inspectthe check valve; if it's loose, replacethe prston.

3.

InstalltheDistonin the clutchdrum. Apply pressure and rotate to ensureproper seating. NOTE: Lubricatethe pistonO-ringwith ATF before installing. CAUTION: Do not pinch tho O-ring by installingthe piston with too much force'

NOTE: Except 1sr-holdclutch CLUTCHDRUM CHECKVALVE

Installthereturnspringand springretainer.and position the snap ring on the retaine..

CLUTCHDRUM

PISTON

14-150

I

5.

Installthe sDecialtools as shown.

CAUTION: lf either end of th6 compreaso. attachment is set over an area of the spring lstainer which is unsuoported by the retum spring,the retainermay b€ damaged. Be su?ethe special tool is adiusted to have full contacr with the spring retainer.

CLUTCHSPRING COMPRESSOR ATTACHMENT oTLAE-PX40100

CLUTCHSPRING COMPRESSOR BOLTASSEMBLY 07GAE- PG40200 ol OTGAE- PG4.I'zOA

t

CLUTCHSPRING COMPRESSOR ATIACHMENT 07LAE- PX40100 o1 07HAE- PL50100

Do not set here.

SPECIALTOOL

CLUTCHSPRING COMPRESSOR ATTACHMENT OTLAE PX4OlOO

RETAINER

6.

Compressthe return spring.

SPRING COMPRESSOR ATTACHMENT 07LAE- PX40100 CLUTCHSPRING COMPRESSOR BOLTASSEMBLY 07GAE- PG40200

I

ol

07HAE- PL50100 RETURNSPRING

OTGAE- PGIO2OA

l

14-151

Clutch Reassembly{cont'd) 7.

10. Soakthe clutch discsthoroughlyin ATF for a minimum of 30 minutes.

Installthe snap ring.

11. Startingwith a clutch plate, alternatelYinstallthe clutch Dlatesand discs. Installthe clutch end plate with flat side toward the disc. NOTE: Beforeinstallinqthe platesand discs,make sure the insideof the clutch drum is ttee of dirt or other loreign matter.

CLUTCH END PLATE Installin this direction.

SNAP RING

Removethe specialtools. lnstallthe disc spring. NOTE: lnstallthediscspringin the directionshown.

DISC SPRING

12. Installthe snap ring.

SCREWDRIVER

2ND CLUTCH

OISC SPRING

1ST, 3RD, 4TH and ,IST-HOLD CLUTCH

j

I

14-152

SNAP FING

\

13. Measurethe clearancebetweenthe clutchend olate and top disc with a dial indicator.Zerothe dial indicator with the clutchend plateloweredand lift it up to the snap ring. The distancethat the clutch end platemovesis the clearancebetweenthe clutchend plate and top disc. NOTEi Measureat three locations. Clutch End Plate-to-ToDDisc Clearance: Clutch

SeNice Limit

lst 2nd 3rd 4th l st-hold

O . 6 5- O . 8 5 m m ( 0 . 0 2 6 - O . 0 3 3 i n l O . 6 5 - 0 . 8 5 m m ( 0 . 0 2 6- 0 . 0 3 3 i n ) O . 4 0 - 0 . 6 0 m m { O . 0 1 6 - O . O 2 4i n ) O . 4 0 - 0 . 6 0 m m ( O . O 1 6 O . O 2 4i n \ O . 5 O - O . 8 Om m ( O . O 2 O - O . O 3i1n )

1ST, 2ND, 3RD and 4TH CLUTCHEND PLATE PlateNo.

Pan Numb€r

Thickn6ss

I

22551-P56-N00 22552,P56-N00 22553-P56-N00 22554-P56-N00 22555-P56- N00 22556 P56-N00 22557-P56 - N00 22558 P56-N00 22559-P56-N00 22560-P56- N00

2 . 1 m m ( 0 . 0 8 3i n ) 2 . 2 m m ( 0 . 0 8 7i n ) 2 . 3 m m { 0 . 0 9 1i n ) 2.4 mm (0.094in) 2.5 mm (0.098in) 2 . 6 m m { 0 . 1 0 2i n ) 2 . 7 m m i 0 . 1 0 6i n ) 2 . 8 m m ( 0 .11 0 i n ) 2 . 9m m { 0 . 1 1 4 in) 3 . 0 m m { 0 . 11 8 i n )

2 3 4 5 6 7 8 I 10

.lST.HOLDCLUTCHEND PLATE PlateNo.

Pan Numbor

22551-PS5-003 2 2 2 5 5-2 P S 5 - 0 0 3 3 22553P - S5,003 4 22554-PS5-003 5 (Nomark) 22555 PS5-003 6 22556-PSs003 7 22557-PS5-003 I

Thickness 2 . 1 0m m ( 0 . 0 8 3i n ) 2 . 2 0m m ( 0 . 0 8 7i n l 2 . 3 0m m { 0 . 0 9 1i n ) 2.40 mm {0.094in) 2 . 5 0m m ( 0 . 0 9 8i n ) 2 . 6 0m m ( 0 . 1 0 2i n ) 2 . 7 0m m ( 0 .1 0 6i n )

14. lf the clearanceis not withinthe servicelimits,select a new clutch end plate from the followingtable. NOTE: lf the thickestclutch end plate is installed, but the clearanceis still over the standard.replace the clutch discs and clutch plates. PLATE NUMEER

Thickness

CLUTCX ENO PLATE

14-153

Torque ConverterHousingBearings MainshaftBearing/OilSeal Replacement 1.

Remove the mainshaft bearing and oil seal using the sDecial tools as shown.

2.

Drive in the new mainshaft bearing until it bottoms in the housing using the special tools as shown.

ATTACHMENT, 62x68mm 07746 0010500

3 . Installthe new oil sealflush with the housingusing the soecialtools as shown.

ATTACHMENT, 72x75m.m 07746 -0010600

14-154

I

CountershaftBearingReplacement \

J

1. Removethe countershaftbearingusingthe special lools as shown.

3/8" 16 SLIDEHAMMER (Commercially available)

ADJUSTAELE BEARING PULLER, 25-40 mm 07736 AO1000A

\

J

2 . lnstall the ATF guide plate. 3.

Drive the new bearing into the housing using the special tools as shown.

ATTACHMENT, 62x68mm 07746-0010500

\

a

0 0.03 mm l0 -0.001 inl

14-155

TransmissionHousingBearings Mainshaft/CountershaftBearingReplacement 1, To removethe mainshaftand countershaftbearings from the transmissionhousing,expandeach snap ring with snap ring pliers,then pushthe bearingout using the specialtools and a press as shown.

2 . Expandeach snap ring with snap ring pliers,insert the new bearingpart-wayintothe housingusingthe soecialtoolsand a oressas shown. Installthe bear ing with the groovefacing outsidethe housing. NOTE: Coat all parts with ATF.

NOTE: Do not remove the snap rings unless it's necessaryto clean the groovesin the housing.

Releasethe pliers,then push the bearingdown into the housinguntil the ring snapsin place aroundit. PRESS

DRIVER 07749-0010000

Mainshafl Installation u86: ATTACHM€NT. 72x75mm 07746 -0010600

DRIVER 07749 -OOrOO00

ATTACHMENT, 62x68mm

07746-OO1

GROOVE

I

Installationuse: Countershaft ATTACHMENT, 62x68mm 07746-0010500

--_-e; \ )

,,',zs>.\

/qnH \1b22 4.

After installingthe bearingverify the following: a The snap ring is seatedin the bearingand housIng grooves. a The ring end gap is correct.

MAINSHAFTBEARING

END GAP: O-7 mm

Mainshaft Romoval use: ATTACHMENT, 07746-0010600 Countarshaft Removal use: ATTACHMENT, 62x68mm 07746 0010500

TFAr{SMTSSION T|oUSING

14-156

SNAP RING

L

I

J

1 . To removethe sub-shattbearingfrom the transmission housing,expandthe snap ring with snap ring plie.s,then push the bearingout using the special tools and a Dressas shown.

Expandthe snapringwith snapringpliers,insertthe new bearingpan-wayintothe housingusingthe special tools and a pressas shown. Installthe bearing with the groove facing outsidethe housing.

NOTE: Do not remove the snap ring unless it's necessaryto cleanthe groove in the housing.

NOTE: Coat all pans with ATF. Releasethe plie.s,then push the bearingdown into the housinguntil the ring snapsin place aroundit, using the specialtools as shown.

PRESS

DRIVER 07749-OOlOO00

ATTACHMENT, 62x68mm 07746 -0010500

GROOVE

I

J 4. ATTACHMENT62r68mm 07746-OOr 0500

SNAP RING

After installingthe bearingverify the following: a The snap ring is seatedin the bearingand housing grooves. a The snap ring operatesproperlY a The ring end gap is correct.

END GAP: 0-7 mm

ATTACHMENT62x68mm 07746-0010500

SNAP RING

)

t 14-157

ParkingBrake Stop

Reverseldler Gear

Inspection/Adjustment

Installation 1.

1 . Set the parkingbrake lever in the E

Installthe reverseidler gear.

2.

position.

\

the distance between the parking brake N4easure pawl shaft and the parkingbrakelever rollerpin as shown. STANDARD:72.9-73.9 mm (2.87-2.91 in)

ROLI-ERPIN

PARKING BRAKE LEVEB

'z.o"* r,"

SHIFTLEVERKNOB Apply non-hardening thread lock sealant.

f,- sxrrrrruorcaron PANEL

9.8 N.m {1.0kgl.m, -7 .2 lbl.ltl

SHIFTLOCK SOLENOID

-6{ stLrcoNE GREASE

_Gl SILICONEGREASE 3 N.m (O.3 kgt.m, 2 tbt'trl

' LOCKPIN ROD

PARKING PIN SWITCH

5 N . m 1 0 . 5k g f . m , 4 l b l , I r l CONTROL

SHIFTLEVER

@6 9.8 N.m (1.0kgl.m, 7 .2 tbl.ttl

AUTOMATICTRANSAXLE GEAEPOSITIONSWITCH Testing,see Section23

CONTROLSEAL

)

9 . 8 N . m l 1 . Ok g f . m ,7 . 2 t b t . f t )

1 2 N . m { 1 . 2 k g f . m ,8 . 7 l b f . f r }

14-177

Shift lndicator Panel Adjustment CAUTION: a All SRS wire harnessesate covered with yellow insulation. Beloreyou disconnect any part ol an SRSwire harness, disconnect the airbag connectols' a Wheneverthe ignitionswitch is ON (lll, ol has b€en tulned OFFlo1 less than three minutes, be calgful not to bump the SRS unit; the ailbags could accidentally deploy and cause damageor iniulies. a Foradditionalprecautions,lefer to the SRSsub-section in section 23.

1 . Check that the index mark on the indicatoraligns

with the $ mark on the shitt indicatorpanelwhen the transmissionis in NEUTRAL

lI not aligned,removethe centerconsolelsee section 20).

3 . Loosenthe shift indicatorpanel mounting screws and adiust by moving the PanelN O T E :W h e n e v e rt h e s h i f t i n d i c a t o rp a n e l i s r e moved,realignit as describedabove INDEXMARK

a;-) \___ti_J

@I

14-178

-

Throttle Control Cable Inspection NOTE: Beforeinspecting the throttlecontrolcable,make sure: a Throttlecable tree play is correct (seesection I 1). a ldle speed is correct (seesection 1l). a To warm up the engineto normaloperatingtemperature (the coolingfan comes on). 1.

Verily that the throttlecontroldrumis synchronized with the throttlelinkagewhiledepressing and releasing the acceleratorpedal. ll the throttlecontroldrum is not synchronizedwith the throttlelinkage,adjustrhe throttlecontrolcable.

Verifythat the throttlecontrolcableis clampedcorrectly in three positions.

CONTROLCABLE

LOWER HOSE

Clampat the end of blue tape on the cable.

(cont'd)

14-179

Throttle Control Cable lnspection (cont'd) 4.

Checkthat there is play in the throttle controldrum while depressingthe acceleratorpedal to the full throttle position.

Removethe cableend of the throttle control cable from the throttle control drum. Check that the throttle coritrol drum moves smoothly.

14-180 \

Adjustment NOTE: Beforeadjustingthe throttlecontrolcable,make sure:

Removethe free play of the throttle control cable with the locknut,while pushingthe throttle control drum to the tull-closedpotisionas shown.

a Throttle cable lree play is correct (see section 11). a ldle speed is correct (seesection 11). a To warm up the engineto normaloperatingtemperature {the cooling fan comes on) 1.

Verifythat the throttlecontrolcableis clampedcor rectly in three positions. THROTTLE CONTROLCABLE

ATF COOLER PIPE

Pushin this directron.

5.

LOWER HOSE

Tightenthe locknuts.

Clampat the end of blue tape on the cable.

Verily that the throttle linkageis in the fully-closed posttron. Loosenthe locknut of the throttle control cable at the throttle linkage.

6 . After tighteningthe locknuts,inspectthe synchronization and throttle control drum movement.

LOCKNUTS

14-181

)

Differential ManualTransmission 81881engine...................................... 15-1 818C1engine...................................... 15-9 818C5engine .....,........... 15-19 AutomaticTransmission .................. .....15-27

Differential(818B1 engine) S p e c i aTl o o l s . . . . . . . . . . . . . . . .1 5 - 2 Differential l l l u s t r a t e Idn d e x . . . . . . . . . . 15-3 BackfashInspection .... 15-4 FinalDriven Gear Replacement...... 15-4 B e a r i n gR e p l a c e m e n. .t. . . . . . . . . . . . . . . .1.5. - 5 O i l S e a lR e m o v a l . . . . . . . .1 5 - 5 S i d eC l e a r a n c e A d j u s t m e n t. . . . . . . . . . .1 5 - 6 O i l S e a lI n s t a l l a t i o n .-...15-8

t

SpecialTools

Ref. No.

o 5\ ,al

r-q)

Tool Numbei

oTJAD-PH80101 o7746-0030100 o7749-0010000 07947-SD90200

otv

Description

PageReJerence 15-8 1 5 - 5 ,6 15-8 15-8

Seal DriverAttachment D r i v e r ,4 0 m m L D . Driver Seal DriverAttachment

€

o

d)

F =

.F

\"P

o

t

\l L

15-2

Differential(81881 engine)

t

lllustratedIndex

OIL SEAL Replace. R e m o v a lp, a g e1 5 - 5 Installation,page 15-8 FINALDRIVENGEAR Inspectfor wear and damage, page 15-4 Replacement,

DIFFEBENTIAL CARRIER Inspection,page 15-4

BALL BEARING Inspectfor wear and operation. page 15 5 Replacement,

BALL BEARING Inspectfor wear and operation. page 15-5 Replacement,

1 0 x 1 . 0m m 1 0 1 N ' m 1 1 0 . 3k g t . m , 7 4 . 5 l b t ' t t ) Lefahandthreads

80 mm SHIM S e l e c t i o np,a g e 1 5 6

Removal,page 15-5 page 15-8 Insrallation,

15-3

Differential(81881 engine) BacklashInspection Placedifferentialassemblyon V-blocksand install both axles. the backlashot both pinion gears N4easure Standa.d(Newl: O.O5-0.15mm (O.OO2-0.006in)

Final Driven Gear RePlacement 1. Removethe bolts in a crisscrosspatternln several steps, then removethe linal driven gear trom the differentialcarrier. NOTE: The final driven gear bolts have left-hand tnreaos. 1 0 x 1 . 0m m 101 N'm 110.3kgf'm,74.5 lbf'fll Left-hand threads

OIAL INDICATOR

FINALDRIVENGEAR Charnferon insidediameterot tinal drivengear faces carrier.

OIFFERENTIAL CARRIER

3.

It the backlashis not within the standard,replace the differentialcarrier.

15-4 \

Installthe final driven gear by tighteningthe bolts in a crissc.osspattern in severalsteps.

t

Seal Removal

BearingReplacement NOTE: Checkthe ball bearingsfor wear and rough rotation. lf bearingsare OK, removalis not necessary. '1. Remove the ball bearingsusing a standardbearing pullerand bearingseparatoras shown.

't.

Removethe differentialassembly.

2 . Remove the 80 mm shim from the transmission housrng.

BEARINGPULLER (Commercially available)

80 mm SHIM

TRANSMISSION HOUSING

3.

Removethe oil sealfrom the transmissionhousinq.

4.

Removethe oil seal from the clutch housinq.

BALL BEARING

a

2 . lnstall new ball bearingsusing the specialtool as shown. NOTE: Drivethe bearingssquarelyuntil they bottom againstthe carrier.

DRIVER,40 mm l.D. 07746-00301OO

BALL BEARING

OIL SEAL Replace.

1s-5

Differential(818BJ engine) Side ClearanceAdjustment 1.

lnstallthe dilferentialassembly,makingsure atbottoms in the clutch housing,usingthe specialtool as shown.

3.

Installthe transmissionhousing(see section 13). NOTE: Do not applyliquidgasketto the matingsurface of the clutch housing. Tighten the transmissionhousing attaching bolts { s e es e c t i o nl 3 } .

DRIVER,40 mm I D. o7746-0030100

8 x 1 . 2 5m m 27 N.m {2.8 kgf.m. 20 lbf'ft} 5 . Usethe specialtool to bottom the differentialassembly in the clutch housing. 6.

HOUSING

2.

I n s t a ltl h e 8 0 m m s h i m . NOTE: Insrallthe 80 mm shim that was removed.

mm SHIM

15-6

Measureclearancebetween the 80 mm shim and bearingouter race in the transmissionhousing.

7 . li the clearanceis not within the standard,selecta new 80 mm shim from the tollowing table. Standard:0-0.10 mm {0.004 in)

8 . Removethe bolts and transmissionhousing. 9 . Replacethe 80 mm shim selectedin step 7, then recheckthe clearance.

1 0 .Reassemblethe transmissionand installthe trans-

80 mm Shim

missionhousing(see section 13). Part Number 41441-PL3-BOO

'Lo

m m ( O . O 3 9 4i n )

I

41442-PL3-BOO

1 , 1 m m ( O . O 4 3 3i n )

c

41443-PL3-B00 4't 444- PL3- BOO

1.2 mm lO.O472 inl 1 . 3 m m ( O . O 5 1 i2n )

41445-PL3- 800 4 1 4 4 6 - P L 3- B O O

1 . 4 m m ( O . 0 5 5 1i n )

41447 -PL3-BOO

1 . 6 m m ( 0 . 0 6 3 0i n )

H

41448-PL3-BO0

1 . 7 m m ( 0 . 0 6 6 9i n )

J

41449-PL3-800 1 . 8 m m ( O . O 7 Oi9n l 4 1 4 5 0 - P L 3 B O O 1 . O Sm m { O . O 431 i n )

D

K M N

P

)

Thickness

o R

1 . 5 m m ( O . O 5 9 il n l

4 1 4 5 1 - P L 3 - B O O 1 . 15 m m { O . O 4 5 3i n ) 4 ' 1 4 5 2- P L 3 - B O 0 1 . 2 5 m m ( 0 . 0 4 9 2 i n ) '1.35 41453-PL3-800 m m ( 0 . 0 5 3 2i n ) 41454-PL3-800 1 . 4 5 m m ( O . 0 5 7 1i n ) 4 1 4 5 5- P L 3 - B O O 1 . 5 5 m m { O . 0 6 1 O in) 4 1 4 5 6- P L 3 - B O O 1 . 6 5 m m ( 0 . 0 6 5 0 i n ) 41457-PL3-BOO

1 . 7 5 m m ( 0 . 0 6 8 9i n )

T

4 1 4 4 1 - P 2 1 - O O O 1 . 8 5 m m ( 0 . 0 7 2 8i n )

U

4 1 4 4 2 - P 2 ' t- O O O 1 . 9 0 m m ( 0 . 0 7 4 8i n ) 41443-P21 -000

1. 9 5 m m ( 0 . 0 7 6 8 i n )

NOTE: lf the clearancemeasuredin step 6 is within the standard,it is not necessaryto go to step 9.

)

15-7

Differential(81881 engine) Oil Seal Installation 1. lnstallthe oil sealinto the transmissionhousingusing the specialtools as shown

ORIVER 07749-OO10000

DRIVER 07749-0010000

OIL SEAL Replace.

OIL SEAL Replace. HOUSING

15-8

Installthe oil seal into the clutch housingusingthe specialtools as shown.

Differential(818C1 engine) S p e c i aTl o o l s . . . . . . . . . . . . . . . .1 5 - 1 0 Differential l l l u s t r a t e Idn d e x . . . . . . . . . . 15-11 BackfashInspection .,.. 15-12 FinafDriven Gear Replacement...... 15-12 TaperedRollerBearingReplacement.15-13 O i l S e a lR e m o v a l . . . . . . . .1 5 - 1 3 BearingOuter Race Replacement... 15-14 Tapered Roller Bearing Preload Adjustment . . . . . . . . . . . .1. 5 - 1 5 Oif Seaf Installation ..... 15-17

SpecialTools \ Ref. No.

q Q)

a9 @ i5l

(t

I

Tool Number O T H A JP K 4 0 2 O 1 oTJAD-PH80101 O T N A DP X 4 O lO O 07746-0030100 07749 0010000 o7947-SD90200

Description

Oty

PreloadInspectionTool Seal DriverAttachment DriverAttachment D r i v e r ,4 0 m m l . D . Driver Seal DriverAttachment

Page Refetence t5-t5

15-14 1 7 't514 15-131 4 ' 15 1 4 1 1 15-17

I ri

I \

f

(t

@

ai

li

$

L [

15-10

D i ffe r ent ial( B 18C1en g i n e ) lllustratedIndex

J

NOTE: lI parts marked with an asterisk {*)were replaced, the tapered roller bearing preload must be adjusted (see page 15 15).

*CLUTCH HOUSING

OIL SEAL Replace. R e m o v a lp, a g e1 5 1 3 p ,a g e1 5 1 7 Installation *THRUSTSHIM T. 2.5 mm {0.098 in) *TAPEREDROLLERBEARING lnsDectfor wear and ooeration. R e p l a c e m e npt a, g e 15 - 1 3

J

*DIFFERNTIAL CARRIER I n s p e c t i o np,a g e 1 5 - 1 2

*BEARINGOUTERRACE Inspectfor wear and damage. R e p l a c e m e npl a, g e 1 5 1 4 1 0 x 1 . 0m m 101 N.m {'10.3kgf.m, 74.5 lbf.It) Le{t hand threads FINALDRIVENGEAR Inspect tor wear and damage.-----------r' page 15-12 Repfacement.

*TAPEREDROLLERBEARING Inspecttor wear and operation. page 15 13 Replacement,

}BEARINGOUTERRACE

*79.5 mm SHIM S e l e c t i o np, a g e1 5 1 6

*TRANSMISSION HOUSING

OIL SEAL Replace. R e m o v a lp, a g e 1 5 - 1 3 Installation,page 15-17

. l a 1 5 - 11

Differential(818C1 engine) Backlashlnspection Placedifferentialassemblyon V-blocksand install both axles, Measurethe backlashof both piniongears. in} Siandard{Newl:O.O5-0.15 mm (0.OO2-0.OOG

FinalDriven Gear Replacement Removethe bolts in a crisscrosspatternin several steps, then removethe tinal driven gear from the difterentialcarrier.

\

NOTE: The final driven gear bolts have left-hand threads.

'l.O mm 10 x 1 0 1 N . m l ' 1 0 . 3k g t ' m , 7 4 5 l b f ' f t ) Left-handthreads-

FINAL DBIVEN GEAR Chamferon insidediameter of final drivengear Iaces carrier

., OIFFERENTIAL CARRIER

lf the backlashis not within the standard,replace the differentialcarrier. Installthe final driven gear by tighteningthe bolts in a crisscrosspattern in severalsteps.

I 15-12

TaperedRollerBearingReplacement NOTE: a The tapered roller bearingand bearing outer race should be replacedas a set. a Inspectand adjustthe taperedrollerbearingpreload wheneverthe taperedrollerbearingis replaced. a Checkthe taperedrollerbearingsfor wear and rough rotation.lI taperedrollerbearingsare OK, removalis not necessary. 1.

oil SealRemoval 1 . Removethe difterentialassembly. 2 . Removethe oil seallrom the transmissionhousing.

Removethe taperedrollerbearingsusing a bearing puller and bearingseparatoras shown. BEARING PULLER (Commercially available) BEARING SEPARATOR (Commercially available)

TRANSMISSION HOUSING

3.

Removethe oil seal irom the clutch housino.

Installnew taperedrollerbearingsusingthe special tool as shown. NOTE: Drivethe taperedrollerbearingson untilthey bottom againstthe dillerentialcarrier.

DRIVER,40 mm LD. 07746 -OO30100

j

15 - 1 3

Differential(818C1 engine) BearingOuter Race Replacement lnstallthe new thrust shim and 79.5 mm shim.then drive the bearingouter races in the both housings using the specialtools as shown.

CAUTION: Do not reuse the thruEt shim and th€ 79.5 mm shim if the outer race was driven out. NOTE: a The bearing outer race and tapered roller bearing should be reDlacedas a set. a Inspectand adjustthe taperedrollerbearingpreload wheneverthe taperedroller bearingis replaced. 1.

2.

\ l

NOTE: a Installthe bearingouter race squarely. a Check that there is no clearancebetween the bearingouterrace.thrust shim,andtransmission housing.

Removethe oil sealsfrom the transmissionhousing a n d c l u t c hh o u s i n g( s e ep a g e 1 5 - 1 3 ) .

BEARING OUTER RACE

Removethe bearingouter race,the thrust shim,and the 79.5 mm shim from the transmissionhousino.

DRIVER 07749-0010000

SEALORIVER ATTACHMENT 07JAD-PH80101

79.5 mm SHIM

ORIVEB ATTACHMENT o7f{AD-PX40lOO

\

TRANSMISSION HOUSING

TRANSMISSION HOUSING

BEARING OUTER RACE

3 . Removethe bearingouterraceandthrust shimfrom the clutch housing. DRIVER

o7749-0010000 ORIVER ATTACHMENT 07NAD-PX40100 CLUTCH HOUSING DRIVER,40 mm LD. 07746 -O030100 THRUST SHIM T. 2.5 mm 10.098inl

5.

15-14

I n s t a l tl h e o i l s e a l( s e ep a g e 1 5 - 1 7 ) .

\

Tapered Roller BearingPreloadAdjustment NOTE: lf any of the items listed below were replaced, the taperedroller bearingpreloadmust be adjusted. a a a a a 1.

3 . Installthe thrustshimand 79.5 mm shim,then drive the bearingouter race in the transmissionhousing { s e ep a g e 1 5 - ' 1 4 ) .

Transmissionhousing Clutch housing Ditferentialcarrier Taperedrollerbearingand bearingouter race Thrust shim

NOTEI a Installthe bearingouter race squarely. a Check that there is no clearancebetween the bearingouter race,thrust shim and transmission housing.

Removethe bearingouterrace,the thrust shim,and the 79.5 mm shim from the transmissionhousing ( s e ep a g e 1 5 - 1 4 ) .

With the mainshattand countershaftremoved,installthe dillerentialassembly,andtorquethe clutch housingand transmissionhousing.

CAUTION: Do not reusethe thrust shim if the bea.ing outer race was driven out2.

8 x 1 . 2 5m m 27 N.m (2.8 kgf.m. 2O lbf.ft)

First try the same size 79,5 mm shim that was removeo.

NOTE: lt is not necessaryto use sealingagent between the housings.

CAUTION: Do not use more than two shims, Rotatethe ditferentialassemblyin both directions to seat the taperedroller bearings. 6. 79.5 mm SHIM

Measurethe tapered roller bearingpreloadot the dilferentialassemblywith the specialtool and a t o r q u ew r e n c h . NOTE: Measurethe taperedrollerbearingpreload in both directions. S T A N D A R D2: . 11 - 3 . O 4 N ' m (21.5-31.O kgf'cm, 1 8 . 7- 2 6 . 9 l b t . i n l

HOUSING

PRELOADINSPECTION TOOL 07HAJ-PK40201

(cont'd)

5-1

Differential( B 1 8 C 1engine) n g PreloadAdjustment (cont'd) Tapered Rollel er Bearinr 7.

lf the taperedrollerbearingpreloadis not within the standard,selectthe 79.5 mm shim from the following table which will give the taperedrollerbearing preloadclosestto the standardmeanvalueo{ 2.50 N . m ( 2 5 . 5 k g t . c m ,2 2 l b f . i n ) . NOTE: Changingthe 79.5 mm shimto the next size will increase or decreasetapered roller bearing p r e l o a da b o u t O . 3 - 0 . 4 N . m ( 3 - 4 k g l . c m , 2 . 6- 3 . 5 l b f . i n ) . 79.5 mm SHIM Part Number

Thickness

4 1 4 6 0 - P s D - 0 0 00.66mm (0.0260in)

8. Recheckthe taperedrollerbearingpreload. 9. How to select the correct 79.5 mm shim: 1) Comparethe taperedrollerbearingpreloadyou get with the 79.5 mm shim that was removed with the soecifiedmean Dreloadof 2.50 N'm ( 2 5 . 5 k g f. c m , 2 2 l b f . i n ) . - 2l ll vour measuredtaperedrollerbearingpreload is lessthan specified,subtractyour's from the specitied. lf vour's is more than specitied,subtract the soecifiedfrom vour measurement. Forexamplewith a 1.38 mm {0.0543 in) shim: @ specified2.50 N.m (25.5 kgf.cm, 22 lbl.in) - you measure0.54 N.m (5.5 kg{.cm,5lbl.in}

AB

41461- P5D- 000

AC

4 1 4 6 2 - P s D - 0 0 01 . 2 0m m ( 0 . 0 4 7 i2n )

2 . 0 N . m ( 2 0 k g f . c m ,1 8 l b f . i n )l e s s

AD

4 1 4 6 3 - P 5 D - 0 0 0 1 . 2 3m m ( 0 . 0 4 8 i4n ) '1.26 mm (0.0496in) 41464-PsD-000

3.29 N.m (33.5kgI.cm,29 lbt.in) @youmeasure - specified 2.50 N.m (25.5kgf.cm,22 lbf.in)

AE

1 . 1 7m m ( 0 . 0 4 6 i1n )

AG

4 1 4 6 5 - P s D - 0 0 01.29mm (0.0508in) in) 4 1 4 6 6 - P s D - 0 0 01.32mm (0.0520

AH

in) 4 1 4 6 7 - P s D - 0 0 0 1.35mm 10.0531

AI

4 1 4 6 8 - P s D - 0 0 0 1.38mm (0.0543in)

AF

41469-P5D-000

1 . 4 1m m ( 0 . 0 5 5i5n l

AK

4 1 4 7 0 - P s D - 0 0 01.44mm (0.0567in)

AL

41471- PsD- 000

'1.47mm {0.0579in}

4 1 4 7 2 - P 5 D - 0 0 0 1 . 5 0m m ( 0 . 0 5 9i1n ) AN

4 1 4 7 3 - P s D - 0 0 01.53mm {0.0602in}

AO

4 1 4 7 4 - P 5 0 - 0 0 0 1 . 5 6m m ( 0 . 0 6 1 i4n )

AP

4 1 4 7 5 - P s D - 0 0 0 1 . 5 9m m ( 0 . 0 6 2 i6n )

AO

41476-P5D-000

AR

4 1 4 7 7 - P 5 D - 0 0 0 1.65mm (0.0650in)

'1.62mm {0.0638in}

4 1 4 7 8 - P 5 D - 0 0 0 1 . 6 8m m ( 0 . 0 6 6 i1n ) 4 1 4 7 9 - P 5 0 - 0 0 0 1 . 7 1m m ( 0 . 0 6 7 i3n )

AU

4 1 4 8 0 - P s D - 0 0 0 1 . 7 4m m ( 0 . 0 6 8 i5n ) - PsD- 000 '1.77mm (0.0697in) 41481 4 1 4 8 2 - P s D - 0 0 0 '1.80mm (0.0709in)

AX

4 1 4 8 3 - P 5 D - 0 0 0 1.83mm (0.0720in)

0 . 8 N . m ( 8 k g f . c m , 7 l b f . i nm) o r e -3) Each shim size up or down from standard makes about O.3-0.4 N.nt (3-4 kgf.cm, 2.6-3.5 lbl.in) difterence in tapered roller bearingpreload. a In example@, your measuredtaperedroller bearingpreloadwas 2.O N.m (2O kgt.cm, 18 lbf in) lessthan standardso you needa 79.5 mm shim live sizesthickerthan standard {try the 1.53 mm (O.0602in) shimand recheck). a l n e x a m p l e@ y o u r ' s w a s 0 . 8 N . m { 8 k g f . c m , 7 l b f . i n ) m o r e t h a n s t a n d a r d s. o you needa thrustshimtwo sizesthinner(try in) shimand recheck). the 1.32 mm (O.O52O 1O. After adjustingthe taperedrollerbearingpreload,asand installthelransmission semblethe transmission, housing(see section 13). 8 x 1 . 2 5m m 27 N,m (2.8 kgt'm, 20 lbf.ft) 11. Rotatethe difterentialassemblyin both directions to seat the taperedrollerbearings.

\

15 - 1 6

Seal Installation l.

lnstalltheoil sealinto the transmissionhousingusing the specialtools as shown.

DR|vEN o7749-0010000

Installthenew oil sealinto the clutch housingusing the soecialtools as shown.

DRIVER 07749-OOIOOOO

OILSEAL Replace.

OIL SEAL Replace. HOUSING

15-17

Differential(818C5engine) SpecialTools .......... ........... 15-20 LimitedSlip Differential Description ..................... 15-21 OperationalGheck ......... 15-23 RotatingTorqueGheck .15-23 lffustrated Index .......... ..15-24 TaperedRollerBearingPreload Adjustment ................. 15-25

SpecialTools

j

o

lI I-

1I $ I,

\

\

15-20

Limited Slip Differential(818C5engine)

t

Description 1. Function Operationof the limited slip differentialis dependentupon the eight pinion gearsthat are in mesh with the two side gears.Theytransferthe drivingpower to the drivingaxlesas well as permjtthe outsidewheelto turn more times than the insidewheelwhen the vehiclegoes arounda turn. All gearsare helicallycut so that this differentialactionis limited by the frictioncreatedbetweeneachgear and differentialcarrierwhen eitherwheelslips. 2. Construction The unit consistsof the two side gears,four short pinion gears,four long pinion gears,two thrust washers,a center washer,and a carrierthat housesthe gearsand washers.One shon and one long pinion gear are in mesh with each otherand are allowedto walk aroundthe sideoears.

II

I+ w @

f 1 t

e a @ O g O O

l,'a

a,

Differentiatcarrier Thrustwasher Leftsidegear Centerwasher Rightsidegear Piniongear ong) Piniongear (short)

Ooeration . Straight-load driving The differentialcarrierand gears rotatetogetheras a unit when both wheels rotatesat the same speed.Turning effon from the final drivengearsare directlytransmittedto both wheets.

(cont'd)

15-21

LimitedSlip Differential(B18C5engine) Description(cont'd) a curve When roundang wheel. Whenthe vehacleroundsa curye,tne differentialallowsthe outer wheelto rotatea littlefasterthan the inner gears directions in the side the gears wa|k around pinion rotate, and and |ong when this takes p|ace.the short directionwith the differentialcarrierheld stashown.lf, for example.the right shaftis rotatedin a counterclockwise gearsto the left side tionary,the force is transmittedthroughthe right side gear,short pinion gearsand long pinion more timesthan the turn wheel to the outer gear,causingthe left shaftto rotatein a clockwisedirection.This allows innerwheelwhen the vehiclegoesarounda turn. PINIONGEAR ILONG) CARRIEB

TTFTSHAFT

RIG}ITSHAFT

RIGHTSIDEGEAR

When limitingdifferentialaction The limitedslip differentialactsto limit the differentialactionwhen eitherwheelslipson ice or snow or on turn. This is done by usingthe frictioncreatedbetweeneachgear and differentialcarrier:"'' (1) The pinionsare forcedagainstthe differentialcarrierby the forceas they are-rotatedand repelledoutward. (2) The ends of the pinion gearsare held firmly againstthe differentialcarrierdue to the side thrustfrom the helicallYcut gears.

tzl PINIONGEARS

With the piniongearslocked,the torqueappliedto the slippingwheel is reduced8nd the torquedeliveredto the otherwheel is increased.

t

15-22

OperationalCheck

RotatingTorqueCheck

Setthe parkingbrakeand blockthe rearwheels.

Settingparkingbrakeand blockthe rearwheels.

Raisethe front of the vehicle,and support it with safetystandsin the properlocations(seesection1).

Raisethe front of the vehicle,and support it with safetystandsin properlocations(seesection1).

With the engine off, shift the transmissioninto lst gear,

W i t h t h e e n g i n e o f f , s h i f t t h e t r a n s m i s s i o ni n t o Neutral.

Rotateeither front wheel bv hand and checkthat the otherwheel rotatesin the oppositedirection.

M e a s u r et h e r o t a t i n g t o r q u e w i t h a b e a m - t y p e torquo wrench in the direction shown, Rotatethe torque wrench morg than two completeturns and takethe maximumreading.

lf the opposite tront wheel does not rotste, or if vou cannot spin the front wheels at all, the limited slip differentialis faulty and should be roplaced.

Shift the transmissioninto 1st gear and measure the rotatingtorqueagain. Calculatethe rotatingtorque: ServiceLimit: Measur€ment from steD5 M e a s u r e m e n t f r o smt e p4 = - For example: 7.8 N.m (0.8kgf.m) = z'ot > z'' zg N"ll (03 kgf'ntl Repeatstep 3 through6 for the otherwheel.

!

Replacethe limited slip differentialassemblyif the rotstinglorque is lowerthan the servicelimit.

15-23

LimitedSlip Differential(B18C5engine) lllustrated Index NOTE: .lfpartsmarkwithanasterisk(*)werereplaced,thetaperedrollerbearingpreloadmustbeadjusted(seepagel5-25 replace it if it is damaged. is non-rebuildable, . Thelimitedslipdifferential assembly

OIL SEALReplace. Removal,page15-13 page15-17 lnstallation.

}I}IRUSTSHIM T. 2.5mm (0.098in)

TAPEREDROLLERBEARING lnsoectfor wear and ooeration, page15-13 Replacement,

*BEARINGOUTERRACE Inspectfor wear and damage. page15-14 Replacement, 10x 1,0mm 101 .ln {10.3kof.m,7a.5lbf'ftl Left-handthreads

*TAPERED ROLLER BEARING InsDect for w€arandoo€ration. page15-13 Replacement,

FINALDRIVENGEAB Inspectfor w6ar and damag9. pagel5-12 Replacement,

TBEARINGOUTEBRACE Inspectlor wear and damage. page15-14 Replacement,

.THRUST T, 2.0mm {0.079in) OILSEALReplace. Removal,page15-13 page15-17 Installation,

l,

,

15-24

TaperedRollerBearingPreloadAdjustment

J

l f a n y o f t h e i t e m s l i s t e d b e l o w w e r e r e p l a c e d ,t h e taperedrollerbearingpreloadmust be adjusted, . . . . . .

Transmissionhousing Clutchhousing Limitedslip diffsrentialassembly Taporedrollerbearingand bearingouter race Thrustshim 7 9 , 5m m s h i m Removethe bearingouter race,the thrustshim,and the 79,5mm shim from the transmissionhousing. R e p l a c et h e t h r u s t s h i m a n d t h e 7 9 . 5m m s h i m i f they were dsmaged when the bearing outer race was drivenout. Firsttry the same size 79.5 mm shim that was removeo.

Installthe thrust shim and only one 79.5 mm shim in the transmissionhousing,then drive in the bearIng our€rrace. Nototheseitemsduringrassembly: . Installthe bearingouter racesquarely. . Check that there is no clearancebetween the bearingouter race,shims and transmission housing, W i t h t h e m a i n s h a t ta n d c o u n t e r s h a f tr e m o v e d , installthedifferentialassemblv.Assemblethe clutch housingand transmissionhousingwithout a sealing a9ent,and torquethe casebolts. 8 x 1.25mm 27 N.m (2.8 kgf.m, 20 lM.ft) Rotatethe differentialassemblvin both directions to seatthe taperedrollerbearings. Measur€the tapered roller bearingpreloadof the differential assemblyin both directionswith the special tool and a toroue wrench. STANDARD:2.11- 3.04 N.m (2!.5 - 31.0 kgt'cm, 18.7- 26.9 lbf.in)

PNELOAD INSPECTION TOOL 07TAJ- ST701dt

HOUSING

(cont'd)

15-25

LimitedSlip Differential(B18C5engine) Tapered Roller Bearing PreloadAdiustment (cont'd) 7.

lf the taperedrollerbearingpreloadis not within the standard,selectthe 79.5mm shim from the following table which will give the taperedroller bearing preload closestto the standardvalue of 2.50 N'm (25.5kgicm, 22 lbf in). Changingthe 79.5 mm shim to the next size will increaseor decreasetapered r o l l e r b e a r i n gp r e l o a da b o u t 0 . 3 - 0 . 4 N ' m ( 3 - 4 kgl.cm,2.6- 3.5 lbf.in). 79.5mm SHIM Part Number

Thickness 0.66mm (0.0260in)

A8

41460-PsD-000 41461- P5D- 000

AC

4 1 4 6 2 - P 5 D - 0 0 0 1 . 2 0m m ( 0 . 0 4 7 i2n )

AD

4 1 4 6 3 - P 5 D - 0 0 0 1 . 2 3m m ( 0 . 0 4 8 i4n )

AE

4 1 4 6 4 - P 5 D - 0 0 0 1.26mm (0.0496in)

AF

4 1 4 6 5 - P 5 D - 0 0 0 1.29mm (0.0508in)

1 . 1 7m m ( 0 . 0 4 6 i1n )

4 1 4 6 6 - P s D - 0 0 0 1.32mm (0.0520in) AI

4 1 4 6 7 - P s D - 0 0 0 1 . 3 5m m ( 0 . 0 5 3 i1n ) 4 1 4 6 8 - P 5 D - 0 0 0 1.38mm (0.0543in)

AJ

4 1 4 6 9 - P s D - 0 0 01 . 4 1m m ( 0 . 0 5 5 i5n )

AK AL

4 1 4 7 0 - P s D - 0 0 0 1.44mm (0.0567in) 1 . 4 7m m ( 0 . 0 5 7 i9n l 41471- PsD- 000

AN

4 1 4 7 2 - P 5 D - 0 0 0 1 . 5 0m m ( 0 . 0 5 9 i1n ) 4 1 4 7 3 - P 5 D - 0 0 0 1.53mm (0.0602in)

AO

4 1 4 7 4 - P s D - 0 0 01 . 5 6m m ( 0 . 0 6 1 i4n )

AP

4 1 4 7 5 - P 5 D - 0 0 0 1.59mm (0.0626in)

AO AR

4 1 4 7 6 - P 5 D - 0 0 0 1 . 6 2m m ( 0 . 0 6 3 i8n ) 4 1 4 7 7 - P 5 D - 0 0 0 1 . 6 5m m ( 0 . 0 6 5 i0n )

AS

4 1 4 7 8 - P s D - 0 0 01.68mm (0.0661in)

AT

4 1 4 7 9 - P 5 D - 0 0 0 1 . 7 1m m ( 0 . 0 6 7 i3n )

AU

4 1 4 8 0 - P s D - 0 0 0 1.74mm (0.0685in) 1.77mm (0.0697in) 41481- PsD- 000 '1.80mm (0.0709in) 41482-P5D-000 4 1 4 8 3 - P 5 D - 0 0 0 1 . 8 3m m ( 0 . 0 7 2 i0n )

AH

AX

8. How to selectthe correct79,5mm shim: -1) Comparethe taperedrollerbearingpreloadyou get with the 79.5 mm shim that was removed w i t h t h e s D e c i f i e dp r e l o a do f 2 . 5 0 N ' m ( 2 5 . 5 kgf.cm,22 lbf.in). -2) lf vour measuredtaperedrollerbearingpreload is lessthan specified,subtractyour's from the sDecified. lf your's is more than specified,subtract the specifiedfrom your measurement. Forexamplewith a 1.38mm (0.0543in) shim: @ specified2.50N.m (25.5kgf.cm,22lbiin) - you measure0.54N.m (5.5kgf'cm,5 lbf in) 2.0 N.m (20kgf.cm,18 lbf.in)less @ you measure3.29N.m (33.5kgf.cm,29 lbf in) - specified2.50N'm (25.5kgf'cm,22 lbf in) 0.8 N.m {8 kgf.cm.7 lbf in) more -3) Eachshim size up or down from standard m a k e sa b o u t 0 . 3 - 0 , 4 N . m ( 3 - 4 k g f ' c m , 2 . 6 - 3 . 5 l b f . i n ) d i f f e r e n c ei n t a p e r e d r o l l e r bearingpreload. o In example@, your measuredtaperedroller b e a r i n gp r e l o a dw a s 2 . 0 N . m ( 2 0 k g f . c m , 18 lbf.in) less than standardso you need a 79.5 mm shim five sizesthicker than standard (try the 1.53mm (0.0602in) shim and recheck). . I n e x a m p l e@ , y o u r ' s w a s 0 . 8 N . m ( 8 kgf.cm,7 lbf.in)more than standard,so you n e e d a t h r u s t s h i m t w o s i z e st h i n n e r ( t r y the 1.32mm {0.0520in) shim and recheck). Recheck the taperedrollerbearingpreload. 1 0 . After adjustingthe tapered roller bearingpreload, and installthe transmisassemblethe transmission, s i o nh o u s i n g . 1 1 . Rotatethe difterentialassemblyin both directions to seatthe taperedrollerbearings.

\

15-26

Differential(AutomaticTransmission) S p e c i aT f o o l s. . . . . . . . . . . ..........15-2A Differential(Automatic Transmissionl lllustratedIndex .......... .. 15-29 BacklashInspection ......15-30 B e a r i n gR e p | a c e m e n. .t . . . . . . . . . . . . . . . . .I.5. .-.3. .0 DifferentialCarrierReplacement......l5-31 OilSealRemoval . . . . . . . . .1. .5 - 3 2 Oil Seal Installation/ S i d eG | e a r a n c.e. . . . . . . . . . . . . . . . . . . . . . .1. .5.-. 3 . .2. . .

SpecialTools \ Ref. No.

o @ \9/

I

Description

Tool Numbel

oTJAD-PH80200 oTNAD-P200100 o7746-0030100 o7749-0010000 o7947-SD90200

o

Pilot.26 x 30 mm D r i v e r5, 2 x 5 5 m m D r i v e r4, 0 m m l . D . Driver DriverAttachment

Oty

I Pag6 Retolence

1 I 1 1 'l

r5-34 15-34 15-30, 32,33 15-34 15-34

@

\

@

!b_./

\

15-28

Differential(Automatic Transmission) lllustrated Index

FINAL DRIVEI{ GEAR

BALL BEARIiIG

ENTIAL caRRlER --tot"'

ROLLER,5xlOmm

BALL BEARING

15-29

Differential(AutomaticTransmissionl BacklashInspection 1. Placethe dilferentialassemblyon V-blocksand install both axles. 2.

Check backlashof both piniongears.

BearingReplacement NOTE: Checkthe bearingsfor wear and roughrotation lf the bearingsare OK, removalis not necessary. 1.

Removethe ball bearingsusing a bearingpuller'

Standard lNsw): 0.05- 0.15 mm {0.(Xt2- o.(Xl6in)

SIDEGEARS

EEABINGPULLER (CommerciallY available)

\ 3.

lf the backlashis not within the standard,reDlace the differentialcarrier.

Installthe new ball bearingsusingthe specialtool with a press as shown.

DRIVER,40 mm l.O. 07746-0030100

I

15-30

J

1. Removethe final driven gear from the differential carner.

5.

Align the hookedend ot the snap ring with the pinion shaft as shown. then installthe snap ring in the dilJerentialcarriergroove.

NOTE: The final driven gear bolts have left-hand threads. Hooked end

2.

SNAP RING Installin this direction.

Prythe snap ring ofl differentialcarrier,then remove the speedometerd.ive gear and 5 x 1O mm roller.

SNAP RING

DIFFERENTIAL CARRIER

DRIVEGEAR

6 . Installthe final driven gear, then tighten the bolts to the specifiedtorque.

lnstallthe 5 x 1Omm rollerin the differentialcarrier.

TOROUE:103 N.m (10.5 kgt.m, 76 lbl.ttl

Installthe speedometerdrive gear with its chamfered sidefacingthe carrier.Align the cutout on the bore of the speedometerdrive gear with the 5 x 1Omm ro er.

NOTE: The final driven gear bolts have left-hand threads.

BOLTS 1 0 x 1 . 0m m 103 N.m (10.5kgf.m, 76 rbt.frl Left-handthreads

SPEEDOMETER DRIVEGEAR Install in this direction.

Cutout FINAL DRIVEN GEAR Installin this direction.

ROLLER, 5x10mm

DIFFERENTIAL CARRIER

7.

Installtheball bearings(seepage 15-30).

Differential(Automatic Transmissionl Oil Seal Removal

Oil Seal Installation/SideClearance-

Removethe differentialassembly.

1.

Installa 2.50 mm {O.O98in}thrust shimin the transmissionhousing.

Removethe oil sealfrom the transmissionhousing. NOTE: Do not installthe oil seal yet.

TRANSMISSION HOUStf{G

Remove the oil seal from the torque converter housing.

Installthe differentialassemblyinto the torqueconverter housingusing the specialtool as shown.

DRIVER,40 mm l.D. 07746-0030100

DIFFERENTIAL ASSEMBLY

/--1 OIL SEAL Replace. TOROUECONVERTER HOUSING

15-32

TOROUECONVERTER HOUSING

Assemblethe transmissionlsee section 141. Installthetransmission housingandtightenthe bolts (see section 14).

4.

Tap on the transmissionhousingsideof the ditferential assembly with the special tool to seat the differentialassemblyin the torque convener housing.

Measurethe clearanc;betweenthe thrust shimand outer race of the ball bearingin the transmission nousrng. S T A N D A R DO : - 0 . 1 5 m m ( O - O . O 0 6i n )

o.

It out of limits. select a new thrust shim from the tollowingtable: THRUSTSHIM, 80 mm Part Number

Thickness

904r4-689-000 90415-689-000 90416-689*000 90417-689-OOO 90418-689-O00 90419-PH8-000

2 . 5 0 m m ( 0 . 0 9 8 4 3i n 2 . 6 0 m m ( 0 . 1 0 2 3 6i n 2 . 7 0 m m ( O . 1 0 6 3 0i n 2 . 8 0 m m { O .1 1 O 2 4i n 2 . 9 0 m m { O . 11 4 16 i n '181 3 . O Om m ( O .l 1 in

NOTE: Il the thrust shim-to-ballbearingouter race clearancemeasuredin step 5 is within the standard, it is not necessaryto performsteps 7 and 8. 7 . Removethe transmissionhousing. L

Replacethe 2.50 mm {0.098 in) thrust shim with the one of the correctthicknessselectedin step 6.

9 . Installthe transmissionhousing(see sectjon 14).

Differential(AutomaticTransmission) Oil Seal Installation/Side Clearance (cont'd) 9. lnstallthe oil sealllush with the transmissionhousing using the specialtools as shown.

ATTACHMENT o7947 -SD90200

PILOT 26x30mm oTJAO-PHA0200

1 0 .Installthe oil seal llush with the torque converter housingusing the specialtools as shown.

15-34

)

SpecialTools \ Ref. No.

I

Tool Number

o

07JAF- SH20400 07LAD- PW50601 07MAC- S100200 07746- 0010300 07746- 0010400 07746- 0030400 07749- 00r0000 07965- SD90100

/a\

@ \9,

@ @ @

o

Descriplion

Oty

,|

SupportBaseAttachment Attachment,40x 50 mm l.D. BallJoint Remover,28 mm Attachment,42 x 47 mm Attachment,52 x 55 mm Attachment,35 mm l.D. Driver SupportBase

1 1 1 1 1 1 I

6i

16-16 16-18 16-4 to- to

1 6 - 1 71. 8 't6-17 ' 1 6 - 1 61,7 ,1 8 1 6 -1 6

@

o

6-2

PageRotersnce

t

Driveshafts Inspection Drivcshatt Boot Checkthe boots on the driveshafttor cracks.damage, leakinggreaseor looseboot bands. l f a n y d a m a g e i s f o u n d , r e p l a c et h e b o o t a n d b o o t oanos.

Removal 1.

Loosenthe wheel nuts slightly, Raisethe front of ca. and support it with safety standsin the prope. locations{seesection1). Removethe wheel nuts and front wheels.

LoosoSplineE Turn the driveshaftby hand and moke sure the splines and joint are not excessively loose. lf damageis found,replacethe jointsif necessary. Twisled or Crscked Makesurethe driveshaftis not tlvistedor cracked. Replaceit if necessary.

Replace.

Drainthe transmissionoil or fluid (seesection13 or 14t. NOTE:lt is not necessaryto drainthe transmission oil or fluid when the left driveshaftis removed. 5.

R a i s et h e l o c k i n gt a b o n t h e s p i n d l en u t , t h e n removethe nut.

6.

Removethe self-lockingnut and flangebolts.

BOOTBANDS FLANGEBOLT '10x 1.25

NUT SELF.LOCKING 12 x 1.25mm Replace.

7.

Remove the damoer fork.

(cont'd)

6-3

Driveshafts Removal(cont'dl 8. Bemove the cotter pin from the lower arm ball joint castle nut. then remove the nut.

12. Pull the inboardjoint, and removethe right driveshaftfrom the differentialcaseas an assemblv. CAUTION: . Do not pull on the driveshaft. as lhe inbosrd ioint may come 8p8rt. . Use care when prying out the assembly,snd pull it straight to avoid damaging the differential oil seal or the intermsdiats rhaft outcr 3e81.

urJrrEr rrN Replace.

mm BALLJOINTREMOVER,2S - SLOO2OO OTMAC

Installa 12 mm hex nut on the ball joint. Be sure that the hex nut is flush with the ball joint pin end. or the threadedsectionof the ball joint pin might be damagedby the specialtool. U s e t h e s p e c i a lt o o l a s s h o w n o n p a g e 1 8 - 1 1 t, o separatethe ball ioint and lower arm. SCREWDRIVER

CAUTION: Be careful not to damage th6 ball ioint boot. NOTE: lf necessary,apply penetratingtype lubricantto loosenthe ball joint. 1 1 . Pry the driveshaftassemblywith a screwdriver,as shown, to force the set ring at the driveshaftend past the groove. Be careful not to damagethe oil sealswhen pryingwith the screwdriver.

-

Left Driveshaft: Removethe left driveshaftfrom the bearingsupport by tapping the inboard joint of the driveshaftwith a Dlastichammer.

BEARINGSUPPORT

16-4

Disassembly 13. Pull the knuckleoutward. then remove the driveshaft outboardjoint from the front wheel hub using a plastichammer.

KNUCKLE

l.

Carefulclampthe driveshaftin a visewith soft jaws, then removethe set ring from the inboardjoint.

2.

R e m o v et h e b o o t b a n d so n t h e i n b o a r di o i n t a n d outboardjoint. CAUTION:Take care not to damags th€ boot. -

lf the boot band is a weldedtype or a low profile type boot band,carefullycut it off with a pair of diagonalcutters.

-

lf the boot band is a doubleloop bandtype, raise the band bendas shown.

DRIVESHAFT

OOUBI-ELOOPBAND Replace.

(cont'd)

16-5

Driveshafts Removallcont'd) -

lf the boot band is an ear clamp type {for outboardjoint on the Canadamode raisethe three tabs with a screwdriver.

4. Mark the rollersand spiderto identifythe locations of rollerson the spider,then removethe rollers. REMOVER BEARING (Commercially available)

EARCLAMPBAND

5. Removethe circlip. 6. Mark the spiderand driveshaftto identifythe position of the soideron the shaft. 7. Removethe spiderusinga bearingremover, 8. Wrap the splineson the driveshaftwith vinyltapeto preventdamageto the boots. 3.

Mark each roller and inboard joint to identify the locationsof rollersand groovesin the inboardjoint. Then removethe inboardjoint on the shoptowel.

,%

VI'{YL TAPE

ouTBoaRD BOOT Insp€ctrorcrackrng, splittingandwear.

NOTE:Be carefulnot to drop the rollerswhen separatingthem from the inboardjoint.

NBOAND Jo|NN Checksplinesfor wear or damage. Checkinside bore lor wear. lnsoectfor cracks.

Inspectfor cracking, splittingandwoar. Removethe inboardboot. GAUTION:Tako care noi to damsge the boot.

1 0 . Removethe dynamicdamperand outboardboot.then removethe vinyl tape. Marla

CAUTION: Take care not to damage the dynamic dampor and boot.

16-6

\

1 1 . Inspectthe outboardioint for faulty movementand wear. lf any roughnessor excessplay is felt, replace the outboardjoint.

16-7

Driveshafts Reassembly NOTE: . Cleanthe disassembledparts with solvent,and dry them thoroughlywith compressedair. Do not wash the rubber parts with solvent. o -@l : Thoroughlypackthe inboardjoint and both joint bootswith the joints bootswith the joint greaseincluded in the new driveshaftset. Greasequantity: lnboardJoint Alf models:120- 130g l1-2- 1.6 ozl Outboard Joint USA model:90 - 100S 13.2- 3.5oz) Canadamodel:105- 115g {3.7- 4.1ozl . The Canadamodel usesa TPE(Thermoplastic PolyesterElastomer)outboardjoint boot. Use the ear clamp type boot band in the outboardjoint boot set. SET RING Replace.

INBOARDJOINT

INBOARDBOOT

LEFTINBOARDJOINT

-#,1

Packcavity with grease.

Packcavity with grease.

OUTEOARDBOOT DYNAMICDAMPER with grease''

OOUBLELOOPBANDS Replace. OUTBOARDJOINT Canadamodel outboard joint only.

DRIVESHAFT OUTBOARD

-6{

Packcavity wrln grease,

16-8

l

1 . Wrap the splineswith vinyl tape to preventdamage to the bootsand dvnamicdamoer.

Installthe spider on the driveshaftby aligningthe markson the spiderand end of the driveshaft. 5.

Fitthe circlipinto the driveshaftgroove.

VINYL TAPE

NOTE:Always rotatethe circlip in its grooveto be sure it is fully seated.

@*c'nc'-'t SPIDEB

OYNAMICDAMPER INBOARDBOOT

2.

I n s t a l lt h e o u t b o a r d b o o t , d y n a m i c d a m p e r a n d i n b o a r db o o t t o t h e d r i v e s h a f tt,h e n r e m o v et h e vinyltape. CAUTION: Take care not to damage the boots and dynamic damper.

3.

Packthe outboardjoint with the joint greaseincluded in the new driveshaftset.

6.

Fit the rollersto the spiderwith their high shoulders facingoutward. Notetheseitemsduring reassembly: . Reinstallthe rollersin their originalpositionson the spiderby aligningthe marks. . H o l d t h e d r i v e s h a f tp o i n t e du p t o p r e v e n tt h e rollersfrom fallingoff. SPIOER

Greasequantily: USA model:90 - 100g (3.2- 3.5oz) Canadamodel:105- 115g (3.7- 41 oz)

High shoulder {aces

Marks

I

(cont'd)

16-9

Driveshafts Reassembly(cont'd) 7.

Packthe inboardjoint with the joint greaseincluded in the new driveshaftset. Greasequantity:120- f30 g 11.2-4.6ozl

9 . F i t t h e j o i n t b o o t e n d s o n t o t h e d r i v e s h a f ta n d Jornts. W h e n i n s t a l l i n gt h e o u t b o a r dj o i n t b o o t o n a Canadamodel,be surethe end of the boot is seated in the groovesof the driveshaftand outboardioint. OUTBOARDBOOT{TPE) C a n a d aA T m o d e l outboard joint only.

8.

Fit the inboardjoint onto the driveshaft. NOTE: . Reinstallthe inboardjoint onto the driveshaftby aligningthe marks on the inboardjoint and the ro ers. . Holdthe driveshaftso the inboardjoint pointsup to p.eventit from fallingoff.

1 0 . Adjustthe lengthof the driveshaftsto the specifications below, then adjust the boots to halfway betweenfull compressionand full extension. NOTE:The ends of boots seat in the grooveof the driveshaftand joint.

Lefr:475- 480mm {18.7- 18.9inl

Right:475- 480rnm (18.7- 18.9int

DRIVESHAFT

16-10

11. Positionthe dynamicdamperas shown below. 81881engine: Left/Right:26 t 2 mm 11.0t 0.1 in) BlSCl engins: Left/Right:29 t 2 mm (1.1i 0.1 in)

-') Pullup the slackin band by hand. M a k ea m a r ko n t h e b a n d1 0- 1 4 m m ( 0 . 4- 0 . 6 in) from the clip. CLIP

DAMPER DYNAMIC

DYNAMICDAMPERBAND

12. Installthe boot bandsfollowingprocedure. Double Loop Boot Band lnstallalion: USA models: all bands Canada model: inboard ioint and dynamic dampel bands -1. Set the double loop band onto the boot with the bandend towardthe front of the vehicle.

DOUBI.fL(X)P BANO /

T h r e a dt h e f r e e e n d o t t h e b a n d t h r o u g ht h e nosesectionof the commerciallyavailableboot bandtool (KD-3191or equivalent),and into the slot on the winding mandrel. - 5 . Placea wrench on the winding mandrelof the boot band tool, and tighten the band until the markedspot on the band meetsthe edgeof the clrp,

BOOTBANDTOOL lKD-3191 o. equivalent)

Markon band.

(cont'd)

1 6 - 11

Driveshafts Reassembly(cont'dl -6. Raiseup the boot band tool to bend the free end of the band 90 degreesto the clip. Center punchthe clip,then fold over the remainingtail onto the clio.

HAMMER

- 7. Unwind the boot bandingtool, and cut off the excessfree end of the band to leave a 5 - '10 mm (0.2- 0.4 in) tail protrudingfrom the elip.

5 - 1 0m m (0.2- 0.a inl

16 -1 2

- 8. Bend the band end by tapping it down with a nammer. NOTE: . Makesurethe banddoes not move. . Removeany greaseremainingin the surrounding surfaces.

E8r Clamp Type Boot Eand Installation: Csnadamodel outboard joi]|t bands

Measurethe clearancebetweenthe closedear portionof the band.

-1. Installthe ear clamp boot band by aligningthe tabs with holesin the band.

S i a n d a r d : 0 - 3m m ( 0 - 0 . 1 2i n )

lf the band's,clearanceis not within the standard, closethe ear portionof the bandfurther.

EARCLAMPBAND Replace.

NOTE: . Makesurethe banddoes not move. . Removeany greaseremainingin the surrounding surfaces.

Closethe ear portion of the band with a commerciallyavailableboot band pincers.

BOOTAAND PINCERS (Commercially available) Oetiker1098or equivalent

POSTION

16-13

Installation 1.

Installthe outboardjoint into the knuckle.

4.

lnsen the inboardend of the driveshaftinto the diff e r e n t i a lo r i n t e r m e d i a t es h a f t u n t i l t h e s e t r i n o locksin the groove. INEOARD JOINT

KNUCKLE

Replace.

INBOARDJOINT

GROOVE

OUTBOARDJOINT

OIFFERENTIAL

Apply 0.5 - 1.0g {0.02- 0.04oz) of specifiedgrease to the whole splinedsurfaceof the left driveshaft. NOTE: After applying grease,remove the grease from the splinedgroovesat intervalsof 2 - 3 splines and from the set ring groove so air can bleedfrom the inboardioint.

lnstallthe damoerfork over the driveshaftand onto t h e l o w e r a r m . I n s t a l lt h e d a m p e r i n t h e d a m p e r fork so the aligning tab is alignedwith the slot in the damoerfork. FLANGEBOLT 10x 1.25mm 43 N.m {4.4kgf.m,32lbtftl

ALIGNINGTAB

SET RING Replace.

SET RING

Installa new set ring onto the driveshaftor intermediateshaftgroove.

6.

Loosely install the flange bolts and the new selflockingnut. NOTE:The bolts and nut should be tightenedwith the vehicle'sweighton the damper.

16-1 4

IntermediateShaft Removal 7. Installthe knuckleon the lowerarm.

Drainthe transmissionoil or fluid {seesection13 or 14t.

NOTE: Wipe off the greasebefore tightening the nut at the ball joint. CAUTION: . Be careful not to damagothe ballioint boot. . Torque the castle nut to tho low€r torque specitication, then tighten it only lar onough to align th6 slot whh tho pin hols. Do not align the nut by loosening.

,.

lmproperly adjustedrackguide

17-11

Troubleshooting GeneralTroubleshooting(cont'dl Assist (excessivelylight steering)at high speod.

Ch6ckth6 rack guide propgr adjustment(seepago17-21).

Shockor vibrationwhen wheelis turnedto full lock.

Checkthe rack guido lor proper adjustment(seepage17-21).

ll the problom is not correcledby adiustingthe rack guide, adjust the front wh66l alignment (see s6ction18).

Rackguid€ is adjustedproperly.

Checkthe belt for slippageand adjust as nec€ssary{s6e page 1720).

lf the problem is not correctedby adjusting the rack guide, replsco the gearbox.

Steeringwheelwill not return smoothly.

{

A and B cylinder lines are normal, chgckwheol alignment(se€ section18).

W h e 6 l a l i g n m e n ti s a b n o r m a l , adjust as needod.

wh€el alignmentis normal. R€mov€ the gearbox from tho f r a m 6 s n d m e a s u r et h e p i n i o n torque on the gearbox.

It shouldbe 0.7 - 1.2N.m {7 - 12 k g l . c m . 6 - 1 0 l b f . i n )o r b e l o w with the steering rack in the straight ahoaddriving position.

lf the measurementsare out of s p € c i f i c a t i o n sa. d j u s t t h e r a c k gurd9.

It the problom is not correctedby adiusting the rack guido. r€place the goarbox.

I a-,

aa Gr

I r- tz

Unev€nor rough steering.

Adjustrackguid€(seepage17-21).

It the problem is not corroctedby adjusting the rack guid€, replace the g€a.box.

Adjust b6ll tension.Ropl6cethe b6lt,it necossary{s€ep€ge17-20).

ldle spoed low or €rratic.

lfth€ enginestallswhen the wheel i s t u r n e d w h i l e t h e v e h i c 1 6i s stopped or moving at low speed. adjustidl6sp6od(s€es€ction111.

Air in r€gervoir,or checkpowsr steeringfluid lovel.

Checkpowsr st6oringfuid lovel.lf the lovel is exceggivelylow, ch6ck tor leaks in the svstem.Add fluid to the sD6ciliedl6v6l,

lf fluid level is OK, chock O-rings and seals on both 6nds ot the pump suction hose. and the P/S pump housing mating surfaces and tho oumo shaft oil seal for suction lgakr. Roplacoparts as n6c6ssary.

Ste€ringwheol kicksback duringwide turns.

Pump b€lt slippingon pulloy (pumpstopsmomentarily).

Adiust b6lt t€nsion {s6e page '1720)or r6olac€b€lt.

Installthe power st66ringpr6ssu16gaug6. Closeth6 prossure control valve lully and m6asure the pump prossure(seepage'1722t.

Chockif pump pressureis normal and the gauge needletrav€l is 500 kPa (5 kgl/cm' , 71 psi) or lesB. Ch€ckthe flow controlvalvo if the no€dl€trav€l oxco€ds500 kPa {5 kg7cml,71 p6i).lf the flow control valve is normal.roplacethe pump as an assemDtv.

7 - 13

Troubleshooting NoiseandVibration NOTErPump noisein first 2 - 3 minutesafterstartingin cold weatheris normal.

Humming

Humming due to pulsationoI lluid is normal, particularlywhen the wheel is turnedwith the vehiclestoooed.

hose) Outlethose (High-pressure touchingthe frame.

Rightcylinderend sealsqueak.

Rattleor chattering

Loosesteeringshaft connector, tie-rod,or ballioint.

C h e c ka n d t i g h t e n , o r r e p l a c e pans as necessary,

Columnshaftwobbling.

Reolacethe columnassemblv.

Checkihe rack guide tor proper adjustment(seepage17-21).

Adiust,if nec€ssary.

I

Rattlingsound and feeling when turning the steeringwheel right and left with the engineOFFis normal.

Pump noise, though not loud, from tho valv6 body unit can be heard when turning the steeringwheelto full lock in eitherdirection.This is normal.Do not hold the steeringwh6el at tull locktor more that live secondswh€n inspecting.

17-14

Pumpnoise

Gratingnoise from pump

Cavitationcausedby air bubbles in the fluid.

C h e c kt h e f l u i d l e v e l . lf low, fill the reservoir to the proper level,and check for leaks. T i g h t e n o r r e p l a c ea s n e c e s s a r y .

Checkfor a crushedinlet hoseor a loose hose clamp allowing air into the suctionside of the system. Tightenor replaceas oecessary.

Checkthe oumo shaftoil seal.

Checkthe reservoirfor cracks.

Pumpnoise

N O T E :P u m p n o i s eu p t o 2 - 3 m i n u t e sa l t e r s t a r t i n gi n c o l d weatheris normal. Comparepump noise at operating tomperatureto another similar vehicle.

lf pump noiseis abnormallyloud, removeand inspectthe pump for wear and damage(see page 1736).

aou""*,nn

Rattleor chattering

Tightenor replacethe pulley. l f s h a f t i s l o o s e , r e p l a c et h e pump.

I 17-15

Troubleshooting FluidLeaks Checkthe gearboxassemblyfor oil leakscarefully,Oil can leak out of various points,dependingon locationof the faulty oil seals/sealrings. Checkthe following before removing the gearboxfrom the frame.

Stoo.ingGearbox

Leakingfrom the oil seal on the top of the valvehousing.

Replacethe valv€ oil seal from the valvohouging.

Leakingtrom cylinder 6nd into l€ft ti6-rod boot,

Roplacethe valve oil seal from the pinion shaft.

B€placetho cylindgr ond seal on the gearhousingside.

I

I

17-16

Leakingfrom cylinder end into right tie-rod boot.

Replacoth€ cylindor end seal on ths cylinderend side.

Leakingfrom the thaft upper end sectionor pin ongagementsgction ofth6 Dinionshaft

RoDlacetho valve bodv unit.

Leakinglrom cylind6r line A or B conn6ction{Etflare nut).

Tighten connector.lf it€ still leaking. replaceth€ lin€, cylinderor valvehousing.

Leaking caused by a damaged cylinderlineA or B.

Replacecylinder line A or B.

L e a k i n gf r o m o u t l e t l i n e a n d returnline joint fitting on the valv6 body unit (at flare nut).

Tightgn tho connector. ll its still leaking,r€placethe hos€, joint fitting or valv€ housing.

ReplacehousingO-rings. It the housingstill loaks.roplace the pump.

Reservoiroverfill6d, Pull oft the hose and drain th€ reservoirto the proper level.

Air l6ak in suction sid€ ot th€ syst e m ( r g s e r v o i r ,s u c t i o n h o s e , front pump s€al).

Pumpoutlotline (high-pressure)

Leakingat the threadedfitting.

Tighton the fitting, lI its still leaking, replacethe O-ring or outlet hose.

Leakingat the swaged,oint.

Pumpsuctionline {low-pressure)

Loaking becauseof damage, deterioration.or improper assem-

Replaceor repair as necessary.

17-17

Inspectionand Adjustment SteeringOperation

Power Assist Checkwith VehicleParked Checkthe power steeringfluid level (see page 1721)and pump belttension(seepage 17-201.

Placethe front wheelsin the straightaheadpositionand measurethe distancethe steeringwheel can be turned without movingthe front wheels.

Startthe engine,allow it to idle.and turn the steer ing wheel from lock-to-lockseveraltimes to warm up the fluid.

ROTATIONALPLAY:0 - 10 mm {0 - 0.39 inl lf the play exceedsthe servicelimit. perform rack guide adiustment(seepage 17-211. lf the play is still excessiveafter rack guide adjustment. inspectthe steeringlinkage and gearboxas described on the neld page.

Attacha springscaleto the steeringwheel.With the engineidling and the car on a clean.dry floor. pull the scaleas shown and read it as soon as the tires beginto turn,

ROTATIONALPLAY

4.

The scaleshould read no more than 34 N (3.5 kgf, 7.7 lbf). lf it reads more, check the gearbox and pump.

SteeringLinkageand Gearbox

STEERING COLUMN Inspecttor loosecolumn mountingboltsand nuts.

TIE.ROD ENDBALLJOINT Inspecttor faultvmovement anooamage,

BOOT Inspectlor damageand deterioration.

STEERING JOINTS Check{or loosejoint bolts.

PINIONSHAFTGROMMET Insp6ctfor damageand deterioration.

STEERING Inspectfor loosemountingbolts. GEARBOXMOUNTINGCUSHIONS Inspectfor deterioration.

TIE.RODLOCKNUT Check{or loose locknut.

BALLJOINT Inspectfor damage and deterioration. See pago 17-61lor replacement.

I 17-19

Inspectionand Adjustment PumpBelt NOTE:When usinga new belt,first adjustthe deflection or tensionto the valuesfor the new belt, then readjust the deflectionor tensionto the valuesfor the used belt after runningenginefor five minutes,

Adiustment 1.

Loosenthe powersteeringpump mountingbolts.

2.

Turn the adjustingbolt to get the proper belt tension,then retightenthe bolts.

3.

Stan the engine and turn the steeringwheel from lock-to-lock severaltimes.then stop the engineand recheckthe deflectionof the belt.

Inspection Attachthe soecialtool to the belt and measurethe tension of the belt. Tension: Usad Belt: 390 - 54ON {/10- 55 kgf. 88 - 120 lbf} Nsw Belt: 740- 880 N {75- 90 kgf. 170-2(X)lbf) NOTE: . lf there are cracksor any damageevidenton the belt, replaceit with a new one. . Followthe manufacturer's instructionsfor the tension gauge. i i

:i i

I ,;h

,lt l

I i

24 N.m l2.a kgf.m, 17 lbf.ftl CRANKSHAFTPULEY

BELTTENSIONGAUGE 07JGG- 001010A Inspectthe pump beltfor cracksor any damage. Replacethe belt with a new one if necessary.

Mea3urementwithout Bah Tonsion Gaugo: Apply a force of 98 N {10 kgt,22 lbll and measurethe deflectionbetweenthe power steering pump and the crankshaftpulleys, Drllection: Us.d B6h: 11.5- 13.5mm (0.45- 0.53in) - 0.39inl New Bsh: 8.0- 10.0mm 10.31 POWERSTEERINGPULLEY

17-20

RackGuide Adjustment

Fluid Replacement

NOTE:Performrack guide adjustmentwith the wheels in the straightaheadposition.

Checkthe reservoirat regularintervals,and add fluid as neceSsary.

Loosenthe rack guide screw locknutwith the specialtool,then loosenthe rackguide screw.

CAUTION: Use only Genuine Honda Powel Ste€ring Fluid-V. Using other fluids such as ATF or othor manulaclurer's power ste€ring fluid will damag€the systom.

1.

Tightenthe rackguide screwuntil it compresses the springand seatsagainstthe rackguide,then loosen it. R e t i g h t e ni h e r a c k g u i d e s c r e w t o 3 . 9 N . m ( 0 . 4 kgf.m, 2.9 lbi.ft), then back it ofl to specifiedangle.

J.

Speciliad Roturn Anglo: 20' Max 4.

SYSTEMCAPACIW: B18Glongine: 1.06lit€r(1.12US.qt,0.93 lmp.qt) Excopt 8l8Cl ongino: 1.0lher (r.06US. qt.0.88 imp.qtl at disa$ombly RESERVOIR CAPACITY: 0.,0liter {0.42US. qt, 0.35 lmp.qt}

Tighten th€ locknut while holding the rack guide screw. LEVEL LINE

LEVELLINE

Raisethe reservoirand disconnectthe return hose that goesto the oil cooler. 2 . Connecta hose of suitablediameterto the disconnectedreturn hose and put the hose end in a suitable container.

RACKGUIDESCREW

CAUTION:Take care not to spill thq fluid on lhe body and parts. Wipe off any spilled fluid al onc€. Startthe engine.let it run at idle,and turn the steering wheel from lock-to-lockseveral times. When f l u i d s t o p s r u n n i n g o u t o f t h e h o s e ,s h u t o f f t h e engine.Discardthe fluid.

25Nm {2.5 kgf.m, 18 lbf ft)

I

LOCKNUTWRENCH.ilo mm 079't6 - SA50001

E

Checkfor tight or loose steeringthrough the completeturningtravel.

6.

Performfollowinginspections: . Steeringoperation(seepage 17-18). a Powerassistwith car parked.

RETURNHOSE { F r o mt h e o i l c o o l e r )

4. 5. 6.

7.

Reinstallthereturnhoseon the reservoir. Fillthe reservoirto the uDDerlevelline. Startthe engineand run it at fast idle,then turn the steeringfrom lock-to-lock severaltimes to bleedair from the system, Recheckthe fluid leveland add some it necessary. CAUTION: Do not lill the reservoir boyond thc upper level line.

Inspectionand Adjustment PumpPressureCheck C h e c kt h e f l u i d D r e s s u r ea s f o l l o w s t o d e t e r m i n e whetherthe troubleis in the pump or gearbox. N O T E ;F i r s tc h e c kt h e p o w e r s t e e r i n gf l u i d l e v e l a n d pump belttension. CAUTION: Disconnectthe pump outlet hose (high-pressure line) with care so as not to spill the power steering fluid on the frame and other parts, 1.

D i s c o n n e ctth e p u m p o u t l e t h o s e ( h i g h - p r e s s u r e ) from the pump outlet fitting, then install the P/S joint adapter(pump)on the pump outlet. HOSEATTACHINGBOLT 11 N.m (1.1kgt.m8lbl.ft)

OUTLETHOSEFITTING

Startthe engineand let it idle. 1 . Turn the steeringwheel from lock-to-lockseveral timesto warm the fluid to operatingtemperature. Measuresteady-state fluid pressurewhile idling. lf t h e p u m p i s i n g o o d c o n d i t i o nt,h e g a u g es h o u l d readlessthan 1500kPa(15 kgflcm' ,213psi). lf it readshigh, checkthe outlet hose or valve body 17-101. unit (seeGeneralTroubleshooting 9 . C l o s et h e p r e s s u r ec o n t r o l v a l v e ,t h e n c l o s et h e s h u t - o f fv a l v e g r a d u a l l yu n t i l t h e p r e s s u r eg a u g e needleis stable,Readthe pressure.

1 0 . lmmediatelyopenthe pressurecontrolvalvefully. CAUTION: Do not keep the pressure control valve closed more then 5 seconds or the pump could be damaged by over-heating.

P/S PRESSURE GAUGE 07a06- 001mo1

P/S

AOAPTERIHOSEI

07NAK- SR30124

lf the pump is in good condition,the gauge should read at least 6,400- 7,400 kPa (65 - 75 kgflcm',924 - 1,067psi). A low.eading means pump output is too low for full assist.Repairor replacethe pump.

P/S PRESSURE GAUGE 07i.{)6- (x)l(xrol

PRESSURE CONTROLVALVE

6 x 1,0mm BOLT lP.n ol tooll '| 1 N.m 11.1kgi.m,8lbtftl

{

VAI.VE SHUT.OFF

PUMP FITTING

Connectthe P/S joint adapter(hose)to the power steering pressuregauge, then connect the pump outlethose (high-pressure)to the adapter. Installthe power steeringpressuregaugeto the P/S joint adapter(pump). Openthe shut-offvalvefully. Openthe pressurecontrolvalvefulli.

I 1 7- 2 2

Fluid LeakageInspection

BOOT Checkfor Ieaks.

GEARBOXand VALVE BOoY UNIT Checktor leaksat the mating surface and Ilare nut connections,

PUMPASSEMBLY CheckIor leaksat the pumD seal,inletand outletfittings.

Inspecthosesfor damage,leaks, interference or twisting, Inspectfluid linesfor damage, rustingor leakage. Inspectfor leaksat hose and lineiointsor connections.

Bl8Cl engine

Exc.pl 818Cl engine

17-23

SteeringWheel Removal Disconnectthe connectorbetweenthe airbag and cablereel.

Airbag Removal 'CAUTION: All SRSwiro harne33e3ar€ coveradwith yellow insu. lation. Beforo you di3connect Eny part of En SRS wiro harn6ss,disconnsct the airbag conncctors. . Whenaver ths ignition switch is ON {ll}, or ha3 b.cn turned OFF lor l.3s than thrcc minuto3, be cErs{ul not to bump th6 SRS unh; the airbags could rccidentally deploy and causedamsgo or iniurias' . Fo. additional preclution3, rofer to tho SRS sub-soc' tion in 36ction 23, .

NOTE:Some SRSsystemconnectorshave a spring loadedlock. To releasethe lock, pull the spring-loadedsleeve toward the stop. Then pull the connector halves apart. Be sure to pullonthe sleeveand not on the connector half itself.

SPRING.LOADED

SRS MAIN HARNESS

Disconnectthe battery negative cable, then disconnectDositivecable. Removethe accesspanel from the steeringwheel lower cover. CABLEREEL

Remove the lid B and cruise control set/resume switch cover. Bemovethe TORX bolts then, remove the airbag assembly. AIRBAGASSEMBLY

L

17-24

Removal Disconnect the connectorsfrom the horn and cruise controlset/resumeswitches.

R e m o v et h e s t e e r i n gw h e e l b y r o c k i n gi t s l i g h t l y f r o m s i d e - t o - s i d ea s y o u p u l l s t e a d i l yw i t h b o t h hands. STEER|NG WHEEL

HORN CONNECTOR

store a removed airbag assembly with @ the pad surtace up. ll the airbag is improperly stored tace down. accidentaldeployment could propel the unit with snough force to causeserious iniury. NOTE: lf an intact airbag assemblyhas been removed f r o m a s c r a p p e dc a r o r h a s b e e n f o u n d d e f e c t i v eo r damagedduring transit,storageor service,it should be deDloyed(seesection23). TORXBOLT 9.8N.m(1.0kqtm, 6.5lbf'ft)

\

Removethe steeringwheel nut.

CAUTION: Carefully inspect the airbsg assembly betore inst8lling. Do nol install 8n airbag assemblythat shows signs ot being dropped or improperly handled, such as dents, cracks or deformation. Oo not disassembleor tampel with the airb8g assembly.

TORXBOLT 9.8N.m11.0kgf.m,6.5lbf.ft)

@.

HORNCONTACTPLATE STEERINGWHEEL

LID

h6

SPACER

@f CRUISECOTROLSET/ RESUMESWITCHES CRUISECONTROLSET/ RESUMESWITCHESCOVER

w

1c4:,/bA

4t

7 -25

SteeringWheel lnstallation Airbag installation

2.

CAUTION: . Before installing ths st€€ring wheel, align th€ front wheels straight ahead. . Be sure to ingtall the harnoss wirss 90 that they 8re not pinched or intorfering with other car parts. . Do not replace the original st€ering wheel with rny other d8ign, since it will mako h impossiblo to p.operly install the sirbag. {Only use genuinc HONDA rephcamont parts) . After rea$embly, contirm that ih€ wheels are still st.ight 8head and that stooring wheel spoke angle is correct. It minor spoko aogle sdiustment is n€cassary. do so only by adiustment ol the tis-rods, not by removing and reposhioning the 3teeringwho€|.

Installthesteeringwheel. NOTE: Be sure the steering wheel shatt engages the cablereeland cancelingsleeve. CAUTION: Do not tap on ths stearing whool or stsering column shaft whon in3tslling tha 3teoring whs6l.

confirm thst the airbag a33emblyis !@ sscurely attached to th€ steering wheel; otherwi3e, severepersonaliniury could result during airbag deploymenl. 1.

B e f o r e i n s t s l l i n gt h e s t e e r i n gw h e e l . c e n t e rt h e cable reel. Do this by first rotating the cable reel clockwise until it stoos. Then rotate it counterclockw i s e ( a p p r o x i m a t e l tyw o t u r n s ) u n t i l . T h e a r r o w makeon the cablereel labelpointsstraightup.

ARROWMARK

49 N'm ls.o kgf.m.36 lbf'ftl Aftach the cruise control sevresume switches connectorto the steeringwheelclip. Connectthe horn conneclor, CRUISECONTROL SW]TCHES SET,/RESUME CONNECTOR

\

|

17-26

Installtheairbagassemblywith new Torx bolts,and installthecovers.

7 . When the connectorhalvesare completelyconnected.

the pawl is released.and the spring loaded sleeve locksthe connector. SPRING.LOADED SLEEVE

cRursE CONTROL SET/RESUME

swtTcHcovER

Attach the connectorin the holder,then installthe accesspanelon the stee.ingwheel lowercover.

Holdthe pawl side connectorhalf.and presson the backof the sleeve-side connectorhalt in the direction shown. As the two connector halves are pressed together,the sleeveis pushedbackby the pawl. NOTE:Do not touch the sleeve.

Connectthe positivecable first. then the negative cableto the battery.

1 0 . After installingthe airbagassembly,confirm proper systemoperation: Turn the ignition switch ON (ll); the instrument p a n e l S R S i n d i c a t o rl i g h t s h o u l d c o m e o n f o r aboutsix secondsand then go off. . Confirmoperationof horn buttons. . Confirm operationof cruise control sevresume switches.

.

17-27

SteeringGolumn Removal Removethe SRSwire harnessconnectorfrom the connectorholder.

a All SRSwire harnessesare covered with yellow insulation. Before vou disconnect any pan of an SRS wire harness,disconnectthe airbagGonnectors. a Wheneverthe ignitionswitch is ON (lll, or has been turned OFFfor less than three minutes, be carelul not to bump the SRS unit; the airbags could accidentally deploy and cause damageor iniuries. a Foradditionalprecautions,lelel to the SRSsub-section in section 23. 1.

R e m o v et h e a i r b a ga s s e m b l ya n d s t e e r i n gw h e e l (seepage 17-25).

2.

Removethe lower cover.

3.

Removethe driver'skneebolster,

Disconnectthe cable reel connectorand SRSmain wire harnessconnector(seepage17-24).

HOI-DER CONNECTOR

SRSWIREHARNESSCONNECTOR

1.

' / /

I

,,1G

Removethe turn signalcancelingsleeve. 9.

LOWERCOVER

R e m o v et h e c o l u m n c o v e r s b y r e m o v i n g t h e screws.

17 -2 8

Disconnectthe crusecontrolswitchconnectorfrom the cable reel,and removethe cable reel trom the combinationswitch.

Removethe combinationswitch from the steering the connectors. columnby disconnecting

10. Removethe steeringjoint cover.

12. Disconnectthe ignitionswitch connectorsfrom the under-dashfuse/relaybox. '13. R e m o v e t h e s t e e r i n g c o l u m n b y r e m o v i n g the aftachingnuts and bolts.

JOINT COVER

1 1 . Removethe steeringjoint bolts,and move the ioint

towardthe column.

17-29

Steering Column Inspection Checkthe steeringcolumn ball bearingand the steering joint bearingsfor play and proper movement.ll there is noiseor if there is excessiveplav,replacethe i o i n to r c o l u m na s s e m b l y . C h e c kt h e r e t a i n i n gc o l l a rt o r d a m a g e .l f i r i s d a m ' aged,replacethe retainingcoilar. Checkthe absorbingplates,absorbingplate guides and slidingcapsulesfor distonionand breakage. Replacethem as an assemblyif they are distortedor DroKen.

RETAININGCOLLAR

AESORBINGPLATE ABSORBINGPLATE

JOINT BEARINGS PLASTIC INJECTIONS

COLUMNSALLBEANING IGNITIONSWITCH seesection23.

{ This pan is attached to the columnbracket with the plasticiniectaons.

Move the tilt lever from the loose positionto lock position 3 to 5 times; then measurethe tilt lever preload10 mm (0.4in) from the end of the tilt lever. Preload:70-90 N {7 -9 kgl, 15-20 lbll

SPRINGSCALE TILT LOCKBOLT

l f t h e m e a s u r e m e n ti s o u t o f t h e s p e c i f i c a t i o n , adjustthe preloadusingthe followingprocedures. a. Loosenthe tilt lever,and set the steeringcolumn in the neutralposition, b. Removethe 6 mm lockbolt and removethe stop. c. Adjustthe preloadby turningthe tilt lock bolt left or right. d. Pull up the tilt lever to the uppermost position and installthe stop. Checkthe preloadagain. lf t h e m e a s u r e m e n ti s s t i l l o u t o f s p e c i f i c a t i o n , repeatthe above procedures(a) through (c) to adjust. CAUTION:Be carelul not to loosen the lilt lsvel when installing the stop or tightening the 6 mm lock bolt.

t

17-30

9.8N.m (1.0kst.m,7.2lblft)

t

I

lnstallation

STEERING COLUMNASSEMBLY

RETAININGCOLLAR

STEERINGJOINT BOLTS 22 N.m {2.2kgI.D. 16 tbf.ftl

13 N.m (1.3kgf.m,9tbf.ft)

FLANGEBOLT 22 N m (2.2 kgt m, 16 lbf.ftl

(cont'd)

17-31

SteeringColumn Installation(cont'dl CAUTION: a All SRS wire harness€sare covored with yollow insulation. B€fors you disconnectany part of an SRSwire harness. disconnoct the airbag connoctois. a Whenever the ignition switch is ON (lll, or has beon turned OFFfor less than throo minutos, be caleful not to bump the SRS unit; ths airbags could accidsntslly deploy and caus€ damago or iniuries. a Foradditionalpracautions,reterto the SRSsub-section in section 23, 1.

I n s t a l lt h e s t e e r i n gc o l u m n w i t h t h e f l a n g e n u t s , then installthecolumnholderand flangebolts. T i g h t e nt h e u p p e r a n d l o w e r s t e e r i n gj o i n t b o l t s looselyinstalledin steps'l and 2. STEERING COLUMN

Slip the upperend of the steeringjoint onto the column shaft (line up the bolt hole with the flat on the shaft).and loosely install the upper steeringjoint bolt JorNTBoLT UPPER STEERTNG Fin6ltorque: 22 N.m 12.2kgf.m, 16 lbf.ft)

FLANGEBOLTS 22 N'm (2.2kgt'm'16lbf'ftl STEERING JOINT

Installthe steeringjoint cover with the clampsand cllP.

Slip the lower end of the steeringjoint onto the pini o n s h a f t .L i n e u p t h e b o l t h o l e w i t h t h e g r o o v e aroundthe shaft)and looselyinstallthelower bolt. NOTE: . B e s u r e t h a t t h e l o w e r s t e e r i n gj o i n t b o l t , i s securelyin the groove in the steering g€arbox p r nr o n . . Beforetighteningthe steeringjoint bolts,pull on the steeringioint to make sure that the steering ioint is fullYseated. LOWER STEERING JOINTBOLT

CLIP

\

17-32

{

Connectthe ignition switch wire connectorsto the under-dashfuse/relaybox. 1 . Installthe combinationswitchand connectthe con, nectors.Be surethe wires are not caughtor pinched by any partswhen installingthe combinationswitch.

12. Installthecolumncovers.

UPPERCOLUMNCOVER

8 . Carefullyinstallthe wire harnesswith the harness bandsand clamps. 9 . I n s t a l tl h e s p r i n ga n d t u r n s i g n a lc a n c e l i n gs l e e v e onto the combinationswitch. COMBINATIONSWITCH

LOWERCOLUMN COVER

scREws

SLEEVE

1 3 . Installthe driver'skneebolster. 1 4 . lnstallthe lowercover. 1 0 . Installthe cable reel,and connectthe cruisecontrol switchconnector.

Installthe steeringwheel (seepage 17 26).

1 1 . C o n n e c t h e c a b l e r e e l c o n n e c t o ra n d S R S m a i n

wire harnessconnector(seepage '17-27).

NOTE:Align the slot in the cable reel with the projectionon the cancelingsleeve.

CABLEREEL CONNECTOR HOLDER

SRSWIRE

LOWEFCOVER

17-33

PowerSteeringHoses,Lines Replacement NOTE: . Connecteachhoseto the correspondingline securely until it contactsthe stop on the line. Installthe clamp or adjustableclamp at the specifieddistancefrom the hoseend as shown. . Add the recommendedpower steeringfluid to the specifiedlevelon the reservoirand checkfor leaks. ADJUSTABLEHOSECLAMP:(al . P o s i t i o nt h e a d j u s t a b l eh o s e c l a m p sa t t h e p o i n t s indicatedby (a) in the drawingbelow. . Slidethe hoseoverthe line until it contactsthe stop.

CAUTION: Ch€ck all clamps for deterioration or deformation; replacethe clamps with new ones it necessary'

HOSECLAMP:(b) . Positionthe hose clamps at the points indicatedby (b) in the drawingbelow. . Slidethe hoseoverthe line until itcontactsthestop.

2.0- {.0 mm - 0.16inl 10.08

2 . 5 - 5 . 5m m 10.01- 0.22 in)

CYLINDERLINES 17 N.m (1.7kgt m, 12 lbf'ft)

2.5- 5.5mm (0.01- 0.22in)

RETURNLINEJOINT 28 N m 12.9kg{'m,2'l lbf'ft|

PUMP OUTI.IT HOSE (High-pressure) 11 N.m 11.1kgl.m,8lbJftl

PUMP INLETHOSE (Low-pressurel

PUMPOUTLETHOSE (High'pressure) 37 N.m (3.8kgtm,27 lbf.ft) RETURNHOSE

Exc.pt Bl8Cl engino

17-34

PowerSteeringPump Replacement NOTE:Beforedisconnecting the hosesfrom the pump, placea suitablecontainerunderthe vehicle. 1.

2.

Disconnectthe pump inlet hose and the pump outlet hose (High-pressure) trom the pump, and plug them.

Removethe belt by looseningthe pump adjusting bolt, mountingboltsand nuts.

NOTE:Take care not to spill the fluid on the body or parts.Wipe off any spilledfluid at once.

Coverthe Ay'Ccompressorwith several shop towels to protectit from spilledpowersteeringfluid,

Removethe pump mountingbolts,then removethe pump. NOTE: . Do not turn the steeringwheel with the pump removed, . Coverthe opening of the pump with a pieceof tape to preventforeign materiai from entering the oumo.

11 N.m 11.1kgf.m,8 lbl ft) PUMP INLETHOSE (Low-pressure) O.RING Replace.

Connectthe pump inlet hose and the pump outlet h o s e ( H i g h - p r e s s u r eT) .i g h t e nt h e p u m p f i t t i n g s securelv,

ADJUSTTNG

BOLT Looselyinstallthe pump in the pump bracketwith the mountingbolts,nuts and adjustingbolt. 7.

InstalltheDumDbelt. CAUTION: . Mako suro that the power staering belt is properly positioned on the pulleys. a Do not gst powor 9t99ring fluid or greas€on the power steering bclt or pulley facos.Clesn off any tluid or grea3abotoro installation

BEI-T POWERSTEERING

?UMP MOUt'lTlNGBOLTS 2a N.m (2.a kgf.m, 17 lbf.ftl

8.

Adjustthe pump belt (seepage 17-20).

a

Fill the reservoirto the upper level line (see page '11.211.

t 17-35

PowerSteeringPump Disassembly CAUTION: The power steering components are made of aluminum. Avoid damaging the componenk during assembly. NOTE: . Cleanthe disassembledpartswith a solvent,and dry them with compressedair. Do not dip the rubberparts in a solvent. . Alwaysreplacethe O-ringsand rubbersealswith new onesbeforeassembly. . Apply recommendedpower steeringfluid to the partsindicatedin the assemblyprocedures. . Do not allow dust,dirt, or otherforeignmaterialsto enterthe power steeringsystem. . Replacethe pump as an assemblyif the partsindicatedwith asterisk(*l areworn ordamaged'

FLANGEBOLTS 20 N.m (2.0kgf.m, 14 tbf.ftl

{.5 mm ROLLER

PUMPCOVER

5 mm ROLLER

IPUMPHOUSING 51 x 2.4 mm O-RING Replace. PUMPSEAL Replace.

13 x 1.9mm O-RING Replace.

' ,r"" aao,"ro"a* .]

INLETJOINT

*PUMP DRIVESHAFT BALLBEARING Inspoction and Replacement, seepage17-38

FLANGEBOLT 11 N.m (1.1kgt'm, 8 tbf.fr)

\

'FLowcoNTRoLvA *r"=-'e lnspectron, seepase17.37

'""^rro /

mm o.RrNG @

^t

PULLEY

;;:,:::

.FLOW CONTROI-VALVECAP 49 N.m {5.0 kgf'm, 36 tbt.ft)

17-36

40 mm CIRCLIP

NUT PULLEY 64 N.m 16.5kgt.m, 47 rbtft)

\

Inspection '1.

Drainthe fluid from the pump.

Flow Control Valv€:

Hold the steering pump in I vise with soft jaws, hold the pulley with the specialtool, and remove the pulleynut and pulley.

1.

Checkthe flow control valve for wear. burrs, and other damage to the edges of the grooves in the valve. FLOW CONTROLVALVE

CAUTION: Be careful not to d8m8go lh€ pump hoBing with tho iEws ol the vi3e. UNIVERSAL HOLDER 07725- lxt3(xxlo

Drl I Ev Nrrr

damage to edges.

Inspectthe bore the flow control valve for scrstches or wear, Slip the valve back in the pump, and checkthat it movesin and out smoothly.

I Loosenthe flow control valve cao with a hex wrench ano remove |l. 4.

Removethe O-ring,{low controlvalveand spring,

5.

Removethe inletjoint and O-ring.

6.

Removethe pump coverand pump coverse8l.

7.

Removethe outer side plate,pump cam ring, pump rotor,pump vanes,side plateand o-rings.

8.

Bemove the circlip, then remove the pump drive shaft by tapping the shaft end with th€ plastic h8mmer.

9.

Removethe pump sealspacerand pump seal.

lf OK, go on step 4; if not, replacethe pump as an assembly.The flow control valve is not available separately. Attach a hose to the end of the valve as shown. FLOWCONTROLVALVE

(cont'd)

17-37

PowerSteeringPump lnspection{cont'd) 5.

Submergethe valve in a containerof power steering fluid or solvent,and blow in the hose.lf air bubbles leakthrough the valve at lessthan 98 kPa ( 1 . 0 k g f / c m ' , 1 4 . 2 p s i ) , r e p l a c et h e p u m p a s a n assembly.

f.

BallBearing: 1.

Inspectthe ball bearingby rotatingthe outer race slowly. lf any play or roughnessis felt, replacethe ball bearing.

2.

Replacethe ball bearingusinga press.

AIR PRESSURE

lf the flow control valve tests OK, reinstallit in the pump. lf the flow controlvalvestill leaksair, replace the pump as an assembly.The flow controlvalve is not availableseDaratelv.

Removal

ln3tall Pross

I Pr€ss

I

installwith the red shieldedside facing down.

NOTErSupponthe innerrace with the tool securelY.

17-38

1.

Installthe new pump seal in the pump housingby hand,then installthe pump sealspacer.

6.

Setthe pump cam ring overthe two rollerswith the " c " markon the cam ring upward.

NOTE:Insen the pump seal with its grooved side facingin, Positionthe pump drive shaft in the pump housing, then drivethe it in usinga 29 mm socketas shown.

PUMPCAM RING

ROLI.-ER SETHOLES

3 . Installthe 40 mm circlipwith its radiusedside facZ-\

angout. 29mm S(rcKET

g

u: Screw locations, 3

6x1.0mm I fiNrrlr\rnr\ 6 N m (0.6kgfm '

law

iw.r,i

6.

lnstallalionis the reverseof the removalprocedure. NOTEI a Makesurethe innerhandlerod, lockrodandconnector are connectedproperly. a Make sure the door locks and opens properly.

)

CONNECTOR Detachthe connector.

20-9

Doors Run Channel Replacement Glass/Regulator/Glass Remove: a Door panel (seepage 2O-4) a Plasticcover (see page 20 4)

6.

Carefullymovethe glassuntilyou can seethe bolts, then loosenthem. Slidethe guide to the rear, then removethe glass from the guide.

Removethe power window switch Jrom the door panel,then connectit to the door harness(seepage 20-16).

N O T E : T a k e c a r en o t t o d r o p t h e g l a s si n s i d et h e door.

L o w e rt h e g l a s sI u l l y .

2 : Boltlocations,

Peeloff the channelguide cover, then removethe screws. NOTE: Wheninstallingthe channelguidecover,ap ply the double-facedadhesivetape to it. GLASS

3 >: Screwlocations,

Ofimnrrrn

CENTERCHANNEL GUIDE

Remove the center channel guide by pulling it upward.

+

ffi / BOLT

20-10

il€+ /

\ GUIDE

GUIDE

\ BOLT Loosen.

)

7.

Carefullypullthe glassout throughthe window slot. NOTE: a Take care not to drop the glass insidethe door. a Check the guide pin for damage,and replaceit it necessary. GUIDEPIN

Disconnectthe connector,then removethe regulator through the center hole in the door. NOTE: Scribea linearoundthe rearrollerguidebolt to show the originaladiustment.

: Bolt locations,6 6x1.0mm I N.m {0.8 kgf m 6lbt.ftl

N O T E rS c r i b ea l i n ea r o u n dt h e g u i d ep i n t o s h o w the originallocation. GUIDEPIN

GUIDEPIN

GUIDEPIN BOLT MOUNTING 6 r 1 . 0m m 3 N.m lO.3kgl m, 2 tbf.trl

REGULATOR

SEAL

(cont d)

20-11

Doors Run ChannelReplacement(cont'd) Glass/Regulator/Glass 9. Remove the power window regulator.

motor from the

NOTE: Before removing the power window motor, mark the location by scribing a line across the sec tor gear and regulator.

N O T E r l f n e c e s s a r yr,e m o v et h e g l a s ss t o p p e r . When installing the glass stopper, align it with the notch in the outer weatherstrip.

V: Bolt locations,3

Qp El Fl

s

o"r.o--

7 N m ( 0 . 7 k sm f . 5 lbf ftl

:

,

?

/

/

1 1 .Greaseallthe slidingsurlacesof the regulatorwhere s h o w n . I n s t a l lt h e p o w e r w i n d o w m o t o r o n t h e regulator. Check that the regulatormoves smoothly by con nectinga 12 V batteryto the power window motor ( s e es e c t i o n2 3 ) .

1 0 . Detach the clips, then peel and remove the glass run cnanner. > : Clip locations, 3

REGULATOR

GLASS STOPPER

d S*--.--;HERwrNDow -Rt-/'

FRONTCHANNEL

CENTEBCHANNEL

20-12

12. Apply clear sealant to locations @ on the door as s h o w n , t h e n i n s t a l lt h e g l a s s r u n c h a n n e l .

1 4 . I n s t a l lt h e g l a s s ( s e e p a g e 2 0 1 O i . t3,

NOTEI a l f n e c e s s a r y ,r e p l a c e a n y d a m a g e d c l i p s

l n s t a l lt h e c e n t e r c h a n n e lg u i d e a n d c h a n n e lg u i d e cover. N O T E : M a k e s u r e t h e g u i d e p i n i s i n s t a l l e di n t h e c e n t e r c h a n n e lg u i d e p r o p e r l y .

>: Clip locarion,3

GUIDEPIN

GLASS

CHANNEL GUIDE

to.

R o l lt h e g l a s su p a n dd o w n t o s e ei I i t m o v e sf r e e l y w i t h o u t b i n d i n g .A l s o m a k e s u r e t h a t t h e r e i s n o c l e a r a n c be e t w e e nt h e g l a s sa n d g l a s sr u n c h a n n e l . d j u s tt h e p o s i t i o no f t h e w h e nt h e g l a s si s c l o s e d A g l a s sa s n e c e s s a r lys e e p a g e2 0 1 6 ) .

CENTERCHANNEL

GUIDEPIN GLASS

Fit the glass run channelinto the front channel andon the dooras shown. GLASSRUN

Outside

\.-, lffi, /{

cxlrurutL \..

I

I Ir-

ll

Forward

CENTER CHANNEL GUIOE

rlc€\ / , nro.r(r" CHANNEL

\ ,*),

E

""o**..

GLASSRUN CHANNEL

r

FRONTCHANNEL CENTEBCHANNEL Outside

1 7 .Attach the door harness to the door correctly (see

l---.*',

page 20 5).

1 8 . Disconnect the power window switch from the door h a r n e s s ,t h e n i n s t a l lt h e p o w e r w i n d o w s w i t c h o n the door panel (seepage 20 16).

't3. I n s t a l tl h e r e g u l a t o (r s e ep a g e 2 O 1 1 ) . N O T E : M a k e s u r e t h e c o n n e c l o ri s c o n n e c t e d properly.

1 9 . W h e n r e i n s t a l l i n gt h e p l a s t i c c o v e r , a p p l Ya d h e s i v e along the edge where neccessary to malntaln a continuous seal and prevent waler leaks (see page 20 6). 2 0 . I n s t a l lt h e d o o r p a n e l ( s e e p a g e 2 0 4 ) .

20-13

Doors Front and Center ChannelR eplacement N O T E : R a i s et h e g l a s st u l l y . L

Peelthe center lower glass run channelout of the center channel.

Remove: a Door panel (seepage 2O-4) a Plasticcover (seepage 2O-4)

2.

NOTE: When installing,applyclearsealantto locations @ on the center channel.

Removethe front and center channels.

2 : Clip locations,21

Ll : C l i p l o c a t i o n , 1

NOTE: Take care not to twist or scratchthe outer m o l di n g . 6 A : Cliplocations, OUTER MOLDING INNER WEATHERSTRIP

CLIP

OUTERMOLDING

i

..-'

\.='''\

4.

---.-__: Screw locations,3

Removethe rod protector.

6 x ' 1 . 0m m 6 N.m {0.6kgl 4 tbf.tr)

>: Screwlocation,1

INNER HANDLE

5 . Pull out the outer handlewith the latch. Prythe outerhandlerod out ol its jointusingdiagonal culters.

Latch side. 3.

Remove the bolts and disconnect

side. the connector.

>: Clip locations,2

>: Bolt locatiohs, 2

NOTE: a To ease reassembly,note location@ of the outer handlerod on the joint before disconnectingit. a Take care not to bend the outer handlerod. a Use a shop towel to protect the openingin the door.

I

f$iT'r.*' 6 x 1.0 mm I \4/l* 9.4 N.m {1.0 ksf.m,i

ryty!!

BUSHING Replace.

J

h

CONNECTOR

SHOPTOWEL

{ c o n t ' d)

20-23 -

- | Screw locations,2

OUTER HANDLE

6bD

SHOPTOWEL

:

LOCKCYLINOEB

7.

>: Clip locaiions,2

l )

CYLINDERROO

Removethe cylindefswitch from the outer handle.

v:

irl

lii

8 . Pull out the retainer clip, then remove the lock cylinderand cylinderprotector.

cYLTNDER g--.-.o"*

3 . Installationis the reverseof the removalprocedure. NOTE: Makesurethe innerhandlerod, lock rod and connectorare connectedproperly.

,l

L

r

lnstallationis the reverseof the removalprocedure. NOTE: a Makesurethe outerhandlerod andconnectorare connectedsecurely. a Make sure the wire harnessis routed properly. a Make sure the door locks and opens properly.

Front Sash Replacement NOTE: Lower the glass.

Remove the front sash through the center hole in the ooor as snown.

1. Removel . Door panel (see page 20-20) a Plasticcover (see page 20,20) a Power mirror (seepage 20-491 a Outer molding (seepage 20-381 Detach the clips, then pry the weatherstripaway from the front sash. Removethe bolts and locknut. NOTE: a Holdthe adjustingbolt with a hex wrench when removingthe locknut. a Scribea linearoundthe locknutto show the original adjustment. >: Bolt locations,2

| , f > 6 x 1 . 0m m r @ l E ) s . 8N . m | \:Z 11.0kel.m, 7.2tbr.ril \ \-__ -_ -_

FRONTSASH 5.

a: llut location. 'l

I lX

" x r . 2 sm m

i,1i;T'-. '\:.[{,W ru_'otn'l_

Installationis the reverseof the removalprocedure. NOTE: After installing,adjust the positionol the front sash as necessary. a A l i g nt h e t r o n t s a s hw i t h t h e g l a s su s i n gt h e a d justing bolt at the bottom of the front sash.

IN a Check for water leaks. NOTE: Do not high-pressurewater.

ADJUSTING BOLT

Doors Guide Replacement Glass/Regulator/Glass NOTE: Scribe a line around the glass mounting bolts to show the original adjustment.

1. Removel a D o o r p a n e l{ s e ep a g e2 0 2 C a P l a s t i cc o v e r ( s e ep a g e2 0 - 2 0 )

>i goll locaiions.3

2.

3.

R e m o v et h e p o w e r w i n d o w s w i t c h f r o m t h e d o o r panel, then connect the door harness (see page 20-41t.

'1 L \

Move the glassuntil you can seethe glassstoppers, then removetheni.

,rr.^ 6 x'l o mm *qlqj I N m {0.8kstm, " 6rbrfrl \

2 >: Glassstopperlocations,

r>^ fo \A ^r / r \ a1l {,$i}t('rQ L iqW ):/}/ A/3 a i,l;o,Jl*,,". rurrrr_

r'ruf

v('rsxen$flff.*

-

a >' L;c"tio;

-fil>'

\@

l:

Locati."

hN lLoosen.

I 5.

Carefullypull the glass out of the window slot. NOTE: Takecarenot to damagelocationQt on the front sash.

GLASS

Carefullymove the glassuntil you can seethe glass mounting bolts, then removethem

i'

'

//)

6 . Removethe inner handle (see page 20-24).

Removethe glass guide.

7 . Disconnectthe connector,and removethe regulator through the center hole in the door.

NOTE: a Holdthe adjustingbolt with a hex wrench when removingthe locknut. a Scribea linearoundthe mountingnut to show the

NOTE: a Holdthe adjustingboltswith a hex wrenchwhen removingthe Iocknuts. a Scribe a line around the locknuts to show the originaladjustment. a : Nut locations,4

A: Eolts locations. 3

original adjustment. a: Nut locations,3 I x 1.25mm 22 N.m (2.2 kgf.m, 16 tbt frl

REGULATOB

a;

LOCKNUT

ir,frrffi

ADJUSTING BOLT

_i@I LOCKNUT

ADJUSTINGBOLT

(cont'd)

20-27

Doors Guide Glass/RegulatoriGlass Replacement(cont'dl L G r e a s ea l l t h e s l i d i n gs u r J a c e so f t h e r e g u l a t o fa n d glass guide where shown.

Outer MoldingReplacement NOTEr Lower the glassJully. 1.

\

Remove: . Door panel lsee page 2O-2O) . Power mirror (seepage 20 49)

2 . Peelthe weatherstripaway from the door lseepage 2 0 2 9 ) , t h e n r e m o v et h e s c r e w .

3 . S t a r t i n ga t t h e r e a r ,p r y t h e o u t e r m o l d i n gu p a n d d e t a c ht h e c l i p s ,t h e n r e m o v et h e o u t e rm o l d i n g . NOTE: Take care not to twist or scratchthe outer m o l di n g . >: Clip locations,4

V : Adjustingbolt locations.3

L@

61

4

SILICONEGREASE

N O T E :l f n e c e s s a r y , replaceany damaged clrps,

\

A\ror., -6-

U s el i q u i d

threadl o c k .

>: Screw locations,2

t\_:-F \ h t \

1 0 . R o l lt h e g l a s s u p a n d d o w n t o s e e i f i t m o v e s l r e e l y

I

,l

without binding.Also make sure that there is no clearance between the glass and weatherstrip when t h e g l a s s i s c l o s e d .A d j u s t t h e p o s i t i o no t t h e g l a s s a s n e c e s s a r y( s e e p a g e 2 0 - 4 0 ) .

't1.

Attach the door harness to the door correctly (see page 20 221.

1 2 . Disconnect the power window switch from the door h a r n e s s ,i h e n i n s l a l l t h e p o w e r w i n d o w s w i t c h o n the door panel (seepage 20 41).

r 3 . W h e n r e i n s t a l l i n gt h e p l a s t i c c o v e r , a p p l y a d h e s i v e along the edge where neccessary to maintain a continuous seal and prevent water leaks (see page 20 22\.

' 1 4 .I n s t a l tl h e d o o r p a n e l( s e ep a g e2 0 ' 2 1 ) .

20-28 L

-

4.

Installationis the reverseof the removalprocedure.

@

llr*ff1

*-r::ff"::"d*'*:T:'""" I | | --*-tj,fit'tt;l,i.xffi':il" )l !

|

__]

_

ro_r,

Doors Rear Door Index Sedan

page 20 38 Replacement,

HINGE WEATHERSTRIP page 20-39 Replacement,

* / -

6,il % TuJo^'

w< k @

eil%

) ' - -

Replacement, page 20-32

I

20-30

INSIDE STABILIZER

\

\

REGULATOR page 20-35 Replacement,

Sr

@ CENTERGLASS GUIDE Beplacement, page 20'35 INNER HANO

h^1 -\7 v Replacement, page 2o-35

LATCH PROTECTOR

20-31

Doors Door Panel/PlasticCover Replacement NOTE: Takecarenot to scratchthe door panelandother parts. 1.

Removethe armrestPocket. V : Scrowlocation,1

Pry out the cap and removethe screw. /qE\

|

vv / l

< : Screwlocation, l

ARMREST POCKET

4.

Releasethe clips that hold the door panel. NOTE: Removethe doo. panelwith as little bending as possibleto avoid creasingor breakingit.

;

,l

ti I

I

Removethe inner handletrim while pullingthe innerhandle. Disconnectthe power window switch connector.

SNAP-ON # A177. ol oquivafont 1mm +------./// {0.04 in) I 45 mm ( 1 . 7 7i n ) : 8oh locations,2 6 x 1.0 mm

9 . 8 N . m{ 1 . 0k g l m , I , ,,:otn , __) 5.

I a

Installationis the reverseof the removalprocedure. NOTE: Make sure the door locks and opens properly.

I

I

\

v

Latch Replacement N O T E : R a i s et h e g l a s st u l l y . 1. Remove: a Door panel lsee page 20-32) a Plasticcover (seepage 20-32) a Outer handle{see page 20-34) 2.

Glass Glass/Regulatol/Center Replacement Guide a Door panel (seepage 20 32) a Plasticcover (seepage 20-32) Connectthe power window switch to the door harn e s s ( s e ep a g e2 0 - 4 1 ) .

the connector, Removethe screws and dasconnect t h e n r e m o v et h e i n n e rh a n d l ea n d l a l c h .

Peelthe weatherstripaway from the door (seepage

NOTE: Take care not to bend the rods.

Loosenthe insidestabilizers.

Scaew locations, 2

N O T E rS c r i b ea l i n ea r o u n dt h e b o l t st o s h o w t h e o r i g i n aal d j u s t m e n t .

€tr' - , /l

Carefullymove the glassuntil you can seethe glass mountingnuts, then removethem.

STAEILIZER

2 a: Nut locations, t,h6xl.omm

)@[

a ru.mro.8ksr'm. 6 tbritl

i \

Detachthe connector.

BOLT 8 x 1.25mm 22 N.n 12.2 kgl'm. 16 lbt.ft)

INSIDESTABILIZERS

Installationis the reverseof the removalprocedure NOTE: Makesurethe innerhandlerod, lock rod and connectorare connectedproperly.

( c o n t ' d)

20-35

Doors Glass/Regulator/Center GlassGuide Replacement(cont'dl 6 . R e m o v teh e c e n t e gr l a s sg u i d e .

5 . C a r e f u l l rye m o v et h e g l a s sJ r o mt h e w i n d o ws l o ta s shown.

NOTE: a Holdthe adiusting boltswitha hexwrenchwhen

N O T E : T a k e c a r en o t t o d r o p t h e g l a s si n s i d et h e door.

removing the locknuts. o Scribe a line around the locknuts to show the o r i g i n a la d j u s t m e n t . a: Nut locations

x

aa.2

BO , 1

1 2 x 1. 2 5 m m

[ \

,"*. 2 2 N . m( 2 . 2k s f . m ,

Vuloru,__

v1'j,t^ (S)t LOCKNUT

ST

Y-l

20-36

7.

9. Grease all the sliding surlaces of the regulator and center glass guide where shown.

D i s c o n n e ct th e c o n n e c t o ra, n d r e m o v et h e r e g u l a ' t o r t h r o u g ht h e c e n l e rh o l ei n t h e d o o r . N O T E : S c r i b ea l i n ea r o u n dt h e r o l l e rg u i d eb o l t st o show the originaladlustment-

>: Bolt locations

l>A.4

>8.2

*,@ d|63il;o,ilIu'- 6rbr.ftr i6pl-". \ _!

1 0 . l n s t a l lt h e p o w e r w i n d o w m o t o r o n t h e r e g u l a t o r . 'l

1. Check that the regulator moves smoothly by con n e c t i n ga I 2 V b a t t e r yt o t h e p o w e r w i n d o w m o t o r (seesection 23).

bolt\ V: Adjusting locations,2 \l

\IL

I A---- | \H./ @

NOTE: Use liqurd thread lock.

I \

'f F' It S l L!=-2

t

I CENTER GLASS GUIDE CONNECTOR

8.

Remove the power window regulator.

motor from the

N O T E : B e f o r er e m o v i n gt h e p o w e r w i n d o w m o t o r , m a r k t h e l o c a t i o nb y s c r i b i n ga l i n e a c r o s st h e s e c tor gear and regulator. V: Bolt locations,3

REGULATOR

POWER wlNDow MOTOR

MOTOR

(cont dI

20-37

Door Glass/Regulator/Center GlassGuide Replacement(cont'd) '12. R o l lt h e g l a s su p a n dd o w n t o s e ei f i t m o v e sf r e e l y without binding.Also make sure that there is no clearancebetweenthe glassand weatherstripwhen the glassis closed.Adjust the positionof the glass a s n e c e s s a r (ys e ep a g e2 0 4 0 ; .

Outer MoldingReplacement \

NOTE: Lower the glassfully. '1.

R e m o v et h e d o o r p a n e l( s e ep a g e2 O - 3 2 ) .

2.

P e e l t h ew e a t h e r s t r iapw a yf r o mt h e d o o r( s e ep a g e 2 O - 3 9 i ,t h e n r e m o v et h e s c r e w .

3.

Startingat the rear, pry the outer moldingup and detach the clips, then removethe outer molding. NOTE: Take care not to twist or scratchthe outer molding.

>i Clip locations,4

A > : Screw location,1

\\ -.0s{0 Attach the door harnessto the door correctly(see p a g e2 O - 3 3 ) .

NOTEi lf necessary, replaceany damaged clrps.

1 4 . Disconnectthe power window switch from the door harness. When reinstallingthe plasticcover, apply adhesive alongthe edgewhere neccessary to maintaina continuous seal and prevent water leaks (see page 20 33).

>: Stabilizo.locstions,2 I ):

1 6 . l n s t a l lt h e d o o r p a n e l{ s e ep a g e2 O - 3 2 ) .

\__

Screw location.1

_,f"\ tjru{ 1i) -

OUTER

4.

lnstallationis the reverseof the removalDrocedure.

1 20-38 l-

WeatherstripReplacement >: Scr€w locations

a>,1 */]

"

l

a : Clip locations,3

iL.:5\ I l-fl

!l

B>, 2

.rf@

tA

IW l

;, I

[^_]

locations.1 8

/il

Itr" rtl

NOTE: a Before installingthe weatherstrip,apply clear sealantto locations@. Sealant:Cemedine#8500. or equivalent a I t n e c e s s a r yr,e p l a c ea n y d a m a g e dc l i p s .

20-39

Doors Glass Adjustment \

*: Adjusting bolt/locknutlocations NOTE: Take care not to damagelocation@ on the front sash. GLASS

GLASSGUIDE

\ GLASS

\ \ t ,"a,o'a \

INSIDE STABILIZEB

STABILIZER

\../

\

\

20-40 r---

NOTE; Placethe vehicleon a lirm, level surfacewhen adjustingthe glass. 1.

5.

Remove the power window switch from the front ooor paner. > i Screw locations, 5

Removethe weatherstrip(seepage20-1601.

v: Clip locations,3

NOTE: Checkthe weatherstriplor damageand deterioration,and replaceit if necessary PLASTIC GROMMET

RETAINER

*T5FrHERsrR'P

\v 2.

I n s t a l tl h e c e n t e rp i l l a rm o l d i n g . CENTEFPILLAR RETAINER

6.

FRONTDOORPANEL power to the door harwindow switch the Connect ness connectors. Front:

CENTERPILLAR

DOORHARNESS

POWER WINDOW

swtrcH

3 . Removethe door panel (see pages 2O-2O,32]'. NOTE: It necessary,peel off the plastic cover. Removethe power mirror (seepage 20-49). 7 . To preventthe glassfrom contactingthe body, hold the glass,and close the door carefully. R a i s et h e g l a s sf u l l y . NOTE: Check the door fit to the body opening.

(cont'd)

20-41

Doors Glass Adjustment (cont'dl 9. Measureand record clearances"H" and "B" at the locationsshown. 1 0 . A d j u s tt h e c l e a r a n c e a s d e s c r i b e di n s t e p s ( 1 1 ) t h r u r 4 ) . MeasuringPoints RETAINER

"H" Clearance 'Clearance

"ll" Clearance

"B" Clearance "B" Clearance

"B" Clearsnce

GLASS

SectionO

RETAINER

RETAINEB

GLASS

GLASS

Section @, Ql

socrion@

(StandardClearance) a P e r m i s s i b lteo l e r a n c et: 0 . 1 m m ( O . 0 4i n )

F r o n t :( 1 1 1a n d ( 1 2 1

\

U n i t :m m i i n )

Measuring Point R e a r :( 1 3 ) a n d ( 1 4 1

Clearance

o

(r\

\9

t-l

0.8 3 . O 1 0 . 3 ( o . 0 3 )1o.12)( o . 4 1 )

B

9.3 9.9 5.6 ( 0 . 3 7) 0 . 3 8 9to.22l

Measuring Point

,6

Clearance n

B

€)

'to 2 . 5 6 . O (0.39 ) 1 0 . 1 )\o.241 5 _ l

11.5 12.1

t o . 2 J( o . 4 5 ) { o . 4 8 ) {

20-42 L---

Front Door: "H" as follows. 1 1 . A d j u s tc l e a r a n c e "

{see page 20-42}

4 Loosenthe nuts and locknutssecuringthe glass guide,and regulator.Adjust the glasslore and a f t b y m o v i n gt h e g l a s sg u i d ea n d r e g u l a t o r . NOTE: Hold rhe adjusting bolts with a hex wrench when looseningthe locknuts.

- 1 Loosenthe bolts and locknutsecuringthe front

sash, and move the front sash all the way f o r wa r d . NOTE: Hold the adjusting bolt with a hex the locknut. w r e n c hw h e n l o o s e n i n g LOCKNUT

- 2 L o o s e nt h e n u t s e c u r i n gt h e s t o p p e rp l a t e s . -3 Loosenthe bolts securingthe glass,and move the glassup or down to alignit with the retain

- 5 R e p e a st t e p s- 3 t h r u - 4 u n t i lc l e a r a n c "eH " is within the specifiedlimits, then tasten the glassguide and regulator. Pressthe stopperplatesagainstthe glassstoppers, then fasten the stopperplates. NOTE: Check that the stopperplatescontact the glass stoppersevenly.

STOPPER €-r7 lErt-: : Spacer,Iastenerlocations

I

SPAC€R, 4

^,

MOLDING

.,^

\rr'P

K/]

r ' \ nitanrs \ lr-rcrumerur SPACER, 1 lB: LOWER

i

q

(4rsryilr!ry' c: UPPER FASTENER,2/} MOLDING \

w

ALIGNMENTMARKS

ALIGNMENT MARKS

I

20-70

8. Set the rear window, then centerit in the opening. Make alignmentmarksacrossthe rearwindow and body with a greasepencilat the tour pointsshown. ALIGNMENTMARK

...\

1 1 . W i t h a s p o n g e a, p p l ya l i g h tc o a t o J b o d y p r i m e rt o the originaladhesiveremainingaroundthe rearwindow openingflange.Let the body primerdry tor at l e a s t 1 Om i n u t e s . NOTE: a Do not apply glass primer to the body, and be carelul not to mix up glass and body primer spon9es. a Nevertouchthe primedsurfaceswith your hands. //ffi:

S ;-1\-\

Apglybodyprimerhere. '16 mm {O.63in)

6mm { 0 . 2 3i n }

1 6 m m { 0 . 6 3i n }

9 . R e m o v et h e r e a rw i n d o w . O. With a sponge, apply a light coat of glass primer aroundthe edgeof the rearwindow as shown, then lightly wipe it off with gauzeor cheesecloth. NOTE: a Do not applybody primerto the rearwindow, and do not get body and glassprimerspongesmixed up. a Nevertouchthe primedsurfaceswith yourhands. lf you do, the adhesivemay not bond to the rear window properly,causinga leak atter the rear window is installed. a Keep water, dust, and abrasivematerialsaway trom the primedsurface. 'fu5

t apptygtassp.im€rhe.e.

All around. '10 mm

{0.4 in)

6 m m 1 0 . 2 3i n l 1 6 m m 1 0 . 6 3i n )

Thoroughlymix the adhesiveand hardenertogether on a glassor metal plate with a putty knife. Follow the instructionsthat came with the adhesive. N O T E : C l e a nt h e p l a t ew i t h a s p o n g ea n d a l c o h o l b e f o r em i x i n g . Beforefilling a cartridge,cut the end of the nozzle as shown.

Cut nozzleend 1 0 m m { 0 . 3 9i n }

RearWindow Installation(cont'dl 14. Pack adhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Put the cartridge in a caulkinggun, and run a beadof adhesivearound the edge of the rear window as shown. NOTE: Apply the adhesivewithin 30 minutesafter applyingthe glass primer.

Scrapeor wipe the excessadhesiveofl with a putty knife or towel.

\

NOTE: To removeadhesivelrom a paintedsurface or the rearwindow, usea soft shoptowel dampened with alcohol. 1 7 . l n s t a l tl h e l o w e r c o v e r .

12 mm (O.47in)

[-/

'16.

ADHESIVE

, oo"r'u.

^X-*

L-l

8 m m 1 0 . 3 1i n )

\..__-, REARWINDOW

i

MOLDING

LOWERCOVER

I

cr-iss

Make a slightlythicker b6ad at each corner.

I

I I

t 1 5 .Use suctioncups to hold the rearwindow over the opening,alignit with the alignmentmarks made in step8, andset it down on the adhesive.Lightlypush on the rear window unlil its edgesare fully seated on the adhesiveall the way around. NOTF: Do not open or close the doors until the adhesiveis dry. ALIGNMENT MARK

18. Letthe adhesivedry for at leastone hour,then spray water over the rear window and check for leaks. Markleakingareas,let the rearwindow dry,then seal with sealant. NOTE: Let the car stand for at least four hours aflf the car hasto be used ter rearwindow installation. within the first four hours,it must be drivenslowly. 19. Reinstallall remainingremovedparts. NOTE: Advise the customernot to do the follow ing things lor two to three days: a 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 s r o l l e du p . a Twist the body excessively{suchas when going in and out of drivewaysat an angleor drivingo!er r o u g h ,u n e v e nr o a d s ) .

\

20-72 !:e-

OuarterGlass lnstallation

Removal CAUTIONi . Wear gloves to remove and install the quarter glass. . Use seat coversto avoid dsmaging any surfaces. 1.

2.

To removethe quarterglass,first removethe quarter trim (seepage20-93). Frcm insidethe car, use a knife to cut through the quarterglassadhesiveall the way around. NOTE: o lf the quarterglassis to be reinstalled, take care not to damagethe molding. . l f t h e m o l d i n gi s d a m a g e d r, e p l a c et h e q u a r t e r glass,moldingand clips as an assembly. . lf any of the clipsare broken,the quarterglasscan be reinstalled usingbutyltape.

1.

Scrapethe old adhesivesmooth with a knife to a thicknessof about 2 mm (0.08in) on the bonding s u r f a c ea r o u n dt h e e n t i r e q u a r t e rg l a s so p e n i n g flange. NOTE: . Do not scrapedown to the paintedsurfaceol the body; damaged paint will interferewith proper bonding. . Mask off surroundingsurfacesbefore applying primer. C l e a nt h e b o d y b o n d i n g s u r f a c ew i t h a s p o n g e dampenedin alcohol. NOTE:After cleaning,keepoil, greaseand water off the surface.

3. lf the old quarter glass is to be reinstalled.use a putty knife to scrapeoff all tracesof old adhesive, then clean the quarter glass surfacewith alcohol where adhesiveis to be applied. NOTE:Make sure the bonding surfaceis kept free of water,oil and grease. CAUTION: Avoid s6tting tho qurrtsr glass on its edges;th€ molding can be permanently dstormed. NOTE:Cleanthe shadowedarea.

ADHESIVE

3.

Carefullyremovethe quarterglass.

CLIP

NOTE: . Checkthe molding for damage,and replacethe quanerglassif necessary. . Removeany brokenclipsfrom the body.

(cont'd)

OuarterGlass Installation(cont'd) lf the old quarter glass is to be reinstalled land either of the clips are broken off the molding), apply a l i g h t c o a t o t p r i m e r ( C 1 0 0 , o r e q u i v a l e n t | ,t h e n apply the butyl tape to the molding as shown. NOTE: . Be careful not to touch the quarter glass where adhesive will be applied. . Do not peel the separator off the butyl tape. //////.t Bulyl lape locations18628,or equivalent) ""' mm {0.13in) Thickness:3.2 Width:6.4 mm (0.25in)

6.

BUTYLTAPE

300mm n 1 . 8i n ) l f t h e o l d q u a r t e rg l a s s i s t o b e r e i n s t a l l e d( a n d either of the clips are brokenoff the molding),seal the body holeswith piecesof urethanetape.Setthe q u a r t e rg l a s su p r i g h ti n t h e o p e n i n g ,m a k e a l i g n ment marksacrossthe quaner glassand body with a g r e a s ep e n c i l a t t h e t h r e e p o i n t s s h o w n , t h e n removethe quarterglass. N O T E :B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s w h e r ea d h e s i v w e illbeapplied.

With a sponge,apply a light coat of glassprimerto the insideface of the quarterglassas shown, then lightlywipe it off with gauzeor cheesecloth. NOTE: . Do not apply body primer to the quarter glass, and do not get body and glass primer sponges mixed up. . N e v e rt o u c h t h e p r i m e d s u r f a c e sw i t h y o u r hands.lf you do, the adhesivemay not bond to the quarter glass properly,causinga leak after the quarterglassis installed. . Keep water, dust, and abrasivematerialsaway from the primedsurface. /////1: Apotvslassoimer here. 6mm {0.24in}

t

)

7.

With a sponge,apply a light coat of body primerto t h e o r i g i n a al d h e s i v er e m a i n i n ga r o u n dt h e q u a n e r glassopening{lange.Let the body primer dry for at l e a s t1 0 m i n u t e s .

10. Packadhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Putthe cartridgein a c a u l k i n gg u n , a n d r u n a b e a d o f a d h e s i v ea r o u n d the edgeof the quarterglassas shown.

NOTE: . D o n o t a p p l y g l a s sp r i m e rt o t h e b o d y ,a n d b e c a r e f u ln o t t o m i x u p g l a s s a n d b o d y p r i m e r sponges. . N e v e rt o u c h t h e p r i m e d s u r f a c e sw i t h y o u r n an o s . //;4: Aoelybodv Pimer hare

NOTE: . lf the old quarterglass is to be reinstalled,peel the separatoroff the butyl tape afterapplyingthe adhesive. . Applythe adhesivewithin 30 minutesafterapplying the glassprimer.

5 m m (0.2inl

ffi 16 mm 10.63inl

6mm lo.24 inl

8 mm 10.3inl 16 rnm ( 0 . 6 3i n ) 8 mm (0.3in) OUARTER TRIM

Tt

jrlrI

)H I )

w

2 mm (0.08in)

l

EUTYLTAPES

l(

OUARTER TRIM

5 mm lO.2in) 8.

:AoHEs' vE

ffi;;[,]\

SIDESPACER

IP'--

12 mm (0.47in)

2 mm 10.08in)

OUARTER

lRtM

Thoroughlymix the adhesiveand hardenertogether on a glassor metalplatewith a putty knife. NOTE: . Cleanthe platewith a spongeand alcoholbefore mrxrng. . Followthe adhesivemanufactur'sinstructions.

L

Before filling a cartridge,cut the end of the nozzle as shown. Cut nozzleend in) 10 mm 10.39

7 mm 10.27 in) (cont'd)

20-75

OuarterGlass Installation(cont'd) 1 1 . Use suction cups to hold the quarter glass over the o p e n i n g ,a l i g n t h e c l i p s o r t h e a l i g n m e n t m a r k s made in step 5, and set it down on the adhesive. Lightly push on the quarter glass until its edges are f 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 . NOTE: Do not open or close the doors until the adhesive is dry.

L e t t h e a d h e s i v ed r y f o r a t l e a s to n e h o u r , t h e n s p r a y w a t e r o v e r t h e q u a r t e rg l a s sa n d c h e c kf o r leaks.lvlarkleakingareas,and let the quarterglass dry, then sealwith sealant.

\./

NOTE:Let the car standfor at leastfour hoursafter quarterglass installation.lf the car has to be used within the first four hours,it must be drivenslowly. 1 4 . R e i n s t aal ll l r e m a i n i n g r e m o v e dp a n s .

NOTE:Advisethe customernot to do the following thingsfor two to threedays: . .

Slamthe doorswith all the windows rolledup. 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 l a n a n g l eo r d r i v i n g over rough,unevenroads).

v 1 2 . Scrapeor wipe the excessadhesiveoff with a putty knileor towel. NOTE: Use a soft shop towel dampenedwith alcohol to remove adhesivefrom a painted surfaceor r lass. t h eq u a r t eg

v ,

20-7 6

r

Moonroof lndex Hatchback

CAELEASSEMBLY Replacement,page 20-81

SUNSHAOE Replacement,page

MOTOB Replacement,page 20-80

GLASSBRACKET page 20 81 Replacement,

(@ SUNSHADERAIL FRONTDRAIN CHANNEL DRAINCHANNEL

SLIDESTOPPER LINK

GUIDERAIL page 20 81 Replacement,

FRAMESEAL FRONTRAIL HOLDER FRONTDRAINTUBE

REARDRAINTUSE

V,

II llj

RIGHT REAR DRA|N vaLVE

. f r / ,rr,^*^/& I DRAINVALVE I

/

@'\ 'FRoNT DRATN VALVE

FRAME page 20 80 Replacement,

[il

il r / 20-77

Moonroof Troubleshooting P.obableCause

Symptom 1 C l o g g e dd r a i nt u b e .

Water leaks

2 Gap between glass weatherstripand roof panel 3 De{ectrveor improperlyInstalledglass weatherstrip 4 Gap betweendrain seal and rool panel. 1 . Excessiveclearancebetween glass weatherstripand roof panel-

Windnoise

1 Loose motor.

Motor noise

2 Worn gear or bearing. 3 Cableassemblvdeformed. ,l

Glassdoes not move, but motor turns

Clutch out ol adiustment. 2 Foreignmatter stuck between guide rail and slider' 3 lnner cable loose. 4 Cableassemblynot attachedproperly

Glassdoes not move and motor does not turn (glasscan be moved with moonroofwrench)

1 . B l o w nf u s e . 2. Faulty switch. 3. Battery run down. 4. Delectivemotor. 5. Faulty relay.

Glass Height Adiustment The roof panelshouldbe even with the glassweathers r r i p ,t o w i t h i n 1 . 8 t O . 5 m m { O . 0 7t 0 . 0 2 i n } a l l t h e w a y a r o u n d .l f n o t , s l i d et h e s u n s h a d eb a c k ,a n d :

V : Boll locations, 6

1 . T i l t - u pt h e g l a s s . 2.

Loosenthe bolts and adjustthe glass.

3.

Repeaton oppositeside if necessary.

1 . 8 i 0 . 5 m m 1 0 . 0 7i 0 . 0 2 i n l

]-

ROOFPANEL

GLASSBRACKET

GLASSWEATHERSTRIP

GLASSBRACKET

{ Side-to-sideiit of glass weatherstrip can be adJusted by loosening the frame mounting bolts and moving the frame right or left and {orward or backward by hand (see page 2O-8Oi.

!

20-78

$ I

Rear Edge Closing Adjustment Openthe glassabouta foot, then closeit to checkwhere rearedgebeginsto rise.lf it risestoo soon and seatstoo tightly againstthe roof panel,or too late and does not s e a tt i g h t l ye n o u g h ,a d j u s ti t . 'l .

Removethe headliner(seepage 2O-98).

2.

R e m o v et h e g l a s s .

3.

R e m o v et h e m o t o r ( s e ep a g e2 O - 8 0 ) .

4.

A l i g nt h e t i l t u p p o s i t i o no f t h e l i f t e ro n e a c hs i d e .

Glassand SunshadeReplacement 1.

Open the sunshade.

2.

Tilt up the glass.

3.

Remove the bolts, then remove the glass from the glass bracket. V : Bolt localions, 6

6x1.0mm l 9 . 8 N . m{ 1 . Ok g t . m , l 7.2 tbt.ftt ) GLASS

t GLASSBRACKET

Checkthat the alignmentle,ftand right, then install the motor. Installthe glass,then check for water leaks. NOTE: Do not use high-pressurewater.

4.

Removethe screw,and lift the sunshaderailon each srcle.

5.

Slide the sunshade torward, then remove the sunshade. 2 v : Screwlocations, I

I

i

Installthe headliner.

Installationis the reverseof the removalprocedureCheck for water leaks. water. NOTE: Do not use high-pressure

20-79

Moonroof Motor, Drain Tube and Frame Replacement

Removethe bolts,then removethe lrame from the car.

1 . R e m o v et h e g l a s s( s e ep a g e2 0 - 7 9 )a n d h e a d l i n e r { s e ep a g e2 O - 9 8 } . 2.

!

Oisconnectthe drain tubes.

CAUTION: Be careful not to damagethe seats, dashboa.d and other interiortrim.

NOTE: You may requireassistancewhen removing the trame.

Disconnectthe motor connector,and removethe clips securingthe ceilinglight wire harness.

A : Bolt locations, 8 < : Clip locations,2

4,

6 x 1.0 mm 9 . 8 N . m 1 1 . 0k g t m , 7.2 tbf.fr)

DRAINTUBE To install,slide the drain tube over the {rame nozzle a t l e a s t1 0 m m i 0 . 4 i n ) .

TUBECLIP FRAMESEAL

-'

FRAME

FRAME

\"

Pull the drain tubes out the front and rear pillars.

3 . Removethe bolts and nuts,then removethe motor, if necessary.

NOTE: Beforepullingout the draintube, tie a string to the end of it so it can be reinstalled.

NOTE: Make sure both slidersare parallelwhen installingthe motor.

REARDRAIN TUBES

: Bolt, nut locations A

B A : Nut, 3

: 8olt, 2

6x 1.0mm I 9.8Nm L

:!)

{1.0kgf 7 .2 tbl

6@

6 x 1 . 0m m 9 . 4N . m ( 1 . Ok g fm ,

1'lIltl /

I I

FRONT DRAIN VALVES

7.

Installationis lhe reverseof the removalprocedure. NOTE: a Cleanthe surtaceof the frame. a Check the lrame seal. a Check tor water leaks.

20-80 \

v

Glass Bracket/Slidet Lifter Guide Railsand Cable Assembly Replacement 1 . Removethe frame from the car (seepage 20 8O). 2 . R e m o v et h e m o t o r ( s e ep a g e2 0 8 0 ) . 3 . R e m o v et h e d r a i nc h a n n e l . NOTE: Take care not to damage,twist or lift the s e aL

Remove the front rail holder on each side.

5.

V: Nut, scaewlocations A V : N u t ,2 6 x 1.0 mm 9.8Nm ( ' 1 . 0k g f m ,

7 2 !!!!!l

B v : S c r e w2, 1er I

./

I

Yc , /I

V : Screw locations.2

/e,

Y)

I

FRAME

4.

6.

R e m o v et h e a n c h o rs p r i n go n e a c h s i d e .

7.

Removethe nuts and screws, then lift and remove b o t hg u i d er a i l sa n dc a b l ea s s e m b l fyr o m t h e f r a m e . Removethe sunshadeand both sunshaderails.

V : Nut, screw locations A V : N u t ,2

B v : S c r e w ,4

R e m o v et h e t r o n t d r a i nc h a n n e ol n e a c h s i d e .

V : Clip locations, 2

N O T E :T o i n s t a l lI,i l l r h e groove in each grommet with sealant.

I

@

FRONTDBAIN CHANNEL

GUIDERAIL

,._--'/ / r \ /-rr / \

---i:579 sur'rsHaor RA|L

\

)

\/ \---_ _/,/

CABLE

ANCHOR SPFING

GUIOERAIL

GROMMET

GUIDERAIL

Moonroof Glass Bracket/Slider,Lifter, Guide Railsand Cable Assembly Replacement (cont'dl

8.

S l i d et h e g u i d er a i lf o r w a r d ,t h e n r e m o v ei t .

\

1 0 .Slide the

anchor rod forward, then remove it lrom the guide rail.

N O T E : T a k ec a r e n o t t o b e n dt h e i n n e rc a b l e .

CABLEASSEMBLY

STOPPER

To install,insertthe anchor rod by turningthe sropper90o

GUIDERAIL

9 . Separatethe glassbracket,lifter, slidestopperlink andslider.

ANCHORROD

1 1 .I nstallationis the reverseof the removalprocedure. I N N E RCABLE

\o

LIFTER

GLASS ERACKET

SLIOER NOTEr To install,apply multipurposegreaseto the lifter and slidestopperlink.

i

I 20-82 L

NOTE: a Damagedparts should be replaced. a A p p l y g r e a s et o t h e s h d i n gp o r t i o n .

OpeningDrag Gheck (Motor Removedl Beforeinstallingthe motor, measurethe effort required t o o p e nt h e g l a s su s i n ga s p r i n gs c a l ea s s h o w n . CAUTION: Wh€n usinga springscale,piotectthe leading odge of the glass with a shop towel. l f l o a di s o v e r 4 0 N 1 4k g f , 9 l b f ) , c h e c ks i d ec l e a r a n c e a n d g l a s sh e i g h ta d j u s t m e n(ts e ep a g e2 0 - 7 8 ) .

Closing Force Check (Motor Installedl '1.

After installingall removedparts,havea helperhold the switch to close the glass whjle you measure {orce requiredto stop it. Attach a spring scale as shown. Readthe force as soon as the glassstops moving, then immediatelyreleasethe switch and spflng scate. CAUTION: When using a sp.ing scale,protectthe leadingedge of the glass with a shop towel. ClosingFo.ce: 200-29O N {2O- 30 kst. 44-66 lbf)

GLASS

SPRING

scAt_E

2 . lf the force is not within specification,installa new lock washer,adjustthe tensionby turningthe mo tor clutch adjustingnut, and bend the lock washer againstthe motor clutch adjustingnut. LOCK WASHER Replace.

t;-


GLASS BRACKET Replacement, page 20 88

ORAINCHANNEL

SUNSHADE Beplacement,page

HoR

I

v#,o**,"*

%bYP FRONT DRAIN CHANNEL

SUNSHADERAIL GUIOERAIL Replacemenl,page 20-88

MOTOR page20 87 Replacement,

REARRAIL HOLDER

SEAL

FRONTDRAINTUBE

\,r,

REARDRAINTUBE

r

RIGHTREAR ORAINVALVE

\

/ A

\

- q € 51-'-

FRONTORAIN

q!-vawe

FRAME page 20-87 Replacement,

20-84

u

I

\"

Troubleshooting ) Symptom

ProbableCause

Water leaks

1 . C l o g g e dd r a i nt u b e . 2. Gap between glass weatherstripand roof panel. 3. Detectiveor improperlyinstalledglass weatherstrip. 4. Gap between drain seal and roof panel.

Windnoise

1. Excessiveclearancebetween qlass weatherstriDand roof oanel.

Motor noise

I 2 3 1 2 3

Glass does not move, but motor turnS

Glassdoes not move and motor does not turn (glasscan be moved with moonroof wrench)

Loosemotor. Worn gear or bearing. Cableassemblydeformed. Clutch out of adjustment. Foreignmatter stuck between guide rail and slider. lnner cable loose. Cableassemblynot attachedproperly.

I B l o w nf u s e . 2 Faulty switch. 3 Batteryrun down. Defectivemotor. 5 F a u l t yr e l a y .

Glass Height Adjustment The rooJpanel shouldbe even with the glassweather s t r i p t, o w i t h i n 1 . 8 t 0 . 5 m m ( O . O 7t O . O 2 i n )a l l t h ew a y a r o u n d .I t n o t , s l i d et h e s u n s h a d eb a c k ,a n d : 1 . T i l t - u pt h e g l a s s . 2.

Loosenthe bolts and adjust the glass.

3.

Repeaton oppositeside if necessary.

Gr_ASS

1 . 8 10.5 mm {0.07 } 0.02 inl

ROOFPANEL

GLASSBRACKET

4-(.' GLASSBRACKET

GLASSWEATHERSTRIP 4.

Side-to-sidefit oI glassweatherstripcan be adjusted by looseningthe frame mountingbolts and mov ing the frame right or left and forward or backward b y h a n d ( s e ep a g e2 0 - 8 7 ) .

s {

I

20-85

Moonroof Rear Edge Closing Adjustment Openthe glassabouta foot, then closeit to checkwhere rearedgebeginsto rise.l,fit risestoo soon and seatstoo tightly againstthe root panel,or too late and does not seat tightly enough,adjust it.

Glassand SunshadeRePlacement 1 . O p e nt h e s u n s h a d e . 2 . T i l t - u pt h e g l a s s . 3.

1 . R e m o v et h e h e a d l i n e(rs e ep a g e2 0 - 1 O 0 ) . 2.

R e m o v et h e g l a s s .

3.

R e m o v et h e m o t o r ( s e ep a g e2 0 ' 8 7 ) .

4.

Align the tilt-up positionof the lifter on each side.

Removethe bolts, then removethe glasslrom the glass bracket. Usethe moonroof

9.8 N m (1.0kgl m,

GLASSERACKET Removethe screws and lift the sunshaderails Silde the sunshade forward, then remove the sunsnaqe. Checkthat the alignmentleft and right, then install the motor.

SUNSHADE RAIL

Installthe glass,then check for water leaks. water. NOTE: Do not use high-pressure l n s t a l tl h e h e a d l i n e r .

6 . lnstallationis the reverseofthe removalprocedure. 7 . Check for water leaks. water. NOTE: Do not use high-pressure

20-86

Motor, DrainTube and FrameReplacement

J

CAUTION: Be ca.eful not to damagethe seats, dashboard and other interiortrim, 1 . R e m o v et h e g l a s s( s e ep a g e2 O - 8 6 )a n d h e a d l i n e r ( s e ep a g e2 0 -1 O O ) . 2.

Disconnectthe motor connector,and removethe c l i p ss e c u r i n gt h e c e i l i n gl i g h t w i r e h a r n e s s . NOTE: To removethe motor, removethe screws.

3.

Disconnectthe drain tubes.

4.

Loosenthe front bolts.

5.

Removethe bolts,then removethe frame from the car. NOTE: a You may requireassistancewhen removingthe frame. a Take care not to bend the sunshaderails. TUBE CLIP

CONNECTOR Make sure the slidersare parallelwhen installingthe motor.

FRAME

FRAMESEAL

EOLT 6 x 1.0 mm 9 . 8 N . m l 1 . Ok g f. m , 7 .2 tbt.ltl

J DRAINTUBE To Install,slidethe drain tube over the frame nozzleat least 10 mm (0.4 in).

SUNSHADE RAILS

Loosen the front bolts,

Fo.ward

6 . Pullthe draintubes out of the front and rearpillars. NOTE: Beforepullingout the draintube, rie a string to the end oI it so it can be reinstalled.

7.

Installationis the reverseol the removalprocedure. FRONT DRAINVALVES

NOTE: a Installthe tube clips with the ends {acing the side to ease installation of the headliner. a Cleanthe surfaceof the frame. a Check the frame seal. a Check lor water leaks. a Make sure the sunshademoves smoothly.

Moonroof

Lifter. Guide Railsand CableAssemblyReplacementGlassBracket/Slider,

1 . Removethe frame (seepage 20-87).

2.

3.

Removethe screwg,then removethe sunshaderail b y s l i d i n gi t b a c k w a r d .

Removethe drain channel. SUNSHADERAIL

NOTE: Take care not to damage,twist or lift the seal. SCREW

SUNSHADE RAIL

Removethe motor (seepage 20-87). 5 . Removethe tront drain channel. 6.

Removethe nut, then removethe front rail holder'

7.

Removethe screws @ attachingthe guide rail, then lilt the guide rail.

8.

Removethe nut, then removethe rear rail holder.

NUT 6x1.0mm 9.8 N m 11.0 kgf rrt, 7 .2 lbl.lrl

N O T E : R e m o v et h e a n c h o rs p r i n g . FRONTDRAIN CHANNEL NUT 6 x 1 . 0m m 9.8 N m {1.0kgl m, 7.2 tbf ft)

GLASSBRACKET/ SLIDER,LIFTER

SUB.SEAL

rnorur/ r.l .i:'r RAIL

',.;.

"o.ol... i\

FRAME NOTE: Install the rear rail holder, then glue the sub seal to the lrame.

9.

S l i d e r h e q l d s s b r a c k e l s l r d e r ,l i f t e l b a c k w a r d , t h e n r e m o v e i t

20-88 L

-

1O. Separatethe glassbracket,litt€r, slide stopper link andslider.

' 1 2 Slide . the guiderail

backward,then removethe guide rail from the inner cable. NOTE: To install,apply caulkingto the guide rail mounting surtaceon the frame.

GLASS BRACKET

INNERCABLE

SLIDER

Applycaolking before installing the guiderail.

NOTE:To install,applymultipurpose grease to the lifterandslidestopperlink. '13. 1 1 .Slidethe anchorrod forward, then removeit from the guide rail.

Removethe screws,then removethe cableassem bly trom the f rame. NOTE: Take care not to bend the cable tubes. FRAME

STOPPER

To install,insertthe anchor rod by turnjng the stopper9Oo.

NOTE:To install,fill the grooveIn eachgrommetwith sealant. 1 4 . Installationis the reverseof the removalprocedure. ANCHORROD

NOTE: a Damagedparts should be replaced. a Apply greaseto the slidingportion.

20-89

Moonroof Opening Drag Check (Motor Removedl Beforeinstallingthe motor, measurethe effort required t o o p e nt h e g l a s su s i n ga s p r i n gs c a l ea s s h o w n . CAUTION: When usinga springscale,proteclthe leading edge ot the glass with a shop towel. lf load is over 40 N (4 kgl, 9 lbfi, check side clearance a n d g l a s sh e i g h ta d j u s t m e n(t s e ep a g e 2 0 - 8 5 )

Closing Force Check {Motor Installed}

'1.

Alter installingall removedparts,havea helperhold the switch to close the glass while you measure Jorce requiredto stop it. Attach a spring scale as shown. Readthe lorce as soon as the glassstops m o v i n g ,t h e n i m m e d i a t e l rye l e a s et h e s w i t c h a n d spring scale. CAUTION: when using a springscale,protecl the leadingedge oI the glass with a shop towel. ClosingForce: 200-290 N (20-30 ksf,44-66 lbtl

GLASS

\

lf the force is not within specitication,installa new lock washer,adiustthe tensionby turnlngthe motor clutch adjustingnut, and bend the lock washer againstthe motor clutch adjustingnut.

clocKwrsE/?l a T o I n c r e a s e\ 1 , force I

20-90 --

COUNTERCLOCKWISE lo oecrease force

InteriorTrim Replacement Hatchback a Weai glovesto removeand installthe ttim and panels. a When prying with a flat tip screwdriver, wrap it with protectivetape to preventdamage.

Rear trim panel/Sidet?im panel/Ouarterpillar trim panel removal: REARSHELF

'1.

NOTE: Take care not to bend or scratchthe trim and panels.

2. Kick panel/Frontpillartrim removali 1 . R e m o v et h e k i c k p a n e l . < : Cliplocations A < : C l i p 1,

B < : C l i p ,1

CV: Clip,'l

fl,ffi,ry

N O T E : R e m o v et h e d r i v e r ' sk i c kp a n e w l h i l ep u l l i n g the hood releasehandle.

REARSHELF Removethe rearseat(seepage20-110). Removethe trunk mat and sparetire lid

KICK PANEL

Pullthe door trim back,then removethe front pillar trim. < : Clip locations,4

5.

FASTENER TRUNKMAT Removethe rear body stiffener (Type R).

>: Bohlocltionr,2 8 x 1.25mm Z2 N-m l?.2 kgt m, 18 tbf.ftl

FRONTPILLAR

lnstallation is the reverse of the removal procedure. NOTE: lf necessary, replace any damaged clips.

20-91

lnterior Trim Replacement(cont'd) 6.

8.

Removethe reartrim Panel.

Removethe sidetrim Panel

> : Clip locations

V : C l i pl o c a t i o n s7, 1) Push the innerclip. NOTE: Do not PUsh ii in too far.

2) Detach the clip by pullingit.

CLIP

INNER CLIP

@ M)

B > : C l i P ,4

A > : C l i p ,4

h

l

l r

l

l

gA) H t s\ )l D V : c l i p ,1

C > : C l i p ,3

ill

1

zz77z7v I

W y ' I/ " W _ / >: Bolt,screwlocations B ) : S c r e w2,

A > : B o l t ,2

I

|

w) w__) .4\

.\

PANEL

Removethe speakerlid and left accesspanelfrom the sidetrim Danel. > : Clip locations Atr : Clip, 2

B V : C l i p ,2

,^*i -v_) -@P,,

--_

HOOKS

l

.1

.oK= tLhHOOKS

NOTE: Disconnectthe cargo area light connector J r o mt h e l e l t s i d et r i m P a n e l .

HOOKS SPEAKER LID LEFT ACCESS PANEL

CARGOAREA LIGHT

9 . Removethe upper anchorbolts from the front and rearseat belts(seepages20-1'17,121)

12. Removethe quarterpillartrim panel. > : Clip locations

1 0 . Removethe door trim. B > : C l i p ,3

A> : Clip, 7

N O T E : W h e ni n s t a l l i n tgh e d o o rt r i m , a l i g ni t w i t h the door openingflange notch.

W; W

.ML

NOTE: Remove the lront seat belt lrom the belt gurde-

BELT 1 1 . Removethe quartertrim and coat hanger(leftside). l

: Screw location, 1

Pry the lid.

'13. Installationis the reverse of the removalprocedure. NOTE: a lf necessary,replaceany damagedclips. a Wheninstalling t h e s i d e t r i m p a n e l ,m a k e s u r e there are no twists or kinks in the front and rear seat belts. a Wheninstalling the reartrim panel,installthe clips as follows. 1 ) P u l lt h e i n n e rc l i p u p a s s h o w n .

t Q---INNER /dm!r. cLrP

u

\7

2 ) I n s t a l lt h e c l i p i n t h e r e a r t r i m p a n e l , t h e n push the innerclip until it's tlush. INNERCLIP

(cont d

20-93

lnteriorTrim Replacement(cont'dl Sedan

Removethe front and rear door trim.

3.

NOTEr When installingthe tront and reardoortrim, align them with the door openingflange notch,

Canter pillar lower trim/Center pillar trim removal: 1. Removethe belt hole cap. then slip the front seat belt through the slit in the belt hole cap. : Bolt locations,2 STRIKER

T CUSHION

5.

)

lf necessary,removethe seat latch from the seatback and removethe striker. CAUTION: Weai gloves to removeand installthe seat latch and latch collal.

>: Bolt, sc.ew locations

B > : S c r e w 1, j

A > : B o l t ,2

I

ffipb I )

-"":=s LATCH COLLAR

LATCH

6.

InStallation is the reverseot the removalprocedure. NOTEI a Make sure the seat backs lock securely. a l f n e c e s s a r ya, d j u s tt h e s t r i k e r s . o Beforeattachingthe seat-backs and seatcushion, makesurethere are no twists or kinks in the rear seat belts. a Wheninstalling the seatcushion,slipthe seatbelt bucklesthrough the slits in the seat cushion. FEARSEATBELT

SEAT.EACKS

LATCH COVER

SEAT LATCH

/ T.BACK

SEAT BELT BUCKLES

SEAT CUSHION ( c o n t ' d)

20-111

Seats Rear Seat Replacement{cont'd) Sedan

3.

NOTE: Take care not to scratch the seat covers and oooy.

Detachthe hook. then removethe trunk mat.

/--x' TRUNK

w

1. Fold the seat-backforward.

SEAT-BACK

Y HOOK

SEAT-BACK

2.

R e m o v et h e c l i p s .

4.

V : Clip locations.8

Removethe bolts, then removethe seat-back.

V : Bolt locations,4 I 6 x 1.0 mm I 9.8 N m (1.0 kgl'm, I 7.2 tbt.ht E I q7 ,2 '/. REARSEATLATCH/ LOCKCYUiIDEB (seepog€2G113) (\Jr', -ET-

TRUNI(MAT

SEAT-BACK

20-112

REARSEAT HVOTBNACKET (s6epage20-113)

SEAT.BACK

5.

Removethe bolt, then removethe seat cushion.

v: Boli location,1

i

-,:

7.

lf necessary, removethe rearseatlatch,lockcylinder a n d r e a rs e a t p i v o t b r a c k e t .

Hook locations,2

Reai seat latch/Lockcylinderfemoval: 6 x l.0 mm 9.8Nm {1.0kg{m, 7.2 tbf {r)

Pry the rear shelf up after removingthe rear shelf trim panel (seepage 20 95) and seal lock cover.

r,1F=

NOTE: Take care not to bend the lock rod. V: Bolt, screw locations A V : B o l t ,2 6x1.0mm 9.8 N.m

!l' v

{1.0kgfm, 7.2tbt4l]

I I

8 V : S c r e w ,2 4x0.7mm 4 N.m

I //

{0.4 kgf m, s ttt.ttl

I ,/

SEAT LOCK COVER

SEAT LOCK

covER\>#\

wr' \[FIJ

B

.

LOCK CYLINDER

6.

Removethe bolts, then removethe seat back side bolstersby lilting them upward. : Soft locations, 2

r

Fl

cR \---l

s.sN.

t1.o ksl m.

7.2rbf.frr

./ l

REARSEAT LATCH

Hook locations, 2

i

6 x 1.0mm

F

'1:

Pry here.

SIDE BOLSTER

Rea, seat pivot bracket removal: N O T E :W h e ni n s t a l l i ntgh e p i v o tb o l t ,a p p l yg r e a s e to it. TOOTHED BUSHTNGLOCKWASHER REARSEAT PIVOTBRACKET PIVOT BOLT 2 2 N . m 1 2 . 2k g f . m . 16 tbf.Ir)

WASHER

20-113

Seats Rear Seat Replacement(cont'd) 8.

I n s t a l l a l i oins t h e r e v e r s eo I t h e r e m o v apl r o c e d u r e . NOTE: a Make sure the seat-backlocks securely. a lJ necessary, adjust the rear seat latch and seat-back. a Betoreattachingthe seat-back,sidebolstersand s e a tc u s h i o n m , a k e s u r e t h e r ea r e n o t w i s t s o r kinks in the rear seat belts and center belt. a Wheninstalling the seatcushion,slipthe seatbelt b u c k l e st h r o u g ht h e s l i t si n t h e s e a t c u s h i o n .

Rear Seat Cover Replacement CAUTION: Wear glovesto.emove and installthe sgat covers. NOTE: a Take care not to tear the seamsor damagethe seat covers, a Removethe clips as shown.

SEAT-BACK Seat-backcover removal: Hatchback Removethe seat-back(seepage20-110). Removethe latch cover and latch collar (see page 20-111). Removeall the clipsfrom rhe backof the seat back, then Ioosenthe seat-backcover.

H/HilflH CLIP

Pullbackthe edgeof the seat-backcoverallthe way a r o u n d .t h e n r e l e a s et h e c l i o s .

CLIP

2 0- 1 1 4

Seat cushioncover aemoval:

Sedan 1.

Removethe seat-back(seepage20-112).

Hatchback

2.

Removeallthe clipsfrom the backof the seat-back, then loosenthe seat back cover.

1.

Removethe seatcushion(seepage20-1I 1).

2.

R e m o v et h e c u s h i o nc e n t e rt r i m p a n e l .

SEAT-BACKCOVER

2 v : Screwlocations,

]

f

t

v ) : , J

3 . Removeall the clips {rom under the seat cushion, then loosenthe seat cushioncovers. CLIP

SEAT CUSHION COVEFS

3 . Pullbackthe edgeof the seat-backcoverall the way around.then releasethe cliDs. SEAT-BACKCOVER

-

4.

CLIP

Pull back the edges of the seat cushioncovers all the way around,then releasethe clips SEAT CUSHION

covERs

CLIPS

CLIP

20-115

Seats Rear Seat Cover Replacement (cont'd) Sedan

' t . Removethe seatcushion {seepage20-113). 2.

Removeall the clips from under the seat cushion, t h e n l o o s e nt h e s e a tc u s h i o nc o v e SEAT CUSHION COVER

CLIP

Pull back the edge of the seat cushioncover all the way around,then releasethe clios SEAT CUSHION COVER

CLIPS

Installationis the reverseo,fthe removalprocedure. NOTE: a To preventwrinkleswhen installinga seat cover, mark sure the materialis stretchedevenly over the pad before securingall the clips. a Replacethe releasedclips with new ones. UPHOLSTERY RINGPLIERS Commerciallyavailable.

NEW CLIP

20-1 1 6

zril H

Seat Belts

I

FrontSeat Belt Replacement CAUTION: Ch€ck the tront seat belts for dsmage, and replacethem if necessary.Be car€ful not to damage them during removal and installation. Hatchback 1. 2.

3.

Slidethe front seatforwardfully. Remove. . Rearshelf(seepage20-91) . Reartrim panel(seepage20-92) . Rearseat{seepage20-110} . Sidetrim panel{seepage20-92) Pull back the carpet as necessary,remove the bolts, thenremovethe middlefloorgusset. >:8oh

€t e

Removethe anchorcoverand anchorcap.

ANCHOR UPPER EOLT 7/16- 20 UNF 32 N.m(3.3kgtm, 24rbf.ftl

locldons

A>, 5

p

5.

PROTECTOR

8>, 3 8r1.25mm

zz trt'mtz.zrgf.m, 16 bf.ftl

10 x t.25 mm :ta N.m 13.9kgf.m, 26 tbrftl

LOWERANCHOR BOLT 7 / 1 6 - 2 0U N F 32 N.m{3.3kg{.m, 24 tbf.ftl

RETRACTOR MOUNTI]IIG BOLT 6r1.0mm 9.8 N.m 11.0tgf.m, 1.2 tblJftl

I

AL-

RETMCTORBOLT 7/16- 20 UtrtF 32 N.m13.3lgi.m, 2'atbt ftl

ANCHORCAP

RETRACTOR

Removeall the anchorbolts and the retractorbolt. remove the retractormounting bolt, then remove the front seatbelt and retractor. 7. 4.

Removethe front seatbeltfrom the belt quide.

BELTGUIDE

Installationis the reverseof the removalprocedure. NOTE: o Checkthat the retractorlockingmechanismfuncI|ons. . Makesureyou assemblethe washersand collars on the upDerand lower anchorboltsas shown. . B e f o r ei n s t a l l i n gt h e a n c h o r b o l t s , m a k e s u r e there are no twistsor kinksin the front seatbelt.

Seat Belts Front Seat Belt Replacement{cont'd} Sedan

4.

Remove the retractor bolt and retractormounting bolt, then remove the Iront seat belt.

1 . S l i d et h e l r o n t s e a tf u l l y l o r w a r d . 2.

Removethe belt hole cap, then slip the front seat belt through the slit in the belr hole cap.

: C l i p ,I

&l

;

WffiI ^ ' )

_ )

PUSHN Replace.

DOORSILL MOLDING

Sedan A : Clip locations.3

: Push nut locations, 4

ffil w /

{cont'd )

20-127

Carpet Replacement(cont'd) 4.

Removethe SRS unit covers.

6.

Cut the carpet under the parkingbrake lever. PARKINGERAKE LEVER

> : Cliplocations, 2

CARPET

Cut here.

7.

Removethe dashboardcenter bracket and center beam bracket.

V i Bolt locations A V : B o l t ,4

B > : B o l t ,1

e x r . z s m mI SRS UNIT COVEBS

22 N.m 12.2kgt'm,

tu-:u

5.

C u t a r e a s@ a n d@ i n t h e c a r p e t t, h e n p u l li t b a c k as shown.

I I

,/

C > : B o l l ,2

6 x 1 . Om m I 9.8Nm I ( ' l . 0k g l m , i 7 .2 tbt4tl /,/

20-128

6 x 1.0 mm 9 . 8 N m 1 1 . 0k g t m . 7 .2 thl.trl

I

8.

Removethe carpet by slidingit rearward.

a Reattachthe cut area @ in the carpet(seepage 20-128)as follow.'

V : Clip locations A V : C l i p ,3

- 1) Cleanthe backof the carpetwith a sponge d a m p e n e di n a l c o h o l . Attach the fastenersto the edgeol the carpet with doublelaced adhesivetape.

B D : C l i p .1

A"= l

\r"

FASTENERS

Hatchback

FASTENERS SEAT HARNESS

2) Attach the other lastener as shown.

FASTENER CARPET

DOORSILL

CARPET

Sedan SEAT HARNESS

I

3) Align the carpet with the fastener, t h e n pressthe carpet down securely.

FASTENERS

FASTENER CARPET REARCONSOLE BRACKET

9.

oooR

CARPET

SILLMOLDING REAR DOOR SILLMOLDING

Installationis the reverseoJthe removalprocedure.

a Reattachthe cut area under the parking brake leverand cut area@ (seepage20-128)with wire ties as shown.

NOTE: a Take care not to damage,wrinkle or twist the carpet. a Make sure the seat harnessis routed correctly. a Slip the slits in the carpetover the rearconsole bracket. CARP

REARCONSOLE BBACKET

Cutotl.

WIRETIE SLIT

a lf necessary,replaceany damagedclips.

20-129

Consoles,Front and Rear Replacement SRS wire harnessesare routed near the front console. CAUTION: a AIISRSwire harnessesare coveredwith vellow insulation. Beforeyou disconnectany pan of an SRSwire halness,disconnectthe airbagconnectors. a Wheneverthe ignitionswitch is ON {lll, o. has been turnedOFFfor lessthan threeminutes,be carefulnot to bump the SRSunit; the airbagscould accidentally deploy and cause damageor injuries. a Foradditionalpfecautions,reterto the SRSsub-section in section 23.

NOTEr Take carenot to scratchthe lront and rearcons o l e s ,a n d d a s h b o a r d . 1 . R e m o v et h e a c c e s sc a p . CAUTION: When pryingwith a tlat tip screwdriver. wrap it with protective tape to prevent damage.

ACCESS CAP

PASSENGER'S AIRBAG

2.

Remove the screws.

V : Screw locations SRS UNIT

AV : Screw, 2

e l

E

- , )

20-130

BV : Screw, 2

i

*)

3.

Removethe rear console-

5.

Removethe Screws.

NOTE: a Lift up the parkingbrake lever. a Detachthe hooks by lifting the front of the rear consoleand slidingit rearward.

NOTE:Removethe shift leverknob (M/T).

>; Screw locationi,4 !

6h:ro " , / I SHIFTLEVER KNOB

FRONTCONSOLE

6.

Removethe front consoleas shown.

NOTE:Wrapthe shift leverand Ay'Tgear positionindicator panelwith a shoptowel to preventdamage.

Removethe ashtrayand front consolepanel. > : Screwlocations,2

Disconnectthe connector.

20-131

Consoles,Front and Rear Replacement(cont'dl 7.

lf necessary,disassemblethe front and rear consoles.

>: Cliplocations >r Scrrw loc.tion3,5 A >j Clip,2 B >r Clip.2

: Screw locations, 9

A

A w.)

C >: Clip,2

ARMREST

1F a';\ \g.E/

\,,

REARCONSOLE PARKINGBRAKE COVER

COVERSET PLATE CONSOLE80X

8.

20-132

Installationis the reverseof the removalorocedure.

Dashboard \

J

Insrallarlon Removal/lnstallation Componentr{emoval/ uomponenl dn d S R Sw i r e h a r n e s s easr e r o u t e dn e a rt h e d a s h b o a r a s r e e n n gc o r u m n . CAUTION: a AIISRSwire harnessesare cove.edwith yellowinsulation. Belore you disconnectany part of an SRSwire hahess, disconnectthe airbagconnectors. o Wheneverthe ignitionswitch is ON (ll), or has been turnedOFFfol lessthan threeminutes,be caretulnot to bump the SRSunit; the airbagscouldaccidentally deploy and cause damageor inturies. a Foradditionalprecautions,reJerto the SRSsub-section in section 23. FRONT AIRBAG PASSENGER'S

CAUTION: When prying with a flat tip screwdriver,wrap it with protective tape, and apply proteclive tape around the relatedparts, to preventdamage, Instrumentpanel,Dashboadlower cover, Knee bolster temovat: 1 . L o w e rt h e s t e e r i n gc o l u m n . 2.

Removethe screws and detach the clips, then rem o v e t h e i n s t r u m e npt a n e l .

3.

R e m o v et h e c o i n p o c k e t .

4.

Removethe screws and detach the clips, then re move the dashboardlower cover. Disconnectthe connector.

A : Screw locations,5

A i Clip locations A A : C l i p ,2

U

B > : C l i p ,2

INSTRUMENT PANEL SRS UNIT

ii'- ' iq4'

ii

\Ll1

COIN POCKET (cont'd l

20-133

Dashboard Component Removal/lnstallation(cont'dl 5.

Remove the knee bolster. : Bolt l o c a t i o n s , 3

A ' i

r

CONNECTOR

6 x 1.0 mm 9.8 N.m {1.0kgt m, 7.2 tbf.fit

: Bolt locations, 2 6x1.0mm 9.8 N.m {1.0kgt m,

0 CASSETTE

KNEEBOLSTER 6.

lnstallationis the reverseo{ the removalprocedure.

Ste.eo ladio/cassette, Heatet contlol Danelremoval: 1.

Remove the rear console, then remove the front console(seepage20-130).

3.

Carefullypry the hazardwarning switch and rear window detoggerswitch out of the heatercontrol panel. Disconnectthe connectors.

HAZARDWARNING

swtTcH

REARWINDOW DEFOGGER SWITCH

Loosen the bolts, then remove the stereo radio/ cassetteby pullingit out. Disconnectthe connectorand antennalead. NOTEr The originalradiohas a codedtheft protection circuit.Be sureto get the customer'scode number before - disconnecting the battery. - removingthe No. 47 (7.5A) tuse from the underhood fuse/relaybox. - removingthe radio, After service,reconnectpower to the radioand turn "CODE" is displayed,enter it on. When the word the customer's 5-digit code to restore radio ope.ation.

20-134

CONNECTORS

4.

Remove the screws. Detach the harness clip and connector clip.

6 . Pullthe heatercontrolpanelout, then disconnectthe connectors. N O T E rT a k e c a r e n o t t o b e n dt h e a i r m i x c o n t r o l c ao t e .

> : Screw locations, 2

CONNECTORS

HEATER CONTROL PANEL

7.

Installationis the reverseof the removalprocedure. N O T E : M a k e s u r et h e c o n n e c t o a r ndair mix control cable are connectedproperly.

CONNECTOR CLIP

5 . Disconnectthe air mix controlcablefrom the heater unit. AIR MIX CONTROL CABLE

(cont'd)

20-135

Dashboard (cont'dl ComponentRemoval/lnstallation Side air vent removal:

Flont passenger's

Driver's

Carefullypry the side air vent at the lower edge, then p u l li t o u t .

1.

2.

Removethe dashboardlower cover (see page 20133). Carefullypry the moonroofswitch out of the side air vent, then disconnectthe conneclor.

Pry here.

3.

Removethe screw, then removethe side air vent.

A: Clip.hooklocations AA : Clip, 1

B V : H o o k ,2

SIDEAIR VENT

PROTECTIVE TAPE

< : Clip, hook locations > : Screw locstion,

I

A < : C l i p ,1 BV : Hook, 3

6F- i

Side deloggertrim removal: Carefullypry the sidedefoggertrim at the rearedge,then removeit.

------r/ A : Clip, hook locations B A : H o o k ,1

AA: Clip,l

_1_iF

/ K

HOOK

Installationis the reverseof the removalprocedure. NOTE: Make sure the connector is connected properly.

20-136

cLtP

/

4.

Clock removal: Carefullypry the clock at the lett edge,then pull it out. Disconnectthe connecto..

CONNECTOE

Removethe damperand striker.

>: Nut,screwlocations A > : N u l ,1

B : S c r e w2,

9;

e_) E

t:

o

Glove box removal: 1 . O p e nt h e g l o v eb o x . 2.

Removethe screw, then removethe damperfrom the glove box. 5.

3.

Installationis the reverseof the removalprocedure.

Removethe screw, then removethe glove box. : Bolt, scrow locations

Al : Bolt, 2

B < : S c r € w1,

A

:7

6x1.0mm 9.8 N.m (1.0kgf m, ?.2 rbl.ftl J

B>12

i 6x1.0mm I 9.8 N'm {1.0kgf'm, 7.2bftrl ._.--r,/

D>:8

C >1 2

E>:4

8 x 1.25mm 22 N.n l'2.2 kgl-m,

!6tbt;1t _ _/

- ------_,/

BUMPER BEAM GUSSET

\

g

GUSSET

{Type-RModel}

I

FRONTBUMP€R

D

{cont'd)

Bumpers Front Bumper Replacement(cont'dl >: Solt scaew location3 A>:5

F

FRONTTURN SIGNALLIGHT F HOLDER

SIDECLIPS

Mffi,-wf l,r/' l//'

R: Scrowlocations,2>: Cliplocation3,2

n 6x1.0mm

.

ffiJls.aN.k - i tr.orgt.-, 7.2 lbl.ftl

\

.

A

H A t\+-z

!

nQn wl\lvxvn \-:

CONNECTOR Disconnect,

REARBUMPER

NOTE:lf necessary, disassemble the rearbumper. >: Cliplocatiom,9 >: Scr.w locationr.4 l

_

4h - (E('-

t s]@

,@

H ,

I

l

!-

\ "

REARBUMPER

ABSOREER

BUMPERBEAM GUSSET BEARBUMPER UPPERBEAM LICENSEPLATE LIGHT

lnstallationis the reverseof the removalDrocedure. NOTE: Make sure the licenseplate light connector is connected,and the grommetis installedproperly.

REARBUMPER

{cont'd)

20-143

Bumpers RearBumperReplacement(cont'd) Sedan:

4.

lf necessary, removethe licenseplate light harness, bracketand lens from the rear bumper (see page 20-1431.

5.

Removethe absorber,bumperbeamgussetand rear oumperoeam.

1 . R e m o v et h e s c r e w l r o m e a c h s i d e . Screw

A

V : Eolt locations,4

,z::

\+,1./

1 2x 1 . 2 5m m

I

64 N.m 16.5kgl.m,

j

-::_:_)

REARBUMPER

2.

Openthe trunk lid, then removethe reartrim panel ( s e ep a g e2 0 - 9 7 ) .

3.

Disconnectthe license plate light connector and grommetfrom the reartrunk area.Removethe clips and bolts, then removethe rear bumper.

5 V: Cliplocations,

2 A: Boltlocations, A

/.r-El^

El

=EE tn)

A ('r\, ,/

* REARBUMPER

20-144

LICENSEPLATELIGHT GROMMET CONNECTOR

fr)

Il

6.

Installationis the reverseof the removalprocedure. NOTE; r M a k e s u r e t h e l i c e n s ep l a t e l i g h t c o n n e c t o ri s connected, and the grommetis installedproperly. . Makesurethe rearbumperengagesthe sideclips securely.

REABBUMPER

20-145

Hood Replacement NOTE: a A n a s s i s t a nits h e l p l u lw h e n r e m o v i n gt h e h o o d . a Take care not to damagethe hood and body. a W h e n r e m o v i n gt h e c l i p s ,u s e a c l i p r e m o v e r . a O p e nt h e h o o d . 'L

IJ necessary,removethe hood edge protector.

N O T E : l f n e c e s s a r y ,r e m o v e t h e h o o d h i n g e . V: Bolt locations,4

,G,, 6 r t.o -,n \Yz s e N.- {1.okot.m. E z.z rur.rtr i

A : Cliplocations, l6 HOOD IIINGE

HOOD

2.

R e m o v et h e b o l t s ,t h e n r e m o v et h e h o o d . i Bolt locations,4

3 . Installationis the reverseof the removalprocedure. NOTE: a l f n e c e s s a r yr,e p l a c ea n y d a m a g e dc l i p s . a Make sure the hood locks securely. a Make sure the hood opens properly. a Adjustthe hood alignment.

6 x 1 . Om m 9.8N.m {1.0kgl m, 7.2 tbfft)

!

D

HOOD

NOTE: Beforeadjustingthe hood, looseneach bolt slightly. 1. Adjust the hood hingesright and left, as well as lore and aft, by using the elongatedholes. 2.

Turn the hood edge cushions,as necessary,to make the hood ,fit flush with the body at front and side edges.

3.

Adjust the hood latch to obtain the proper height at the forward edge.

HOODEDGE CUSHION

NOTEi Move the hood latch right or lett until the striker is centeredin the hood latch as shown.

HOOD LATCH

HOOOLATCH

7.2lblltl

4.

After adjustment,tighten each bolt securely.

Hatch Replacement NOTE: a An assistantis helpfulwhen removingthe hatch. a Take care not to damagethe hatch and body. a Takecarenot to scratchthe hatchsidetrim and hatch trim panel. a Open the hatch. a R e m o v et h e h i g hm o u n tb r a k eI i g h t{ s e es e c t i o n2 3 ) .

N O T E : D e t a c h t h e c l i p s b y s l i d i n gt h e h a t c h t r i m p a n e l forward, then remove it.

'1. Remove t h e h a t c h s i d et r i m o n e a c hs i d e . : Clip locaiions,

_); (zZZ////1

r . - l f

Removethe hatchspoilerasdescribed on page20-161 (if so equipped). 4.

Disconnectthe connectors,then removethe wire h a r n e s s efsr o m t h e h a t c h . V I Clip locations

A : Special bolt locations,2

AV:

A

2.

A

w

Removethe hatch trim panel

A: Clip locations

A

# *l

r

^

{

I

+

..h[-

g)

BA: Clip. 6

bll /

NOTE: Betore pulling out the wire harness,tie a stringto the end of it so you can pull it back in when t h e h a t c hi s r e i n s t a l l e d .

8V : Clip, 3

AA : Clip, 11

i

Clip, 3

N

fN#=l

WIRE HARNESSES

y /

HATCH TRIM PANEL

CONNECTORS CONNECTOR

WIBE HABNESS

lrl

5.

20-148

Removethe rear wiper motor (seesection 23i

\

6.

Removethe upper anchorbolts from the front and rearseat belts(seepages20-111,1211, then remove t h e u p p e rp o r t i o no f t h e q u a r t e rp i l l a rt r i m p a n e l (seepage20-99).

7.

Removethe rear roof trim, then pull the rearof the h e a d l i n edr o w n ( s e ep a g e2 O - 9 9 ) .

NOTE: lf necessary,replacethe support strut.

N O T E : T a k ec a r e n o t t o b e n dt h e h e a d l i n e r . 8 . Removethe supportstrut on each side while holdingthe hatch. NOTE: Do not raisethe hatch too far; the corners of the glass may hit the roof and break. HATCH

22 N.m/ 12.2kgl'm, 16 tbt.fr)

lf necessary,removethe hatch hinge. V : Boll locations,4

SUPPORT STRUT

L

Removethe nuts, then removethe hatch.

I x 1 . 2 5m m 22 N.m (2.2 kgl.m,

HATCH

4 : Nut locations, HATCH

HATCH

1 0 Installationis the reverseof the removalprocedure. NOTE: a lf necessary,replaceany damagedclips. a Makesurethe connectorsareconnectedproperly. a N4akesure the hatch locks securely. a Make sure the hatch opens properly. . Adjustthe hatchalignment(seepage20-150).

20-149

Adjustment NOTE: . Beforeadjustingthe hatch,looseneachbolt and nut slightly. . Do not installthesupportstruts. 1. Adjustthe hatchhingesrightand left,aswell asforeand aft. byusing the elongatedholes. to makethe hatchfit flush with the body at eachside. 2. Turn the hatchedgecushions,as necessary, 3. Adjustthe hstchfit to the hatchopeningby movingthe striker. 4. Useshims.as necessary, to makethe hatchfit flush with the body at the rearedge. 5. Adiustthe hatchside stop so that there is no clearancebetweenit and the body side stop,then tightenthe mounting bolt (TvpeR). HATCH HATCH

HATCH EDGECUSHION

8 x 1.25mm

SIDE STOP lTyp. R Modell

SHIM

stoE STOP (Typ. R Modoll

HATCH EDGE CUSHION

STRIKER HATCH EDGECUSHION

Type R Model: 6xl,0mft SIDESTOP SIDESTOP 9.8 N.m 11.0kg{.m, (Bodyside) (Hatch side) 7.2 tbf.ftl

8 x 1.25mm 22 N.m 12.2kgl.m, 16 rbt.ft)

SIDESTOP (Hatchside)

NOTE:Move the strikerright or left until it's centered in the hatchlatchas shown.

STRIKER

6x1.0mm 9.8 N.m (1.0 kgt m, ?.2 tbf.ftl SIDESTOP (Bodyside)

Adjust for no clearance,

Trunk Lid Replacement NOTE: a An assistantis helpfulwhen removingthe trunk lid. a Take care not to damagethe t.unk lid and body. a Open the trunk lid. 1.

Disconnectthe connectorsand trunk lid openerca' ble.Removethe wire harnessandtrunk lid opnercablefromthe trunklid.

2.

Removethe bolts, then remove the trunk lid.

> : Bolt locaiions,4 6x LOmm

6!--'.'.'''* 9.8 N.mn.o ksf.m. l \ : Clip locations A> : Clip, 3

B< : Clip, 1

CA : Clip, 5

w j & 4*i

q r /

? , /

WIREHARNESS

TRUNKLID OPENERCAELE

CONNECTOR

CONNECTOR

TRUNKLID LATCH (seepage20-1591

3 . lf necessary,removethe trunk lid hinge. NOTE: a Removethe rear shelt {see page 20-95). a Removethe torsionbars with the torsionbar assembly tool.

TRUNKLID HINGE

TRUNKLID OPENER CABLE A TRUNKLID

TORSION

( c o n t ' d)

20-15 1

Trunk Lid Replacement(cont'dl a Remove the bolts, then remove the trunk t i d nrnge. V: Bolt locations,4 6 x 1 . 0m m 9 . 8 N m { ' 1 . 0k g t m , 7.2 lbr'ftl ) NOTE: Take care not to hit the rear wrndow when removingthe bolts.

4.

Installationis the reverseo{ the removalprocedure. NOTE: a Makesurethe connectorsareconnectedproperly. a Adjust the torsion bars lore or aft with the tor sion bar assemblytool as shown.

O =NormalPosition O = Highertension

a Make sure the trunk lid locks securely. a Make sure the trunk lid opens properlv. a Adiustthe trunk lid alignment.

i I

Adjustment NOTE: Beforeadjustingthe trunk lid. looseneach bolt slightly. 1.

Adjust the trunk lid hingesright and left, as well as fore and att, by using the elongatedholes.

2.

Turnthe trunk lid edgecushions,as necessary. to makethe trunk lid fit flush with the body at the rearand sideedges.

3.

Adjust the lit betweenthe trunk lid and the trunk lid openingby moving the striker. TNUNKLID EDGE CUSHION

TRUNKLIO HINGE

'1.0 mm 6 x

NOTE: Move the strikerright or left until it's centered in the trunk lid latch as shown.

6 r 1 . 0m m 9 . 8 N m ( 1 . Ok g f. m , 7 .2 tbt.ltl

STRIKER

STFIKER

4.

After adjustment,tighten each bolt securely.

20-15 3

OpenerCables Replacement \

NOTE: a W h e n r e m o v i n gt h e c l i p s ,u s e a c l i p r e m o v e r . a Take care not to bend the openercables. HOODOPENER

Hood Opener Cable: V : Clip locations

>: Scraw localions,8

AV:Clip,5

6h* |

M)

"

_,/

NOTE: Loosenthe screw, then remove t h e c l r pu s i n ga c l i p r e m o v e r ,

Fuel Lid Opcner CableslHatchback): NOTE:Removethe rear seat(seepage 20-1l0), rear trim panel and side trim panel (seepage 20-91),then pull the carpet (seepage20-126J. back,as necessary A: Clip,cablocushionlocation3 I A: Clip,6 A A: Clip,1 FUELLIO LATCH (seepage20-157)

)

\,)

-----d, FUEL LID

\

20-154

Trunk Lid/Fuel Lid OpenerCable (Sedan): NOTE:Removethe rear seat (seepage20-1'l2land centerpillar lower trim (seepage20-94),then pull the carpetback,as necessary {seepage20-126).Removethe lefttrunk side panel(seepage20-97). > : Clip. cabl6 cushion locations A > : C l i p ,1

Qs

B V : C l i p ,2

,

C a : C l i p ,1

D > : C l i p ,3

E A : C l i p ,1

w-l6t

r>>.

lww-

F < | Cablecushion,1

ei

)tQ,,

rTRUNK LID LATCH (seepage20'159)

OPENER (seepage20-157)

(seepage20,157) Installationis the reverseof the removalprocedure. NOTE: a Makesure eachopenercableis routedand connectedproperly. a Makesurethe hood,hatch,trunk lid and fuel lid open properly.

20-155

Openerand Latch Replacement

HANDLE

NOTE: Take care not to bend the openercables.

Hood ReleaseHandle: 2 < : Boltlocations,

Hood Latch: < | Bolt locations

6 x 1 . 0m m 9.8 N.m ( 1. 0 k g f m , 7 .2 thl ltl HOODOPENER CABLE (seepage20-154)

Pullup on the handlewhile removing the bolt.

HOOD OPENER CAELE

NOTE:Greaseeachlocationofthe hood latchindicatedbvthe arrows.

Removethe kick panel(seepage

20-9r ). FuelLid Opener{Hstchbackl: \-

D

23-47

Fuses Under-dashFuse/RelayBox

C92l ITo d..hbo.rd wir. h.rness lc551ll C923lTo main wir. harn6! (Cil,alll C920[To SRSmsin harnc$ lc8{,l}l

C922 [To ignition rwitchl

C919[To root wir. hsmolr {C661ll

C€24[To m.in wiro hrrno$ lc,l,l2]l

- r-t r-'l r-'tn n r-'tn n r-1r-'l r-l 4

2321

2s 26 27 28 29 30 3t

32 33

IJ IJ IJ LI LI IJ LI LJ IJ LI LJ I.J

- r-t n n14 r-l r-'tr-t r-'l r-'tr-1 ,t8 r-1n 15 t6 12 13 20 a 17

19

21

22

lTo pow.r window rclayl

I-J LI IJ IJ tJ LI LI IJ IJ IJ LI IJ

- r-'t |;l n r-1 n |;t r-'t r-t r-1n r-'t i t 3 1 2 9 1 0 5

a

6 7

8

1 1

LI IJ IJ IJ LI IJ LI LI I-J LI LJ LI

al Sparefuse l: Optionconnector(+B) 2: Option conn€ctor(oash lights) 3: Option connector(ACC) 4: Optionconnector{lG2} *: Not us€d Fusa Number

Amp!

wire Color

1

204

WHT/GRN

CgNlS Oo turn 3ign.l/h.z.rd rcl.yl C928 [To r..] window d.toggd r.l.yl

Compon€nt(s)or Circuit(3)Protaqtad Power door lock control unit Not used

10A 4

GRN,4/VHT

Rearwindow washermotor

GRN/BLK

Rearwindow wioer motor

1 0A

RED/BLU

Right headlight (high beam)

10A

RED/GRN

Left headlight(highbeam),high beam indicatorlight Not used

7

20A.

GRN/BLK

Left rear power window motor

a

204

YEUBLK

Rightrearpowerwindow motor

1 5A

BLK/YEL

lgnitioncoil

10

204

BLU/BLK

powerwindow motor Passeflger's

l1

204

WHTI/EL

Powerwindow masterswitch,powerwindow controlunit

23-48

T

I

1

't2

10A 1 5A

14

7 . 5A

15

relay Turn signal/hazard

YEUGRN

PGM-Flmain relay

GRN or RED

SRSunit (VA)

BLK/WHT

Cruisecontrolsystem

BLK/YE L

Alternator,VSS,ELDunit (USA),TCM,chargingsystemlight ABS controlunit,rearwindow defoggerrelay(Viaswitch)

7 . 5A

BLVBLU

11

7 . 5A

BLK//EL

18

7 . 5A

YEUBLK

19

7 . 5A

YEL

20

1 0A

WHT/YEL

21

1 0A

RED/WHT

Daytimerunninglightscontrolunit (Canada) Rightheadlight(low beam)

22

1 0A

RED|YEL

Lettheadlight(low beam)

23

1 0A

G R No r P N K

24

7 . 5A

26

J

YEUBLK

't6

7 . 5A

)

Component{s}or Circuit(rl ftqt6cted

Wire Color

FusoNumber

28

GRN/ORN

Eack-uplights

SRSunit (VB) Moonroofrelays Powerwindow relay

YEUBLU

Clock,gaugeand indicatorlights Integratedcontrolunit

20A

GRN/BLK

Windshieldwiper motor,windshieldwashermotor

10A

YEUGRN

Cigarettelighter

10A

YEURED

Audio unit connector Integratedcontrolunit

29 RED/BLK

30 31

AVCsystem, heatersystem, power marror Daytimerunninglightsrelay(Canada)

Dashlights,clock Integratedcontrolunit

7 . 5A

8LU/WHT

ECM.PGM-Flmain relav

10A

RED/BLK

Frontparkinglights,taillights,licenseplatelights

7 . 5A

WHT/GRN

Interlockcontrolunit,key interlocksolenoid

23-49

Fuses Under-dashFuse/Relay Box (cont'd) NOTE; View from the backsideof the under-dashfuse/relavbox.

C918lTo m.in wi]o h.rn.3. (O€9ll C9l7 lTo main wir. hrrn63 (C+Oll

C9l2[Tor.ar wir. hrrnsr lc503ll

C9l3 fTo mlin wir. harnc*r lG,l:}8)l C!14 [To intogrrtod cont.ol unhl Cll8lTo m.in wiro h.rnegr (C,l,(}ll

23- 5 0

C315lTo ro.r wire hlrn.3t (C504)l

Under-hoodABS Fuse/RelayBox T5 [To under-hoodABS tuse/rel.y box c.blel

ol ,'lo

Cgul [To ABS pump moto. ?elay]

f*l f*-l f os

f.erll r: Not u3od

C90l llo mrin wir. h.rners lC212ll o main wire harno!31C213)l

)

J

61

Compon€ntls)or Circuit{sl Protoqted

Wire Color

FuseNumber 40A 204

WHT

ABS pump motor N o . 6 5( 1 0A ) f u s e

WHT/GRN

ABS modulatorunit (ViaABS fail-saferelay),ABS pump motor relay {ViaABS failsafe relav} Not used Not used

64 65

1 0A

BRN//EL

ABS controlunit {MCK)

23-51

Fuses Under-hoodFuse/RelayBox AITEFNATOR [To .ngine wiro hrrn83 1T101)l

BATTERY lTo stano. csblcalTlll

rr 17

LI Fl 51 LI

rl56 lJ

rr 51

IJ

C!104[To condenso]fan relayl

*: Not u6ed

C!107[To blow.r motor r.l.yl

C905 [To A/C compr.ssor clutch l.hyl

C9O6[To radirto] fan

NOTE:View from the backsideof the under-hoodfuse/relavbox. ClOg [To main wiro ha]ne3s{C215ll

C908[To m.in wiro h.rn.$ (C2l7ll

C€10[To mrin wir. hlrnoit lC216ll Cltl1 lTo main wire harnesslc218ll: USA

23-52

J

Amps

41

100A

42

40A

WHT/BLK

43

7 . 5A

WHT/RED

Ceilinglight,cargoarealight,datalink connector(DLCl,power antennaconnector

44

't5A

YEL/WHT

PGM-Flmain relay

Wir€ Color

45

Battery.power distribution lgnition switch (BAT)

Not used No. 7 (20A) fuse (Viapowerwindow relay),No. 8 (20A) tuse (Via powerwindow relay) No. 10 (20A) fuse (Viapowerwindow relay),No. 11 (20A) fuse (Via powerwindow relay)

46

40A

WHT/8LU

41

7 . 5A

WHT/BLU

48

40A

WHT

49

30A

WHT/BLU

Moonroofrelay

50

40A

WHT/GRN

51

154

WHT

Rearwindow defogger{Viarearwindow defoggerrelay) Combinationlight switch(Dashlights)

20A

WHT/GRN

Horn,horn relay,brakelights,AgS controlunit,ECM,TCM

10A

WHT/GRN

relay,hazardwarninglight Turn signal/hazard

40A

WHT/flED

40A

BLU/WHT

No. 1 (20A) fuse Blower motor (Via blower motor relsy)

54

)1 -

Component(s)or Circuh(rl Protastcd

FusoNumbor

56

204

57

204

BLU/BLK RED BLVRED

reminderunit Clock,8udiounit connector,ECM,TCM,Maint€nance Combinationlight switch(Headlight)

Condenserfan motor (Viacondenser{an motor relay) A,/Ccompressorclutch (via Ay'ccomp.essor clutch relay) Radiatorf8n motor (Viaradiatorfan relay)

23-53

Power Distribution Circuit ldentification UNDER.HOOO ABS FUSE/RELAY 8OX

I L

ABSOUMP MO'OFCELAY telay) Li,z (viaABSlail.sale lgS moou arorunr (VaABSlai.sale retay)

(20A)FUSE N0.62 lai-l lviaABS \salereay /

ABSpump motor BRN/YEL

ABSconlrolunir(MCK)

YEUFED

ABScon$olunit (PMR)

8LK -

Shnermolor

BLK/RED

T G1

"LL,,r,

wHriGRN--WHT/GRN

Hazadwarning light Turnsignal/hazard elay (Viaswilch) Horn

--T MT/GRN

relav Horn

ALTERNATOR

Nors{7.5A1V

-ol-

-l WHTTGRN

BRAKE SWITCH ION:Pedaldepressedl GRNMHT-F

ABSconlrollnrt

t_

_f,-"* Gml G401

G R N / R E-D

EcMTcM ughts &eke ECM

--+ *HT,BLK vlHi.nED-I4 YEITWHT

I/HTa_U-l

F^r ig|ryJ,itil.* UNDEF OASH F\ FELAY BOX > FUSE Lz 2359) {Topage PGM.Flmain retav

T.\ 'l >

UNDER.DASH .uSERELAV 8OX fro page2357)

Clock ECM TCM Mainlenance reminder unl

23-54

\

I

BOX UNOERHOODFUSE/RELAY

*, HtXl!;%,'$1r.,',"'

_+> wHr

rr,orro, l,)ooll;%,r$lrr.

F.-

wr cn,r_l9>

---$ *,,'orn.

t

H?!!;oA%iu'n"*"o'

uo""*"* &?Tll:11$

-+ wHr **, orn

N t'/'

FlrsERE'AYBox DASF u-NoEF I aaaqezJ''L

N 0 . 1 (77 . 5 A ) F U S E (Fiompage23 56)

{

BLUA/VHI

V L

r,*,rr,

Bowermotor

"*-f_

f r

oro, G40l

-'ncthermoslal(viadiode) BLU/YEL

8LU/BLK

lanmolor Condenser

clulch ,JC compressor

BLKRED_

€CM

BLKRED-

molor Radiatorian

GFNl-

)

t

EcM P36,r1ot 1"nt'n '"n

(cont'd)

23-55 _-_

_-.- l

DistributorReassembly

J

'1.

When reassembling the distributor,installthe rotor on the shatt so that it faces anthe directionshown ( t o w a r dt h e N o . 1 c v l i n d e r ) .

lgnitionWire Inspectionand Test CAUTION: Carelullyremovethe ignitionwires by pulling on the rubberboots. Do not bendthe wires; you might break them inside. '1.

Checkthe conditionot the wire terminals.lJ anyterminalis corroded,cleanit, and if it is brokenor distorted. reolacethe wire.

Checkfor broken, corroded,and bent terminals.

IGNITION WIRE

)

J

2 . Align the index mark on rhe distributor ignition (Dl) housing with the index mark on the end of the shaft.

Connectohmmeterprobesand measureresistance. lgnitionWire Resistance: 25 kO max. at 68oF {20oC}

INDEXMARKS IGNITIONWIRE

) l 3.

It resistance exceeds25 k0, replacethe ignitionwire.

23-95

lgnition System lgnitionCoil Replacement

lgnition Coil Test 1 . With the ignitionswitch OFF,removethe distribu-

tor ignition (Dl) cap.

1. With the ignitionswitch OFF,removethe distributor ignition(Dl)cap,rotor,and capseal,then remove the leak cover.

2 . Removethe two screwsto disconnectthe BLK/YEL andWHT/BLUwi.es from terminalsA ( + ) and B {- ) respectively.

T E R M I N AA L (+I

ROTOR SECONDARY WINDING TERMINAL

3.

Removethe two screwsto disconnectthe BLK/YEL and WHT/BLUwires lrom the coil.

Using an ohmmeter,measureresistancebetween the terminals.ReDlace the coilif the resistance is not within soecifications. NOTE: Resistancewill vary with the coil temperature; specificationsare at 68oF (20oC)

Removethe two screws, and slidethe ignitioncoil out of the distributorignition (Dl) housing.

DISTRIBUTORIGNITION{DII HOUSING

Plimary Winding Rssistance (Betweenth€ A 8nd B torminalsl:0.6-O,8 ohms Socondary Winding Resistance (Betwe€n the A and secondarywinding torminalsl: 12.4-19.2 kA A {+}

{

t l

tl t

9

t

SECONDARY WllrlDlNG TENMINAL

23-96 L--

B(-t

WHT/BLU WIRE

lgnition Control Module (lCM) Input Test NOTE: a Seesection1 1 if the malfunctionindicatorlamp (MlLl has been reportedon. a Performan input test for the ignitioncontrol module (lCM)after finishingthe fundamentaltests for the ignition system and the fuel and emissionssystems. a The tachometershouldoperatenormally. 1.

Removethe distributo.ignition(Dl) cap, the rotor, and the leak cover.

2.

Disconnectthe BLK/YEL,WHT/BLU,YEL/GRN,and BLU wires from the lCM.

BLU WIRE

4. Turn the ignitionswitch ON (ll). Checkfor voltage betweenthe WHT/BLUwire and body ground. There should be battery voltage. a lf there is no battery voltage,check: - ignitioncoil. - WHT/BLUwire betweenthe ignitioncoil and tcM. a lf there is battery voltage,go to step 5. 5. Disconnectthe 32P connectorfrom the ECM, and checkfor continuityon the YEUGRNwire between the ICMand ECM. Thereshouldbe continuity. 6. Checkfor continuityon the YEL/GRNwire to body grouno. There should be no continuity. 7 . Reconnectthe ECM32Pconnector. D i s c o n n e c t h e g a u g e a s s e m b l y1 3 P c o n n e c t o r , TCM 26Pconnector,and cruisecontrol l4P connector.

9. Check for continuityon the BLU wire betweenthe ICM and tachometer. There should be continuity. '10. Checkfor

continuityon the BLUwireto bodyground. There should be no continuity.

YEL/GRNI,\'IRE

3.

1 1 . lf all the testsare normal,reconnectthe connectors, and replacethe lCM.

Turn the ignitionswitch ON {ll}. Check for voltage betweenthe BLK/YELwire and body ground. Thereshould be battery voltage. a lf thereis no batteryvoltage,checkthe BLKiYEL wire betweenthe ignitionswitch and the lCM. a It there is battery voltage,go to step 4,

)

I

)

23-97 /i

lgnition System Spark Plug lnspection 1.

I n s p e c t t h e e l e c t r o d e sa n d c e r a m i c i n s u l a t o rf o r :

. . . . Damaged gaskei

lmpropergap Oil-fouling Carbondeposits Crackedcenter electrodeinsulator

3 . 818C1 engine: a Do not adjust the gap ol a platinumtip plug; replacethe spark plug it the centerelectrodeis roundedor if the gap is not within the specificattons. Electrode Gap:

Standard I

t.s-3., mm(0.051-3.oo4in)

PLATINUM TIP

Burnedor worn electrodesmay be causedby: . A d v a n c e di g n i t i o nt i m i n g . Loose spark plug . Plug heat rangetoo low . I n s u f f i c i e ncto o l i n g Fouled plugs may be caused bY: . Retardedignitionliming . O i l i n c o m b u s t i o nc h a m b e r . Incorrectspark plug gap . Plug heat rangetoo high . E x c e s s i v red l i n g ' l o ws p e e dr u n n i n g . C l o g g e da i r c l e a n e e r lement . Deterioratedignitioncoil or ignition wires 81881,818C5engine: . Adjustthe gap wjth a suitablegappingtool, and replacethe plug if the centerelectrodeis rounded as shownbelow.

NOTE: Use onlv the spark plugs listed below

Spark plug Bl88l engine: NGK DENSO

I ZFR5F-11 I KJ16CR-111

818C1engine: NGK DENSO

PFR6G-13 I PK2OPR-113

818C5engine: NGK DENSO

PFR6G-I1 PK2OPR-111

ElectrodeGap: Standard

'l

.1

; r m m { 0 . 0 4 3 ; o o ai n )

compoundto the Applya smallquantityot anti-seize plug threadsbelore installingthe plugs. 5 . Screw the plugsinto the cylinderheadtinger tight, t h e nt o r q u et h e mt o 1 8 N . m ( 1. 8 k g f . m , 1 3 l b f . f t ) .

23-98 E.

ChargingSystem ComponentLocationlndex

CHARGINGSYSTEMLIGHT (ln the gaugeassembly) Test,pages23-102,103 page23-122 BulbLocations, UNDER-HOOD FUSE/RELAY BOX (USA: HASbUiIt-iNELECTRICAL (ELD)UNIT} LOAD DETECTOR Troubleshooting of ELD,secrion 11

BATTERY Test,

)

ALTERNATOR page23'102 Troubleshooting, Alternator/Fegulator Tosl,pages23-105,'106 page107 Replacement, Overhaul,page23-108

ALTERNATORBELT page23_115 Insp€ction and Adiustment,

)

23-99

ChargingSystem CircuitDiagram

UNDER.HOOD FUSE/RELAY BOX No41(1tl0A)

N0.42(40A)

/^\

GFN/REO

II I

I-t

BLK/YEL

INTEGRATEO CONTROL UNIT

V I

-"

I

WHT/8LU L

ECM

V I I

FIETDWINOING

ALTERNATOR

a 23-100 I-

CircuitDiagram -

UNDEH.HOOD FUSE/RELAY BOX No.4l(100A)

,.4

No42(40A)

*l I

/'1\ / ari \

v

\ orrror

cr / swlrcH

I

BtKAEt

I

rt-r | I

) m.rs IUNDER-DASH t (7.5A)|FUSE/RELAYBOX

I

BLK,YEL

-i

* I

rh 3i{i3#'

Ynu

ECM

)

-

|

WHT/8LU

TNTEGBATEo CoNTROL UN|T

v

i

,."

L

B

FTELDWTNoTNG

ALTERNATOF

)

23-101

ChargingSystem Troubleshooting It the chargingsystemlight does not come on or does not go off, or the batteryis deador low, test the followingitemsin the orderlistedbelow: 1. 2. 3. 4. 5.

Battery Chargingsystemlight Voltage Alternatorcontrolsystem Alternator/regulator

ChargingSystem Light Test Charging System Light Check: Make sure the charging system lightcomeson.

Doesthe chargingsystem lightcomeon?

Ch€cktor a blown No. 15 (7.5A) tuse and . blown charging system light bulb. ll the fuse and bulb are OK, .eptir tho open in lhe WHT/BLUor BLK/YELwire.

Ch.rging System Light Check (cont'd): Startthe engine.

Doesthe chargingsystem light go off?

Pertormthe Ahernator/Regulstol Test (s€. prge 23-101, ALTERNATOR'PCONNECTOR IUSAI

Voltago Check: Measurethe voltageat the No. 1 l N o . 2 l t e r m i n a lo f t h e 4 P [ 3 P ] connectorwith tho ignition switch oN {lr).

IG IBLK/YEL)

I

4

Wire sideof femaleterminals

Repair tho open in ih€ 8LK/YEL wir6 betweon the alte]nator and undor-dashlure/reley box. ALTERNATOR 3P CONNECTOR lCanadal Wire sideof femaleterminals

23-102 L-*

{

{Frompreviouspage} irP CONNECTOR ALTERNATOB

Checkfor an opon in lhe L circuit: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 4P connector from the alternator. 3. Groundthe No. 3 terminalof the 4P [3Plconnector. 4. Turnthe ignitionswitchON (ll).

Doesthe chargingsystem lightcomeon?

Wire side of temalet€rminals

L

[ ]: Canada

IWHT/BLUI

Repai. ths open in tho WHT/ALU or BLK/YELwir€.

ALTERNATOR 3P CONNECTOR {Canadal Wire side of femaleterminals

t Chock tor a sho.l in the L circuit lcont'd): Disconnect the No.3 terminalof the 4P [3Pl connectorfrom the ground.

4

L

IWHT/BLU)

Doesthe chargingsystem light go offi

Repairthe shon to ground in tho WHT/BLUwiro.

,

1 12 3 l

l

iin"vr.rr\

)

23-103

GhargingSystem Troubleshooting Ahcrn.tor Control Swtom T.rt (USA) NOTE:Betoretesting,checkproperoperationof the ELDby confirmingwith the MIL (s€esection11). BATTERY Ch.ck tor . .hort In th. clrcuit (ALTCltn.lr 1. Disconnectthe 4P connoctor Irom th6 altemator. 2. Starttho engine,and turn tho (highbeam)ON. h6adlights 3. Moasur€voltago botwoenth6 4P conn€ctort6rminal No. 2 and the positivot€rminsl ol tho batterv.

CAUTION: Ba 3urc to ut! | vollmatal with hr plu! tarmlnal connactadto battary plua and ita mlnua talmlnal to lha 4P connactortarrninal No. 2.

c IWHT/GBN} Wire sido ol t€m6let€rminal6

ALTENNATOR ilP COiINECTOR

A l:t2F) ECMCONI{ECTOR I

16thor6 1 V or less?

2

3

72

{ 15

5

G

1a I t

It

t

a 26 n

tl

V

,/,

ALTC (wl{T/GRNI

Wir€ side of fem6let€rminals

Chrck for .n oD.n In th. wllr IALTClln.): 1. turn the headlightand ignition switch OFF. 2. Disconnectth6 A (32P)connoctorfrom the ECM. 3. Ch6ckfor continuity b6tw6en tho ECM connoctor A (32P) t€rminal No, 19 and alternator 4P connoctortorminal No. 2.

I|l0

z l a 2a

13 6

(l

c IWHT/GBNI

3

4

Wire 3id€ of femal6t€rminelg

ALTERNATOR .P CONI{ECTOB Rrp.h op.n In th. wh. brlw..n th. rltarn oi.nd ECM.

Ch.ct for rhort in th. wire (ALTC lin.l: '1. Turn the headlightand igni tion switch OFF. 2. Disconn€ctthe A {32P}conn6ctorfrom tho ECM. 3. Check for conlinuity b€twoen t h s E C M c o n n e c t o rA ( 3 2 P ) terminal No. 19 8nd body ground.

ECMCONNECTON A I32P} t

2

3

12

a

5

t

0

t 5 10 l 1 I t t9 6

Rap.ir 3hort in lha wira bstwaan th. .h.rnator ard ECI\|.

23-104 b-.

t0 t t

z2 a 2a

26 21

() Slbrlltut. ! tnown-good ECM. .nd rach.ck. It Drorcrlb.d voltrgr ir now avalldla, raphce lha origin.l Ecilt.

m

9

ALTC IWHT/GRNI

FULLFIELD TESTER (8LU) T.EAD

LOAO ADJUSTER ICARBONPILE)

{ Alternator/RegulatorTest

VOLTMETER NEGATIVE LEAO{BL|(}

NOTE:8e surethe batteryis sufficientlycharged. Ahernator/RegulatorTosl-1: 1 . C o n n e c ta S u n V A T - 4 0 ( o r e q u i v a l e n t e s t e r l ,a n d t u r n the selectorswitch to position '1(starting). 2. Shift to neutralposition,and s t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm with no l o a d u n t i l t h e r a d i a t o rt a n comeson, thon let it idle. 3 . R a i s et h e e n g i n e s p € e d t o 2,000rpm, and hold it there.

VOLTMEIER POSmVE LEADIREDI TESTSELECTOR FIELO swtTcH VOLT SELECTOR SELECTOR INDUCTIVE PICK.UP IGRNI

NEGANVETESTER CABLEIBLKI

ls the voltageover 15.1V?

)

t

Altsrnator/RogulatorTest-z: pedal, 1. Release the accelerator and letthe engineidle. 2, Makesure all accessories are turnod off. Turn the selector switchto position2 (charging). 3. Removethe inductivepick-up, and zero the ammeter. 4 . P l a c et h e i n d u c t i v ep i c k - u p over the battery ground cable so that the arrow points toward the batterYnegative terminal, 5 . R a i s et h e e n g i n e s p e e d t o 2.000rpm,and hold it there.

POSITIVETESTER CABLEIREDI

INDUCTIVE PICK.UP

NEGATIVE TERMINAL

ls the voltagelessthan 13.5V?

Ahelnstor/RegulatorT$t-3i Apply a load with the VAT-40 until the battery voltage drops to between12 - 13.5V.

To next page

)

{cont'd)

23-105

ChargingSystem Troubleshooting(cont'dl From previol.rspage

lsthe amperage70 A or more?

Alternator/RegulatorTest-4: W i t h t h e e n g i n es p e e ds t i l l a t 2,000rpm,Iull-Iieldthe alternator.

The charging swtem is OK. CAUTION:Th6 voltago will rise quickly when the ahernator is ful!fieldcd. Do not .llow th6 voltag€ to €xc6ed18 V; it may damagetho ol6drical system. NOTE: Attach a probe to the VAT'40 full field test lead, and insert the probe into the lull field accesshole at the back of the alternator.Switch the field selectorto the "A {Ground}" positionmomentarily, and checkthe amperagereading.

REGULATOB (Locatedinside FULLFIELO ACCESSHOLE

ENDCOVEB

FULL FIELD ACCESSHOLE

ENDCOVER

23-106 L^

AlternatorReplacement t

NOTE: The originalradio has a coded theft protection circuit.Be sureto get the customer'scodenumberbefore - disconnectingthe battery. - removingthe No. 47 (7.5A) fusefrom the under-hood fuse/relaybox. removingthe radio. After service,reconnectpowerto the radioandturn it on. When the word "CODE" is displayed,enter the cus tomer's s-digit code to restoreradio operation. 1.

Disconnectthe groundcablefrom the batterynegative (- ) terminal.

2.

Disconnectthe alternatorconnector from the allernalor, TERMINALNUT 8 N,m (O.8 kgf'm, 6 lbl'ft)

7 . Removethe lower and uppermountingbracketbolts and the mountingbrackets.

UPPERMOUNTING BRACKETEOLTS 44 N.m {4.5 kgl.m, 33 lbl'ft)

b-h..K \ ) I

B TERMINAL

24 N.m (2.4 kgf.m, 17 rbf.ftl

ALTERNATOR CONNECTOR

3 . Removethe terminalnut and the WHT wire from the B terminal. Loosenthe adjustingnut, then removethe mountIngnut.

BRACKET

BOLTS BRACKET il4 N.m {4.5 kgl.m,33 lbt.ft)

8. Removethe adiustingnut and uppermountingbolt, then lift out the alternator.

{--,

9. lnstallthealternatorin the reverseorderof removal. CAUTION: Adiust the alternator belt tension aftsr installationlseopage23-1151.

MOUNTING BOLT

the batterygroundcableand turn NOTE: Reconnect " C O D E "i s d i s p l a y e d , t h e r a d i oo n . W h e nt h e w o r d code. s-digit enter the customer's

NUT MOUNTING 44 N.m (4.5 kgf.m.33 lbt.ftl 5. Removethe alternatorbeltfrom the alternatorpulley.

)

-

6.

Removethe lower mountingbolt, then lilt the alternaror upwaro.

23-107

ChargingSystem AlternatorOverhaul CAUTION: Do not remove the pulley unless the tront bearingneeds replacement.

PULLEY

To loosenthe pulley locknut, use 10 mm and 22 mm wrenches.lf necessary,use an impact wrench.

DENSO: ROTOR

BEARING

10 mm 8OX WRENCH PULLEYLOCKNUT 1 ' 1 1N . f t ( 1 1 . 3 k g f . m , 8 2 l b t . f t )

FRONTBEARING

STATOR/DRIVE END HOUSING OENSO: Test,page23-1'10 MITSUBISHII Test,page23-112

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

offi

END COVER

k-"o*"... ".," '

23-108 L_

BRACKET

Rectifier Test {

DENSO: NOTE: The diodesaredesignedto allow currentto pass in one directionwhile blockingit in the oppositedirection. Each diode must be tested tor continuityin both directionswith an ohmmeterthat has diode checking capability.Since the alternatorrectifieris made up ot eight diodes(four pairs),there are a total of 16 checks. '1.

)

Checkfor continuityin each directionbetweenthe B and P terminals,and betweenthe E (ground)and P terminalsof eachdiodepair.All diodesshouldhave continuityin only one direction.

J

Alternator BrushInspection l.

Removethe end cover, then take out the brush holderby removingits two screws.

2 . Measurethe length of the brusheswith a vernier caliper. Altelnator Brush Length: Standard:1O.5 mm {O.41 in} ServiceLimit: 1.5 mm (0.06 in)

VERNIERCALIPER

lf the brushesare lessthan the servicelimit,replace the brush holderassembly.

)

J

2 . lf any of the eight diodesfails, replacethe recti{ier assembly.iDiodesare not availableseparately.)

23-109

ChargingSystem Rotor Slip Ring Test

Stator Test

DENSO: 'l . Checkthat thereis continuitybetweenthe sliprings.

1.

Checkthat there is continuitybetweeneach pairot leads.

ROTORSHAFT

cotl coRE

2 . Checkthat there is no continuitybetweenthe slip rings and the rotor or rotor shaft.

2 . Checkthat thereis no continuitybetweeneachlead

3 . lf the rotor failseithercontinuitycheck,replacethe alternator.

3 . lf the coil lails eithercontinuitycheck, replacethe

23-110 b-.

a n dt h e c o i lc o r e .

alternator.

RectifierRemoval {

3.

MITSUBISHI: 1.

Removethe four throughbolts.

Separatethe rear housingfrom the drive-endhousing by insertinga flat tip screwdriverinto the openings and pryingthem a part. Be carefulnot to damagethe statorwith the tip of the screwdriver.

FEARHOUSING

DRIVE.ENDHOUSIT{G

)

{ Separatethe rear housing and drive-endno u s r n g with the statoranachedto the rearhousinq.

2.

Heatthe rear bearingseatwith a 1,000W hair drier for aboutfive minutes(120- 140'F,50 - 60'C).

DRIVE.ENDHOUSING

HAIN DRIER

NEARAEARING SEAT STATOR

REARHOUSING

)

t

(cont'd)

23-111

GhargingSystem ReetifierRemoval (cont'd) MITSUBISHI: 5.

6.

1.

Separatethe rear housingfrom the stator/rectifier assemblyby removingthe four screwsand the terminal nut.

NOTE:The diodesare designedto allow currentto pass in one directionwhile blockingit in the oppositedirection. Since the alternatorrectifier is made up of nine diodes,eachdiode must be testedfor continuityin both directionswith an ohmmeter that has diode checkino capability;a total of 22 checks. 1.

Checkfor continuityin eachdirectionbetween - the B and P terminals. - the B' and P terminals, - E (ground)and the P terminals. All diodesshouldhave continuityin only one direcuon.

2.

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

Unsolderthe rectifierfrom the statorleads. . To avoid damagingthe diodeswith heat, pinch the stator leads between pliers to carry heat off, and applythe solderingiron only long enoughto separatethe leadsfrom the rectifier. . Usea 100W solderingiron.

Installthenew rectifierin the reverseorderof removal. . A p p l y t h e s o l d e r i n gi r o n o n l y l o n g e n o u g ht o ensure a good connectionso the heat will not damagethe diodes. . Useonly a rgsin coretype solderor solderjoints will cor.ode.

23-112 b.

RectifierTest

{

i'[

AlternatorBrushInspection

RotorSlip RingTest {

Separatethe drive-endhousingfrom the rear housing as describedon page23-l 11.

MITSUBISHI: 1.

betweenthe slip rings. Checktheresistance Thereshouldbe 1.8- 3.0ohms. . .

go to step2, meetsthe specification, lf resistance l f r e s i s t a n c ed o e s n o t m e e t t h e s p e c i f i c a t i o n , replacethe alternator. ROIOR SHAFT

Separatethe rear housingfrom the stator/rectifier assemblyby removingthe four screwsand the terminal nut from the rearhousing(seepage23-111). M e a s u r et h e l e n g t h o f t h e b r u s h e sw i t h v e r n i e r calrpers. Alternator Brush Length: O Standard(NEW) 1 9 . 0m m ( 0 . 7 5i n )

O ServiceLimit 5 . 0m m ( 0 . 2 0i n )

SLIPRII{GS

Checkthat there is no continuitybetweenthe slip ringsand the rotoror rotorshaft. lf the rotor fails eithercontinuitycheck,replacethe alternator.

J

Stator Test 1.

Checkthat there is continuitybetweeneach pair of leads.

lf the brushesare lessthan the servicelimit, replace them.

co|L conE Checkthat there is no continuitybetweeneach and the coil core.

J

lf the coil core fails eithercontinuitycheck,replace the alternator.

23-113

lF

GhargingSystem RearBearingReplacement MITSUBISHI: 1.

AlternatorReassembly 1 . P u s ht h e b r u s h e si n , t h e n i n s e r ta p i n o r d r i l l b i t (about1.8mm diameter)toholdthem there.

Pulloff the rearbearing. Makesurethe tips of the bearingpullerjaws are thin enoughto fit betweenthe bearingand the s l i pr i n g s . Do not reusethe bearing.

SLIPRINGS

BEARINGPULITR (Commorciallyav6ilable)

ARUSHES

REARBEARING

Heat the rear bearing seat in the rear housing as describedon page 23-12.After heating,continue immediatelywith assemblingbeforethe rear bearing seatcoolscompletely. Put the rear housing/stator assemblyand drive-end housing/rotorassemblytogether,tighten the four t h r o u g hb o l t sa n d p u l lo u t t h e p i n .

Use a hand pressto installthe new bearing.Apply pressureonly on the inner raceto avoid damaging the bearing.

BRUSH AOCCSSHOI,"€ THROUGHBOLT

*,

DRIVE.END HOUSI'{G/ROTOR ASSEMBLY REAR STATORASSEMSLY

After assemblingthe alternator.turn the pulley by hand to make sure the rotor rotatessmoothlv and without noise.

23-114 L

:

-

Altelnator ttelr Inspecuon ano Aol t

Detlection Method: Apply a force ol 98 N (10 ksl, 22 lbl) and measurethe deflectionbetween the alternatorand the crankshaft DUllev,

Belt TensionGaugeMethod: Followingthe gaugemanulacturer'sinstructions,attach the belt tension gauge to the belt and measurethe tension. T e n s i o n 3: 4 0 - 4 9 0 N { 3 5 - 5 0 k g f , 7 7 - 1 1 O l b f )

Defloction:9- 11 mm (O.35-O.43 inl

NOTE:On a brand-newbelt (onethat has been run f o r l e s st h a n f i v e m i n u t e s ) t, e n s i o ns h o u l d b e 818B1,818C1engine:690- 880 N (70- 90 kgf, 1541 9 8 l b f ) , 8 1 8 C 5e n g i n e :5 4 0 - 7 4 0 N ( 5 5 - 7 5 k g f , 1 2 1- 1 6 5 l b f ) w h e n f i r s t m e a s u r e d l.f t h e b e l t i s worn or damaged,replaceit.

NOTE:On a brand-newbelt (onethat has been run for lessthan five minutes),the deflectionshouldbe 8 1 8 8 1 ,B l 8 C l e n g i n e :6 - 8 m m ( 0 . 2 3- 0 . 3 2 i n l , 818C5engine:7 - I mm (0.28- 0.35 in) when first measured,lf the belt is worn or damaged,replaceit.

ALTERNATOR ADJUSTINGNUT 24 N.m 12.4 kgf'm, 17 lbt.ftJ ADJUSTINGNUT ALTERNATOR 24 N.m 12,4 kgl.m, 17 lbI'ftl

J

MOUNTING NUT 44 N.m (4.5 kgf.m, 33 tbf.ft)

BELTTENSIONGAUGE

PULLEY ALTERNATOR BELT CRANKSHAFT

lf adiustment is necessary: 1.

Loosenthe alternatoradjustingnut and mounting nut.

lf adiustment is necessary: 1.

Loosenthe alternatoradjustingnut and mounting nut.

2 . Movethe alternator to obtainthe properbelttension, then retightenthe adiustingnut and mountingnut to the specifiedtorques.

2 . Movethe alternatorto obtainthe properbelttension,

3 . Recheckthe dellectionof the belt.

3.

NOTE: lI necessary,adjustthe P/S pump belt (see section 17) and A/C compressorbelt (see section 221.

)

-0010r0A oTJGG

then retightenthe adjustingnut and mountingnut to the specifiedtorques. Recheckthe tensionot the belt. NOTE: It necessary,adjustthe P/S pump belt (see section 17) and A/C compressorbelt (seesection 22t.

J

23-115

Fan Controls ComponentLocationIndex For the A/C system, see section 22.

RADIATORFAN RELAY Test,page23,69 : lt tt tt tt l c=, Ll

l]-]l

L-t t lf

-r f1 a l f a'rI r""""r I i la-t a

fr -

l

-

|

t L )

I r t 1/^\ tr.z{

l/-\l N/

|

CONDENSER FAN RELAY Test,page 23-69

L

UNDER-HOOD FUSE/RELAY BOX

FAN MOTOR Test,page23-119

RADIATOR FAN

swtTcH Test,page23-119

TORFAN MOTOR Test,page23,119

CircuitDiagram(WithoutA/Cl

IGNITION SWITCH

-t

|-;ffi;I

(104) No.42

(lmAl N0.41

UNOEF.OASH FUSE,NELAY BOX

-YELf\-.rl]

BTK'EL-l RADIATOR FAN RELAY

BLIVREO

RAOIATOR FAN S\,YITCH foN : above) (199'F(93'C)J

BLK

I

G 201 G401

23-117 .l

FanControls

FUSEiNELAYBOX UNDER.HOOD No41(100A)

IGNTIONSWITCH

No42(40A)

WHT/ELK +-WHTT

/ BAI

UNDER DASH FUSE/8ELAY 8ox

|-;;;l

BL(rYEL t==rYEL-l

BLUiYEL

II I

.h

Ith*'T'o'oo'

+

8LU/RED

A/CSYSTEM

.,'l'**u.' 23-114

\

rcotr I I

I

Fan Motor Test the 2Pconnectorfrom the fan motor. Disconnect Test the motor by connectingbatterypower to the B terminal,and groundto the A termlnal.

Radiator Fan Switch Test NOTE:Bleedair from the coolingsystemafter installing the radiatorfan switch(seesection10) 1.

Removethe radiatorfan switchfrom the thermostat housing.

2.

Suspendthe radiatorfan switch in a containerol coolanlas shown.

lf the fan motor fails to run smoothly, replaceit. NOTE: The illustrationshows the radiatorfan.

Heatthe coolantand checkenginecoolanttempera ture with a thermometer. Checkthe continuitybetweenthe A and B terminals accordingto the table:

Operatlon

1 9 6 .- 2 0 3 ' F (91" 95'C) -5" SWITCH 1 4 . Fi 3 " _ 8 " C ) ; * , * when than the temperature OFF rt goeson. ON

)

T er mI n a l -------\ -----Tcmoerature

B

-o

23-119

GaugeAssembly Component Location Index

GAUGEASSEMBLY GaugeLocationIndex, page 23-12:| fndicatorLocationIndex.page 23-121 Terminal LocationIndex, page 23-121 EulbLocation, pag623-122 Disassembly, page23-127 Removal,paqe23-126

FUELGAUGESENDINGUNIT Test, page 23-132 Replacement,page 23-132

VEHICLESPEEDSENSOR{VSSI Test,page 23-128 InputTest,page23-128 page23-130 Replacement,

PARKINGBRAKESWNCH Test,page23-135 ARAKEFLUIDLEVELSWITCH Test,page 23,135

ENGINEOIL PRESSURE SWITCH Test, p6ge23-130 ENGINECOOLANTTEMPERATUFE IECTIGAUGE SENOINGUNIT Test,page 23-134

23-120

lt

ri

LocationIndex Gauge/lndicator/Terminal

"8" (C5601 coNNECTOR

"C" coNNECTOR (Css8l

rll 81 ------------

c1 ------>cl0

816

ililllllilll page23-131 t Test, page 23-132

.u (,w.-7'\

/'-\

tt'-1

r

I

'l

I z{.-a

,I

I I

l\-//11 t,-\\Jl

\y' !t

.r'

Jilliltl ACHOMETER: rdicates ates 10O rpm al OOpulsesper minute control e ignition l f the rodule rle {lCM).

/n

" r-oe)\ -7 t--

^a1(

u;" u

I

A,/TGEARPOS]TION INDICATORSYSTEM S€epage23-140

F
A5

D1-------->D13 SPEEOOMETER: lndicates(60 mph at 1025 rpm) or {60 km/h at 637 rpm) of the vehiclespeedsensor{VSS).

ililtl|illl

"A" coNNECTOR (C557) "D" (C5591 coNNECTOR

23-121

I

r I

GaugeAssembly Bulb Locations

HIGH BEAM INDICATORLIGHTI1 .4 \A,

LEFTTURNSIGNALINDICATORLIGHT(1.4 WI RIGHTTURN SIGNALINOICATOR LIGHT('I.4 WI CHARGINGSYSTEMLIGHT{1,4 WI BRAKESYSTEMLIGHTI1.4 WI DOOR-OPEN INDICATORLIGHT(1.4 WI A/T GEARPOSITIONINDICATORLIGHT(1.'t2 W x 7)

LOW ENGINEOIL PRESSURE INDICATORLIGHT(1.4 W} MALFUNCTION INDICATORLAMP ( M t L l( 1 . 4 W l

*ABS/SRSINOICATORLIGHT(1.' W)

LOW FUELINDICATORI-IGHTI3.4 W)

LIGHTS REMINDER LIGHTI1.4 WI

13.4W x 3) cRursELTGHT | 1.4 Wt SEATBELTREMINDERLIGHT{1.4WI

HATCH-OPEN INDICATORLIGHT{1.4 W}: Harchback TRUNK'OPEN INDICATORLIcHT (1.4 W): Sedan

+: On the ABS/SRS printedcircuitboard

23-122

GircuitDiagram UNDER.DASH FUSE/RELAY 8OX

BOX UNDEFHOODFUSE/RELAY

N o . l 5( 7 . 5 4 )

No2s(75A)

WHTiGRN

V I

$il,4, MODULE(ICM)

|

(10A) No.rs FUSE

V

ru{nounrno (Topase2312s)

I | BtU

lou

RED/BLU

.J'CRUISE CONTROL UNIT

YEUBLU

t,,

I'

YEUGRN

YE

lt ln

ASSEMBLY GAUGE

. MAINTENANCE REMINDER UNIT ' TCM ' ECM ' CRUISE CONTROT UNlT

f7

| ,,J,,

I- o R N

1l P**,,,' -t|;;il'-I

I SPEED I I SENSoBIVSS) |

BLKMHT

ffirxl-" I

G501

BLK

I

G10l

23-123 -/

i

Gauge Assembly (cont'dl CircuitDiagram

BLK,IYEL

TURN SIGNAL SWITCN

(10A) No.5

v--=v

tt

t lt

l

GBN/BLIJ

l

l l l

GRN,YEL

I e's

V I

REO/GRN

I s,o

I e,s

RIGNT TURN SIGNAL INDICATOR L]GHT (1.4w)

*v^" -'v* | |

RED/BLU GBN/RED | | I .NTEGFATEDI

|

.roL-" I

ts r A

lou

. ABSCoN-FOL U\lT .INTEGBATED

BLK

or*frro

Fo.''-,,-j r l A A

BED/BLU

GRN/RED

T :

GXXX

| -

I

_

v H^,J.**. I

. INTEGRATEO

coNrRor uNrT

,'T--l ffi--l

T

G3O1

"i.uv"'T GBN

ll#, l!i,Iib'. :

012 | GRNORN

ECM

GHNiRED

Yu'**- Y*,,r" Y** l3$i;.?.''13ffi3|

TAILGATE.OPEN INDICATOR LIGHT (1.4!9

G20l G401

lI*nilI*i

il i*it i

i . li i ; , Ii L__

(Hatchback)

23-124

L:'_"

(Sedan)

J BLKYEL YEUBLU

(104)FUSE N0.53 lFrofipage23A'123)

V I tt

WHT/GFN

)

-

LOW ENGINE OIL PFESSURE INDICATOR LIGHT 0.4w) 011 | YEUREO

IT

A8S CONTROL UNIT

V I l l

BLU/REO

MENTENANCE REMINDER LIGHT

0.4v,/i

lo'

PNK

II I

J

lon

lo'

WHT€IU

PNK

II I

J

\? ALTERNATOR

MAINTENANCE HAZARO REMINDER WARNING UNIT swtTcH

BLK

P" -:

)

J

I :

G201 G401

23-125

GaugeAssembly Removal 1 . Removethe two screwsfrom the instrumentpanel.

3 . Tilt the steeringwheeldown with the tilt adjustment lever.

2 . Removethe instrumentpanel. NOTE: Remove the instrument panel carefully w i t h o u td a m a g i n gt h e c l i p s .

Removethe three mountingscrews, and spreada protectivecloth on the steeringcolumn.

CLOTH PROTECTIVE 5 . Prythe gaugeassemblyout, and disconnectall con nectorsfrom it.

GAUGEASSEMBLY

6 : Take out the gauge assembly as shown.

GAUGEASSEMBLY

23-126

Disassembly {

NOTE: Handle the terminals and Drinted circuit boards carelully to avoid damaging them.

MOUNTINGSCREW{x 3) TACHOMETER

FUELGAUGE MOUNTINGSCBEW{x 3l

e o

ENGINECOOLANT TEMPERATURE {ECT) GAUGE MOUNTINGSCREW{x 3}

SPEEDOMETER MOUNTINGSCREW(x 4)

)

t

ENGINECOOLANT TEMPERATURE IECTI GAUGEUNIT Test,page 23-134

PRINTEDCIRCUITBOARD SRS PRINTED CIRCUITBOARD

TACHOMETEFUNIT page23-121 Specification,

' /*'

r@/ ror

6rH" d'dP

\

METERHOUSTNG

FUELGUAGEUNIT Test,page23 131

I t

METERUNTT SPEEDO/ODO/TRIP ' SPEEDOMETER page23-121 Specification, Troubleshooting, Page23_128 . ODOMETER page23-128 Troubleshooting, . TRIPMETER Troubleshooting, Page23 128

23-127

VehicleSpeedSensor(VSSI Troubleshooting Beforetesting,inspectthe No. 15 (7,5A) fuse in the under-dashfuse/relaybox. Test tho 8LK wiro: 1. Disconnectthe 3P connector from the vohicle speedsensor

(vss).

REOTESTHARNESS

2. Connect the test harness (07LA,J- PT3020A)only to the enginewire harnoss. 3, Connectthe REDtest harness clip to the positiveprobe of an ohmmel€r. 4. Checkfor continuity betwoen the REDtest harnessclip and body ground.

PBOTECTIVE TAPE

Roplir op.n in th. BLK wiro b.tw..n tha VSS .nd G101.

To3t thc BLK/YEL wiro: 1. Conn6ctth€ WHT test harness clip to the positive prob€ of a voltmeter,and connectthe RED t€st harnessclip to the nogative probe. 2. Turn the ignitionswitchON (lll.

GRNTEST CLIP TESTHARNESS OTLAJ- PT3O2OA

w'{T TES? HARIVESSCLIP

R.p.lr op.n In tho BLK/YELwire brtw..n th. VSSandth. underdr.h tu../r.l!y box.

Tort th. BLU/WHTwiro: Connect the GRN test harness c l i p t o t h e p o s i t i v ep r o b € o t a voltmeter,and connectthe RED test harness clip to the nggatjve probe.

ls thereabout5 V or more?

{To next page)

23-128

TAPE

Roprh op.n in th. 8LU/WHT wire b.tw.on tho VSS lnd PCM.

{

WHT TEST CLIP Test tho vss: 1. Turnthe ignitionswitchOFF. 2. Connectthe other test har nessconnectorto the VSS. 3. Raiseth€ front and roarof the v e h i c l e ,a n d s u p p o r ti t w i t h safetystands. 4. Put the transmissionin neutral with the ignition switch

TESTHABNESS OTLAJ- PT3O2OA FEDTESTHARNESS GRNTESTHARNESSCLIP

PROTECTIVE TAPE

oNflr). 5. Slowly rotate one wheel with the otherwheelblocked.

Doesvoltagepulsefrom 0 to approx.5V or more?

SpocdomatcrTe3t: 1. Disconnoct the 16Pconngctor " B " f r o m t h e g a u g ea s s e m -

{

)

{

'8" GAUGEASSEMBLY16PCONNECTOR

2. Touch8 probeto the ORN wire, and connectit to body groundthrougha voltmetor. 3. Slowly rotate one wheel with the otherwheelblocked.

Doesthe meterindicatepulsing voltage?

CLIP

Repairopen in the ORNand BLU/ WHT wire botw.en tho VSS .nd the soa€do-mster.

VehicleSpeedSensor(VSS) Replacement

EngineOil Pressure lndicatorSystem EngineOil PressureSwitch Test

1.

Disconnect the 3P connectorfrom the vehiclespeed sensor(VSSl.

2.

Removethe two mountingbolts, then removethe VSS.

1.

Removethe YEL/REDwire trom the engineoil pressure swlrcn.

SWITCH ENGINEOIL PBESSURE 3P CONNECTOR

BOLT 9.8 N.m ( 1 . Ok g f . m , 22 tbt,ltl DRIVELINK

POSITIVETERMINAL

2 . Checkfor continuitybetweenthe positiveterminal andthe engine(ground)with the ignitionswitchOFF. a lf there is continuity,go to step 3. a lf there is no continuity,replacethe switch.

3 . Checklor continuityagain,this time with the engine 3 . Installin the reverseorder of removal. NOTE: The VSS drive link is a very small part; D C careful not to lose it.

running. a lf there is continuity,go to step 4. a lf there is no continuity,the switch is OK. Make sureengineoil levelis OK, then checkengine oil pressure(seesection 8). a lf engineoil pressureis OK, replacethe switch. a lf engineoil pressureis low, checkthe engineoil pump (seesection8) and,iI necessary, replaceit.

23-130 E-_

Fuel Gauge GaugeTest {

NOTE:Referto page 23-123for the fuel gauge system circuit. 1 . C h e c kt h e N o . 2 5 ( 7 . 5A ) f u s e i n t h e u n d e r - d a s h fuse/relaybox before testing. 2.

Removethe rear seat (see section 20).

3 . Removethe protectivecoverand accesspanelfrom

6 . Turn the ignitionswitch OFF.Attach a jumperwire between the BLKMHT and YEL/WHT terminals, then turn the ignitionswitch ON {1.,. Checkthat the pointerof the fuel gaugestarls moving toward the "F" mark. CAUTION: Turnthe ignitionswitch OFFbeforethe pointerreaches"F" on the gaugedial, Failureto do so may damage the tuel gauge.

the tloor. 4.

With the ignitionswitchOFF,disconnectthe 3p connectorfrom the fuel gaugesendingunit. PROTECTIVE COVER

NOTE: The fuel gaugeis a bobbin(cross-coil) type gauge,hencethe fuel levelis continuouslyindicated even when the ignitionswitch is OFF, and the pointermoves more slowlv than that ol a bimetal rype gauge. a lf the pointerol the fuel gaugedoes not move at all, replacethe gauge. a It the gaugeis OK, inspectthe fuel gaugesendingunit.

3P CONNECTOR

)

t.t

View from wire side

5 . Connect the voltmeter positive probe to the YEL/WHTterminaland the negativeprobe to the BLK/WHTterminal,then turn the ignitionswitch ON (ll). The.e should be between 5 and 8 V. a lf the voltage is as specified,go to step 6. a lI the voltage is not as specified,check for - an open in the YEL/WHT, BLU/WHT or BLK/WHTwire. - poor ground (G501,G502).

t . ! 23-131

Fuel Gauge SendingUnit Test/Replacement not smoke while working on tha fu6l @oo system. Keep open llames away trom youl work alea. 1.

Removethe rear seat {see section 2O}.

2.

Removethe protectivecoverand accesspaneltrom the floor.

3.

With the ignitionswitchOFF,disconnectthe 3P connectorfrom the fuel gaugesendingunit.

4.

Removethe fuel gauge sendingunit.

5.

lreasurethe resistancebetweenthe A and B termin a l sa t E ( e m p t y ) ,l / 2 ( h a l f f u l l )a n d F { f u l l }b y m o v ing the tloat. Float Position Resistance(Ol

6.

E 1t2 1 0 5 11 0 2 5 . 5 3 9 . 5

F

2

5

Checkthe changein resistanceby movingthe float uo anddown.

(

1 . lf unableto obtainthe abovereadingsor if resistance doesnot change,replacethe fuelgaugesendingunit. NOTE: Usenew O-ringsor packingswhen reassembling. For details,refer to section 1 1.

o

23-132

Low Fuel lndicator

Seat Belt Reminder System

IndicatorLight Test

Seat Belt Switch Test

NOTE:Referto page23-123for the wiring descriptionof the low fuel indicatorcircuit.

1.

I

Slide the driver'sseat to the middle position.then disconnectthe 2P connectorfrom the back of the seat.

Parkcar on level ground.

1.

Checktor continuitybetweenthe A and B terminals in each conditionaccordingto the table.

oo not smoke whilc wolking on the @ fuel system. Keepopen tlamesaway from your work area. Drain fuel only into an approved container.

Terminal

\ Drainfuel into an approvedcontainer.Then install the drain bolt with a new washer.

2.

UNBUCKLED

3 . A d d l e s s t h a n8 . 2 t l 2 . 2 U . S . G a 1 l , . 8 l m p . G a l ) of fu e l and turn the ignitionswitch ON {ll). The low fuel indicator light shouldcome on within lour minutes. .

B

c""dil----l

o

o

BUCKLED

lf the light does not come on. removethe access panel and disconnectthe 3P connectorfrom the f u e l g a u g e s e n d i n gu n i t . C o n n e c t h e A ( B L V terminalwith WHT)terminalto the C (BLU,/WHT) a jumperwire. - lf the Iightcomeson, the problemis eitherthe sendingunit or its ground. - lf the light does not come on, the problemis an openin the BLU/WHTwire to the gaugeassembly, no power to the gauge,or a blown bulb.

I

i

a lf the light comeson, add approx.4 ! (1.1 U . S . G a lO . . 9l m p . G a lo) f f u e l ,t h e l i g h ts h o u l dg o off within four minutes.

ANCHOR

3P CONNECTOR

N O T E : R e f e r t o p a g e 2 3 - 1 5 6f o r t h e s e a t b e l t reminderinputtest, 3.

lf necessary,replacethe seat belt switch.

)

23-133

EngineCoolantTemperature(ECT)Gauge ECT SendingUnit Test

GaugeTest

Disconnectthe YEL/GRNwire from the ECT sendingunit.

NOTE:Referto page23-123for the wiring descriptionof the enginecoolanttemperature(ECT)gaugecircuitdiagram.

With the enginecold, use an ohmmeterto measure resistancebetweenthe positiveterminalandthe eng i n e( g r o u n d ) .

1 . C h e c kt h e N o . 2 5 ( 7 . 5 A ) f u s e i n t h e u n d e r - d a s h fuse/relaybox before testing. 2.

Make sure the ignitionswitch is OFF,then disconnect the YEL/GRNwire trom the ECT gaugesendi n g u n i t a n d g r o u n di t w i t h a j u m p e rw i r e .

POSITIVETERMINAL

YEL/GRNWIRE

Check the temperatureol the coolant.

SENDINGUNIT

Runthe engineand measurethe changein resistance with the engineat operatingtemperature(the radiator fan comes on). T u r n t h e i g n i t i o ns w i t c h O N ( l l ) . Checkthat the pointerof the ECTgaugestartsmovi n g t o w a r dt h e " H " m a r k . CAUTION: Turn the ignition switch OFF before the pointerreaches"H" on the gaugedial.Failureto do so may damagethe gauge. a lf the pointerof the gaugedoes not move at all, wire. c h e c kl o r a n o p e ni n t h e Y E Lo r Y E L / G R N lf the wires are OK, replacethe ECT gauge. a lf the ECT gauge works, test the ECT sending unrt.

23-134

Temperature

133oF(56oC)

1 8 5 0 F( 8 5 . C ) 212.F(100'C)

Resistance{O)

137

46-30

5.

It the obtainedreadingsare substantiallydifferent above,replacethe ECTsendfrom the sDecifications I n gu n r t .

'il

--r T -

BrakeSystem Indicator

'1

+ T

L.J

Parking Brake Switch Test

BrakeFluid LevelSwitch Test

1 . Removethe Iloor console,and disconnectthe con-

Removethe reservoircap.

nector from the switch. Checkthat the float moves up and down freely; if it does not, replacethe reservoircap assembly.

2 . Checkfor continuitybetweenthe positiveterminal and body groundin eachleverpositionaccordingto the table.

Checkfor continuitybetweenthe terminalsin each lloat positionaccordingto the table.

4l Terminal

\

l"*rr*ril---lt UP

POSITIVE

o

BODY

| ermrnal

\ Floatposition

o

POSITIVE

NEGATIVE

\

UP

DOWN

--o

o

DOWN

POStnVE TERMINAL RESERVOIR CAP

DOWN POSITION

NEGATIVE TERMINAL MAGNET

*----raoo, POSITTVE TERMINAL POSITIVE TERMINAL

I

UP POSITION

BODY GROUND

Canada: lf the parkingbrakeswitchis OK, but the brakesystem indicatordoes not function,perform the input test for the daytimerunninglightscontrol unit {see page23-164).

Switch contacrs closed when float drops.

TIVE TERMINAL

Switch contactsopen at properfluid level.

4.

lf necessary,replacethe reservoircap assemblv.

MaintenanceReminderSystem ComponentLocationIndex \ MAINTENANCEBEMINDERLIGHT {ln the gaugeassembly) GaugeAssembly.page23-120

VEHICLESPEEDSENSORIVSS) (Onth6 transmission housing) Test,page 23-128,129 page23-130 Replacement,

MAIMTENANCE REMINDERUNIT (Behindth€ dashboardlower cover) Input T6st, page23-139

t 23-136

I

t

Basedon signalsreceivedfrom the vehiclespeedsensor(VSS).the microcomputerin the maintenancereminderunit, which is locatedbehindthe dashboardlower cover,computesthe distancestraveled.When you turn the ignitionswitch ON (ll), the reminderlight in the gaugeassemblywill come on for two seconds(bulbcheck tunction).At 9,650 1 160 km {6,000 1 1O0 miles}intervals,the reminderlight will glow for two secondsand then blink ten secondsafter you turn the ignition switch ON (ll). This will repeatevery rime you turn the ignitionswitch ON {ll) until rhe car reaches 1 2 , O 7 O! 16 0 k m ( 7 , 5 0 0 t 1 0 0 m i l e s ) . Beyondthe 12.o1O ! 160 km (7,5OOt IOO mile) interval,the light will continueto glow after the bulb check until you turn the ignitionswitch otf or reset the unit. To resetthe unit, the car must be parkedand the ignitionswitch must be ON (ll). Pressthe reset button on the unit for more than three seconds,and the reminderlight will go off. NOTE: . Turn the ignitionswitchOFFbeforeyou removethe 5P connectorfrom the maintenancereminderunit, otherwisevou wiil cancelall data in the memory. a The data will remainin the memoryeven when the ignitionswitch is turned off, or if the unit is disconnected.When the ignitionswitch is turned ON (lll, and the car is driven, additionaldata will be stored.

)

{

)

{

23-137

MaintenanceReminderSystem CircuitDiagram FUSEIRELAY BOX UNOER.HOOO N0.41(lmA)

No42(40A)

REMINDER MAINTENANCE UNIT

8LK

c201 G401

23-138

MaintenanceReminderUnit Input Test v

1.

With the ignjtionswitchOFF,disconnectthe 5Pconnectorfrom the reminderunit.

2 . Inspectthe connectorand socket terminalsto be sure they are all makinggood contact.

View from wire side ORN

a lf the terminalsare bent,looseor corroded,repair them as necessary,and recheckthe system. a lf the terminalslook OK, make the followinginput tests at the connector. - lf a test indicatesa problem,find and correct the cause,then recheckthe system. lf allthe inputtestsproveOK,the remind€runit must be faulty; replaceit.

MAINTENANCE REMINDER UNIT

)

t No.

Wile

I

BLK

2

Test condition

Check for continuityto ground: . P o o rg r o u n d( G 2 0 1 ,G 4 0 1 1 . An open in the wire Thereshould be continuity.

U n d e ra l l c o n d i t i o n s

. Blown No. 47 (7.5A) fuse in the underCheck for voltageto ground: There should be battery voltage hood fuse/relaybox . An open in the wire . Blown No.25 {7.5A) fuse in the underCheck lor voltageto ground: There should be battery voltage. dashfuse/relaybox . An open in the wire B l o w nN o . 2 5( 7 . 5A l f u s e i n t h e u n d e r Connectto body ground:The dashfuse/relaybox r e m i n d elri g h t s h o u l dg o o n . Blown bulb An open in the wire

WHT/BLU

YEL l g n i t i o nO N { l l )

4

5

PNK

ORN

Possiblecause it lesult is not obtained

Under all conditions

l g n i t i o n O N flr)

3

Test: Dosired result

l g n i t i o nO N ( l l ) ,c a r i n neutralwith front of car raised,one wheel rotated with other wheel blocked

Check for voltageto ground: Meter should indicatepulsang voltage.

. Faulty vehiclespeedsensor (VSS) . An open in the wire

t 23-139

A/T Gear PositionIndicator ComponentLocationIndex

GAUGEASSEMALY Removal,page23-126 page23-127 Disassembly, page23-122 BulbLocations, INTERLOCK SYSTEM page23-'147 Description,

A/T GEARPOS]TION INDICATOR InputTest,page23-142

:S SWITCH A/T GEARPOSTTION Test,page 23-144 R6olacement, section14

23-140

CircuitDiagram { UNDER-DASH FUSE/RELAY BOX

IGNTION SWITCH

FUSEiRELAY 80X UNDER-HOOD

---wrl w--BLh

f

/;;\ ,:+ \---l

l-^--;;;;l

BLK/Et.d\o-ft

I t,;:'*'

. TRANSMISS]ON CONTROL (TCM) MODULE

I V

ECM

f7

YEUBLU

I

LTGRN/BLK

essembly) ( n l h eg a u q a

D4

TRANSMISSION CONTROL MODULE

rrcM)

f7

DIMMINGC RCUIT A/TGEAHPOSITIONNDICATOR

I

I

GRN/BLK

)

{

c6 NTERLOCK CONTROL UNIT (

f7 N ol 9 ( 1 0 4 ) FUSE

f7

c7

GRN

c8

lc9

L T G R N M H T BLK

CRN]BLU

TRANSMISSION CONTROL MODULE TICM)

GRN/YEL

I

GRNMHT

I

RED/BLK

A/TGEAR POSTION CONSOLE LIGHT (1.4w)

/

,/

t2

A?TGEAR POSITION SWTCH RED

II

BLK

I

Y?

I

{,

DASHLIGHTS BFIGHTNESS CONTROLLER

oro, G40l

G20l G401

23-141

A/T Gear PositionIndicator IndicatorInput Test Removethe gauge assemblyfrom the dashboard(see page 23-1261, and disconnectconnectors"8", "C" and "D" from it. Inspectthe connectorterminalsto be sure they are all makinggood contact. a lI the terminalsarebent,looseor corroded,repairthem as necessary,and recheckthe system. a lI the terminalslookOK,makethe followinginputtests at the connector. - l{ any test indicatesa problem,find and correctthe cause,then recheckthe system. lf all the input tests prove OK, the gaugeassembly must be faulty; replaceit.

"B" CONNECTOR

=------'\\-\-\ \----

23-142

=

{

CONNECTOR"D": View from wire side of lemale terminals

No.

Wire

1

BLK

2

YEL

CONNECTOR

Wire

1

RED/BLK ano RED

Possiblecause il result is not obtained

Test condition

Test: Desiredresult

Undera l l c o n d i t i o n s

Check {or continuityto ground: There should be continuity.

P o o rg r o u n d( G 2 0 1, G 4 0 1 ) An open in the wire

lgnitionswitch ON (ll)

Check for voltage to groundl There should be battery voltage

Blown No. 25 (7.5A) fuse in the under-dashfuse/relaybox An open in the wire

"8":

No.

YEL/BLU

RED/BLK

View from wire side ot female terminals

Test condition

Test: Desiredresult

Possiblecause if result is not obtained

. Faulty dash lights brightnesscontrol C o m b i n a t i olni g h t Check for voltage between RED/BLK system switch ON and dash a n d R E Dt e r m i n a l s l lights brightnesscontrol There should be battery voltage. . An open in the wire d i a lo n f u l l b r i g h t

"C": View from wile side ot female CONNECTOR terminals

)

LT No.

Test condition

Shifl leverin position@ GRN/WHT NOTE:Don't pushthe brakepedal. G R N / R E D 5nrrI rever In pos[ron ll 1

GRN

Test: Desiredresult C h e c k { o r c o n t i n u i t yt o g r o u n d : There should be continuity. NOTE: There should be no continuity in any other position.

Possiblecause iI lesult is not obtained Faulty A/T gear positionswitch P o o rg r o u n d( G 2 0 1, G 4 0 1 ) An open in the wire

shl, b*|' il. p"1,!lN

G R N / B L U )nrn reverIn posrronurl G R N / Y E L snt

r""-. r p*;ir" tZ-

LT. Shift leverin positionf GRN/WHT

2

GRN/BLK

3

LTGRN/BLK

l g n i t i o ns w i t c h O N ( l l ) and shift lever in any position except E

l g n i t i o ns w i t c h O N ( l l )

. Faultytransmissioncontrol module Check for voltageto ground: (TCM) There should be battery voltage . A n o p e ni n t h e w i r e lor two secondsafter the i g n i t i o ns w i t c h i s t u r n e dO N ( l l ) , 'l and less than V two seconds later. . Faulty transmissioncontrol module Check lor voltageto ground: There should be battery voltage. ( T C M )o r E C M ' A n o p e ni n t h e w i r e

23-143

A/T GearPositionIndicator A/T GearPosition Switch Test

I

1 . Removethe console,then disconnectthe 14Pconnectorfrom the switch.

2 . Checkfor continuitybetweenthe terminalsin each positionaccordingto the table. terminal sroe

Move the lever back and forth at each position without touchingthe push button,and checkfof continuitywithin the rangeof free play. lf there is no continuitywithin the rangeof free play, adjustthe installingpositionof the switch as describedon the next page.

Back-uD Light Switch

A/T Geal Position Switch lwithout cluise control) Terminal

_\ P*m""

\

B

F

G

N

iT

L

o- --o --o o--o o--o o-_o o--o o-_o o-

tr a E E N

tr E

rermrnal _\

B

E

F

G

N

M

L

t]"t-

o-- --o

tr oE

G_

E

o-

K

--o o- --o

c

D

o- --o Neutlal Position Switch J

--o --o

tr E

G-

23-144

J

--o oo-

N

D

Back- up Light Switch

A/T G€ar Position Switch lwith cluise controll \

c

Noutral Position Switch

--o -o --o

o- --o

o- --o o- --o

-

A/T Gear Position Switch Replacement 1.

Removethe console.then disconnectthe 14Pconnectorfrom the switch.

2.

Removethe two consoleswitch mountingnuts.

A/T Gear PositionSwitch Adjustment 1. Shitt to the @ position,and loosenthe nuts. 2.

Slide the switch in the directionof @ position lwithin2.0 mm (O.079in.)lso that thereis continuity "A" and "L" terminalsin the rangeoI betweenthe play the shift lever. free oI

3.

Recheckfor continuity between each of the termanals. NOTE: a ll adjustmentis not possible,check for damage to the shift lever detent and/or the bracket. lf there is no damage,replacethe consoleswitch. a The engineshouldstart when the shift leveris in positionS in the rangeof free play.

LOCK PIN

)

3 . Positionthe switch sliderto "Neutral" as shown above. Move the shitt lever to "Neutral", then slip the switch into position.

E position

5 . Attach the switch with the two nuts. Testthe switch in the @ andI positionof the shift lever.The engineshouldstart when the shift lever is in positionE anywherein the rangeof free play. 1.

)

'/ia

Connectthe l4P connector,clamp the harnessand installthe console.

NUTS

23-145

Interlock System Component Location Index SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,and proceduresin the SRS section (23) belore performingrepairsor service.

KEY INTERLOCK SOLENOID swlTCH and KEY INTERLOCK {ln the steeringlock assembly} INTERLOCK CONTROL UNIT

PARKINGPIN SWITCH Test, page 23-142 page 23-142 Replacement,

SHIFT LOCK SOL€NOID Test, page 23 143 page 23-143 Replacement,

Description The car is equippedwith the lollowing devicesto plevent inadvertentshifiing: a A/T selectorwith shift lock a Key cylinderwith interlockedignitionkey Shift Lock Svstem: The shift lock system preventsthe shilt lever trom moving to @ or [6ol from the p is depressedand the acceleratoris in its rest position.

positionunlessthe brake pedal

NOTE: a The shift lever cannot be shifted when the brake pedal and the acceleratorare depressedat the same time. a In caseof systemmalfunction,the shift levercan be releasedby pushinga key into the releaseslot nearthe shift lever.

23-146

Description t

Ths cal is equipped with the tottowing devices to prevent inadvertenl shifting: a Key cylinderwith interlockedignition key (Key InterlockSystem) a shift lever with shift lock (shilt Lock system) Key Interlock System: When the shift leveris in any other positionthan @ or is not securelylockedin @ (parkingpin switch is ON), a solenoid is activated,making it impossibleto removethe ignitionkey from the ignitionswitch. To be able to removethe key, the shift lever must be in E] and must be securelylockedin this position{parkingpin switch must be turned oft by the lock pin)

)

t The shift lever is in any othel position than El and the psrking pin switch is ON: CYLINDER

PARKINGPIN

SHIFT LOCK LEVER

The shitt lever is in l!] and the parking pin switch is OFF: KEY CYLINOER

SHIFTLOCKLEVER

{t

23-147

lnterlockSystem CircuitDiagram NOTE: Differentwireswith the samecolorhavebeengivena numbersuflixto distinguishthem (forexample, I cRNA/VHTandcRNMHT ' are notthesame). UNDER-HOOO FUSEi RELAY BOX

N0.41(100A)

N0.42(404)

WHT/ BLK.--

WHI

YEUBLU

cnrivrr' THBOTTLE (TP) PosrT|0N SENSOR

KEY INTERLOCK swtTcH

f7

I

RED/BLK

cnrruvgr'

+

WHT/BLU

. BRAKE LIGNTS .CSUISE CONTROLUNIT . ABSCOIITROL UNIT ' ECM

INTEBLOCK CONTROL UNIT A]'IGEAR POStTION INOICATOR

v

t

(Cjl:inposiron Et

23-14A

,

Control Unit Input Test Disconnect the 8P connectorfrom the interlockconCONTROLUNIT INTERLOCK trol unit. 2. lnspect the connectorand socket terminalsto be sure they are all makinggood contact. a It the terminalsare bent,looseor corroded,repair them as necessary,and recheckthe system. a lf the terminalslook OK, make the following input tests at the connector. - lf a test indicatesa problem,tind and correct the cause,then recheckthe system. - lf all the input tests prove OK, substitutea known-goodcontrolunit, and recheckthe system. lf the check is OK, the controlunit must be faulty; replaceit. NOTE:lf the shift locksolenoidclickswhen the ignition switch is turned ON (ll) and you step on the brskeDedal(with the shift leverin E). the shift lock GRN/wHT2 system is electronicallynormal; if the shift lever cannotbe shiftedfrom fl, test the 46 gear position switch as describedon page 23-142,and see section 14. Shift Lock System: Possiblecauss it result is not obtained Test: Desired result Test condition No. Wire 1.

lgnitionswitch ON (ll) Brakepedal pushed 1 WHT/RED

)

{r/

t

3

GRN/WHT'

lgnitionswitch ON (ll) Brakepedal and acceleratorpushedat the same me

Check for voltageto ground: There should be less than battery voltage.

Shift lever in position

Check tor continuityto ground: There should be continuity.

lgnitionswitch ON (ll)

Check for voltageto ground: Thereshould be battery voltage

E

YEL/BLK

Key Int€rlock Systcm: Test condition Wire No. BLK

Under all conditions Shift lever in position

GRNiWHT'

E

lgnitionswitch turned

WHT/YEL to ACC (l) and the key pushedin

3 WHT/BLU

I'

4

Check for voltageto ground: There should be battery voltage

WHT/BLK

Test: Dcsired lesult

Blown No. 52 {20A) fuse in the box under-hoodfuse/relaY Faultytransmissioncontrol module (TCM) Faulty ECM Faulty brake switch Faultythrottle position (TP)sensor An open in the wire Faulty A/T gear positionswitch P o o rg r o u n d{ G 2 0 ' ,1G 4 0 1 ) An open in the wire Blown No. 25 (7.5A) fuse in the fuse/relaybox under-dash Faulty shift lock solenoid An open in the wire Possible cause it result is not obtainsd

Check lor continuityto ground: . P o o rg r o u n d( G 2 0 1 ,G 4 0 1 ) . An open in the wire There should be continuitY. Faulty A/T gear positionswitch Check for continuityto ground: P o o rg r o u n d{ G 2 O 1 ,G 4 0 1} Thereshould be continuity. An open in the wire Blown No. 52 (20A) fuse in the Check tor voltageto ground: There should be battery voltage. under-hoodfuse/relaYbox Faulty steeringlock assemblY (key interlocksolenoidl An open in the wire

Shift lever in position E and push button pressed

Check for continuityto ground: There should be continuity.

Faulty pafkingpin switch , 4 O1 ) P o o rg r o u n d( G 2 O 1 G An open in the wire

Shiftleverin position E andpushbutton reteaseo

Check for continuityto ground: There should be no continuity.

Faulty parkingpin switch Short to ground An open in the wire

23-149

,l

Interlock System Key InterlockSolenoidTest

Parking Pin Switch Test/ Replacement

1. Removethe dashboardlower cover.

\

1 . Removethe lront console(see section 20).

2.

Removethe knee bolster.

3.

D i s c o n n e ctth e 7 P c o n n e c t o rf r o m t h e m a i n w i r e harness.

2.

O i s c o n n e ctth e p a r k i n gp i n s w i t c h 3 P c o n n e c t o r from the main wire harness.

3 . CheckIor continuitybetweenthe terminalsin each switch positionaccordingto the table.

--

\

Terminal

---_\

B

,o"n* Shitt lever in position@

Push button pusneo

o-

----o

Push button reteaseo

Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.

\_____,___ ___l

J

Position lqnition s-wirchACC

Keyplshedin Key released*

G-

7

lf necessary,removethe self-lockingnut and the parkingpin switch.

--o

o- --o

* : 1 5- 2 0o h m s 5.

Checkthat the key cannotbe removedwhen the battery is connectedto the No. 6 and No. 7 terminals. a lf the key cannot be removed,the key interlock solenoidis OK. a lf the key can be removed,replacethe steering lock assembly(keyinterlocksolenoidis not available separately).

PARKING PIN SELF'LOCKINGNUT SWITCH Replace 3 N.m {0.3 kgf.m,2.2 lbf.ft)

,

Shift Lock SolenoidTest/Beplacement r-

SHIFTLOCK SOLENOID

1 . Removethe console,then disconnectthe 2P connectorof the shift lock solenoidtrom the main wire harness. NOTE: Do not connectpower to the B (- ) terminal (reversepolarity)or you will damagethe diode inside the solenoid.

2 . Connectbatterypowerto the A terminal,groundthe B t e r m i n a l m o m e n t a r i l y ,a n d c h e c k s o l e n o i d operation.

SELF-L

SHIFTLOCKCOLLAR NUTS

Replace.

9 . 8 N . m { 1 . 0k g f . m , 7.2 lbI.Ir) 5.

Check and, if necessary,adiust the solenoid'spo sition. a W h e n t h e s h i f t l o c k s o l e n o i di s O N , c h e c kt h a t t h e r ei s a c l e a r a n coef 2 . 5 ! O . 5m m { 0 . 0 9 8 t O.020in) betweenthe top rearcorneroI the shilt lock lever and the lock pin groove,then tighten the self-lockingnuts.

)

NOTE: Use new self-lockingnuts. 2 . 5 t O . 5m m (0.098 I 0.020 in)

SHIFTLOCK LEVER

a lf the solenoiddoes not operate,replaceit as describedin steps 3,4, and 5. a lf the solenoiddoesoperate,checkand, i{ neces sary,adjustits two positionsas shown in step 5. 3.

Removethe shift lock collar and the solenoidpin.

4.

Removethe selfiockingnuts and shift locksolenoid, then installthenew solenoidin the reverseorderof removal.

LOCKPINGROOVE a When the shift lock solenoidis OFF,make sure that the lock pin is blockedby the shitt lock lever. LOCKPIN

LOCKPIN GROOVE

)

23-151

IntegratedControlUnit CircuitDiagram Description An integratedcontrolunit, locatedin lhe left kick panel,integratesthe lunctionsof the key-in/seatbelt r€minder, side marker lightllasher,wiper/washer,lights-onreminder,rearwindowdeloggertimer,brakesystemlightbulbcheck,and engineoil pressureindicator flashercircuits. NOTE: Differentwireswiththe samecolorhavebeengivena numbersuflixto distinguishthem (forexample, I andGRN/RED'are notthesame). GRN/RED

UNDER-NOOO FUSE/RELAY BOX WHT/ BLK+WHT WHT/ REO

UNDER.DASH FUSARETAY BOX

r

REARWINDOW DEFOGGER RELAY REAFWINDOW W N D S H I E L D W I P E R i WASHER SWITCH DEFOGGEN INDCATOR LGHT INT OFF/INT

f-7

I I

BLU/YEL

f7 tt

YEUBLU

YEUBLU

f7 l l

n

YEUBLU8LU/GRN 1 . 6 :

LOW ENGINEOII PRESSURE INOICATOB LIGHT

s

6

s

t ; t -

F

,]

L

rmecnlleo counoLultr

; WINDSHIELD ' WIPERMASHER I swlTcH

YEUREO

t

t f V7

I

t

YEL

BLUMHT

J

J

iI

"'i'-'i*-

FEAR

I

SWITCH

L__

wtN0sHr€10 : wtN00w WIPER I OEFOGGERMOTOR

(*)

l

I

|

WHTIBLU

J

v i

VOTTAGE REGULATOR (lnallernatol)

"oto: ___l

G441

l

I

YEURED

ENGINE olL PRESSURE

swrTcH

WINDSHIELO I WASHEB I

(*) :Wilhcombined washer-wiper operalion

23-152

l

BLK

YEUREO

CUTRELAY

-> BruiBLK

{

i",rrrl%.^ ,*,r.,.

SEATBELT REM]NDEB LIGHT (1.4w)

INTEGRATEO CONTROL UNIT

FRONT PASSENGER'S DOOR SWITCH

23-153

IntegratedControl Unit Input Test Removethe dashboardlower cover and knee bolster, then disconnectthe 15Pconnectortrom the integrated controlunit. Removethe integratedcontrol unit lrom the under-dach fuse/relaybox.

NOTE: a Ditferentwires with the same color have beengiven a number suffix to distinguishthem (lor example, G R N / B L Ua1n d G R N / B L Ua, r e n o t t h e s a m e ) . a Do not disconnectany connectorson the under-dash fuse/relaybox except the integratedcontrol unit.

Inspectthe connectorand socketterminalsto be sure they are all makinggood contact. a lf the terminalsarebent,looseor corroded,repairthem as necessary,and recheckthe system. a lf the terminalslookOK, makethe lollowinginputtests at the connectorand under-dashluse/relaybox. - ll any test indicatesa problem,find andcorrectthe cause,then recheckthe system. lf allthe inputtests proveOK,the controlunit must be faulty; replaceit.

A------>G

H -----

- ->N

15P CONNECTOR wire side

YEL/BLU

23-154

*BLK/GRN A B

C D *E F G

YEL/BLU View from wire side

All Systems: No. Terminal 1

N

U n d e ra l l c o n d i t i o n s U n d e ra l l c o n d i t i o n s

2 l g n i t i o ns w i t c h O N ( l l )

3

Test: Desiredresult

Test condition

F

Check for continuityto ground: . P o o rg r o u n d( G 2 0 1 ,G 4 0 1 ) . An open in the wire There should be continuity. . Blown No. 43 (7.5A) fusein the Check Jor voltageto groundl under hood fuse/relaybox There should be battery voltage ' A n o p e ni n t h e w i r e . Blown No. 25 (7.5A) fuse in the Check for voltageto ground: voltage. underdashfuse/relaybox Thereshould be battery . A n o p e ni n t h e w i r e

RearWindow DefoggerTimel System: No. Wire Test condition

)

1

2

YEL

Possiblecause if result is not obtained

Test: Desired result

Deloggerswitch pusneo

Check for continuityto ground: Thereshould be continuityas the switch is pushed.

l g n i t i o ns w i t c h O N ( l l )

Connectto groundrThe rear window defoggershould work and the defoggerswitch indica t o r l i g h t s h o u l dc o m e o n .

BLU/YEL

Possiblecause it lesult is not obtained Faultydefoggerswitch P o o rg r o u n d( G 2 0 1 ,G 4 0 1) An open in the wire Blown No. 16 (7.5A) fuse in the under-dashfuse/relaybox Faulty deloggerrelay B l o w nb u l b An open in the wire

Inte.mittentWiper RelaySystem: Wire/ No.

Terminal

YEL/BLU

2

Test: Desiredresult

l g n i t i o ns w i t c h O N ( l l ) and windshield wiper switch INT

Check lor voltageto ground: There should be battery voltage

B l o w nN o . 2 6( 2 0A i f u s ei n t h e under-dashfuse/relaybox w i p e rs w i t c h F a u l t yw i n d s h i e l d A n o p e ni n t h e w i r e

Windshield wiper

Check for continuity between the BLU/WHT and BLU/GRN ter minals: There should be contrnurty.

Faulty windshield wiper switch Faulty windshield wiper motor An open in the wire

l g n i t i o ns w i t c h O N ( l l )

Check lor voltageto ground: There should be battery voltage

An open in the wire

l g n i t i o ns w i t c h O N ( l l )

Check lor voltage to ground: There should be battery voltage.

Faulty windshield washer switch An open in the ware

BLU/WHT switch OFF or INT and and wiper blades in BLU/GRN park position

3

* B L K / G R Na n d w i n d s h i e l d w a s h e r

v

Possiblecause if result is not obtained

Test condition

motor switch ON *: With combined washer-wiper oDeration

(cont'd)

23-155

IntegratedControl Unit lnput Test (cont'd) *BLK/GRN

YEL/BLU View from wire side

'With combinedwasher-wiperoperation

EngineOil PressureIndicatorFlasherSystem: Wire/ No. Terminal Test condition E n g i n er u n n i n g

1

lgnitionswitch OFF l g n i t i o ns w i t c h O N ( l l ) 2

YEL/RED

Start the engine.

Key-in/SeatBelt ReminderSystem: Wile Test condition No. 1

GRN/BLU

Driver'sdoor open

2

Front passenger'sdoor swrlcn open LT GRN/ NOTE: Before testing, RED remove No. 43 {7.5 A) fuse from the underhoodfuse/relaybox.

3

LT BLU

4

lgnition key inserted into the ignition switch

l g n i t i o ns w i t c h O N ( l l l R E D / B L U and driver's seat belt unbuckled

Testi Desired result

Possiblecause if result is not obtainsd

. Faulty chargingsystem Check for voltageto ground: There should be battery voltage. . An open in the wire Check for continuityto ground: . Faulty engineoil pressureswitch . An open in the wire There should be continuity. Check indicatorlight. It the light . Blown bulb . An open in the wire does not come on, attach the YEL/REDterminalto groundl The light shouldcome on as the ignitionswitch is turned ON. Check tor voltageto ground: There should be battery voltage

Test: Desired result

lnsufticientoil lmproperlubrication Faultyengineoil pressureswitch

Possiblecause if fesult is not obtained

Check for continuityto ground: . Faultydriver's door switch . An open in the wire There should be continuity. Check for continuityto ground: . Faultyfront passenger'sdoor switch ' A n o p e ni n t h e w i r e There should be continuity.

Check for voltage to ground: There should be 1 V or less.

Faulty ignitionkey switch P o o rg r o u n d( G 2 O 1 ,G 4 0 1l An open in the wire

Check for voltageto ground: There should be 1 V or less.

Faultyseat belt switch P o o rg r o u n d( G 5 5 1 l An open in the wire

NOTE:Referto page23-133for the seatbelt switchtest.

Bulb Check System (brake system light) No. Terminal Test condition

Tost: Desiled result

lgnitionswitch at S T A R Ti I I I )

Check for voltageto ground: There should be battery voltage.

lgnitionswitch ON {ll). brakefluid reservoir full, and parkingbrake teveroown

Connectto ground: Brake system light should come on.

M

2

D

Possiblo cause if lesult is not obtained Blown No.31 (7.5A) fuse in the under-dashfuse/relaybox Faulty clutch interlockswitch or starter cut relay (M/T) Faulty neutralpositionswitch (A/T) An open in the wire . Blown brakesystem light . An open in the wire

)

23-157 )

Key-inReminderS ystem

\f

DoorSwitch Test

lgnition Key Switch Test NOTE: Referto page 23-153for a diagram of the keyin remindercircuit,and to page23-148for the input test of the beepercircuit. Whenthe ignitionkey is not removed.the key-inreminder in the integratedcontrolunit sensesgroundthroughthe closedignitionkey switch. When you openthe driver's door,the beepercircuitsensesgroundthroughthe closed door switch. With groundat the "LT BLU" and "GRN/ BLU" terminals,the beepersounds.

1 . O p e nt h e d o o r . 2.

Removethe screw, then pull out the door switch.

3.

Disconnect the 1Pconnectorfrom the switch.

BASE PLATE

1.

Removethe d;shboardlowercoverand kneebolster (seepage23-71).

2.

D i s c o n n e ctth e 7 P c o n n e c t o rf r o m t h e m a i n w i r e narness.

1P CONNECTOR

4.

Checkfor continuitybetweenthe positiveterminal and the baseplate (ground)in each switch position accordinqto the table.

Terrninal

\

3.

Checklor continuitybetweenthe No. 2 and No. 4 terminalsin each conditionaccordingto the table.

POSITIVE (door closedl PUSHED (dooropen) RELEASED

Terminal

\

2 Condition

KEYINSERTED KEYBEMOVED

23-15 8

o--

o

BASEPLATE

Position

o

o

EngineOil Pressure IndicatorSystem Description NOTE: Referto page 23-152for the circuit diagram of the engineoil pressureindicatorflasher.and to page23 156for the input test of the flashercircuit. The low engineoil pressureindicatorlight works in two ways. lt will flash continuouslyfollowinga momentary loss ol oil pressure,or it will go on and stay on wath a completeloss of oil pressure. When the engine first starts, before oil pressurerises above 29.4 kPa (O.3 kgf/cmr, 4.3 psi), current flows throughthe low engineoil pressureindicatorlight and the oil pressureswitch to ground.This tests the circuit. With the enginerunning,voltageis appliedto the Ilasher circuit of the integratedcontrolunit. With normaloil pressure,the oil pressureswitch is openand the low engine oil pressureindicatorlight does not operate.lf the oil pressureswitch closesmomentarily(morethan O.5 seconds).but then opensagain,terminal"YEL/RED"will senseground through the switch- The integratedcontrol unit will then provideand removegroundtor the low engine oil pressure indicator light through terminal "YEL/RED". T h e l i g h tw i l l f l a s ho n a n do f f u n t i l t h ei g n i tion switch is turned to "OFF".

)

lf engineoil pressuretalls below 29.4 kPa (O.3kgf/cmr, 4.3 psi) and does not increase,the oil pressureswitch will stayclosed.The low engineoil pressureindicatorlight will go on andstayon. NOTE:Referto page 23-130for the engineoil pressure switchtest.

I 23-159

LightingSystem ComponentLocationsIndex

HIGHBEAM INDICATORLIGHT {ln the galge assembly} page23-122 BulbLocations.

COMAINATIONLIGHTSwlTCH Replscement,page23-168 Test,page23-162

OAYTIME RESISTOR(Can.dal Test,page 23-168

HEADLIGHTS Adjustment,page23-170 page23-170 Replacement,

CONTBOLUNIT {Can.d.) Input,Testpage23-164

23-160

!/

Hatchback:

LICENSEPALTELIGHTS page23-177 Replacement, TAILLIGHT . Replacement, page23 174 . Bulbr€placement, page23-174

Sedan:

LICENSEPALTELIGHTS page23-177 Replacement, INNERTAILI-IGHT . Replacement, page23-175 . Bulbreplacement, page23-176 . Replacement, page23-175 .8ulb replacement, page23'176

23-161

Lighting System CircuitDiagram(USA)

FUSE/RELAY BOX UNDER.HOOD

RED] BtU

No.5 {10A)

I

I No22 ( lroA)

I

I

I No4 ( {1oA)

T REO/BLK

IAilsurax

II

I

I

B L(

-l

G201 G401

23-162

N0.32

( 00A)

I

R€O/BtK

I

. OASHLIGHTS . PANKNGL GNTS BFIGI.ITNESS . T A L LG H T S PLATE CONTROLLER. LICENSE . DASHTIGHTS LIGHTS

Yller,l

I

I: I

RED/CRN

II

No30 (7.5A)

N0.21 (104)

8LK

I

G20l G40l

CircuitDiagram(Canada) UNDER.HOOD FUSE/RELAY BOX

BATTEFY

No41{100A)

@-**

N0.42(40A)

, /| \ \--, ({c) HEADLIGHT

UNDER.DASH FUSE/FELAY BOX

I

I

lrrt, llrffi ltlrr R E DG q N

R E DY E -

R E DB L -

) No.21

i

No.3o

uoo'

. (7.sA)

FED/BLK

F

N0.32 (104)

) N0.20 ) N0.18 {JOA) (7.5A)

) '

) '

I I :i,ff'*''" I I

CoNTFOL UN|T . INTEGBATED

t

l

+ .ffi$liilTl + l l tl - vl ^ "

| I

(

I

RED TVHT

I

I

Q

REO/8LKWHT/YELYEUBLK

i*n[i+'i ri---J-

BEDE-U +1

4-

l^

l,,oo,**qff DAYTIMEBUNNING L]GHISRESISTOR

i---

|

I

REDAVHTGRN/RED

.'""0 {36['45,1'il]'' RED/GFN

t

GRN/FED

A L l t) )

GRN/RED

Y*r*ro Yro^,

3Ai{5" iivP, IswrrcH I I

I

II II BLK

-l

G301

23-163

Lighting System Daytime RunningLights Control Unit Input Test (Ganada) Removethe dashboardlowercoverand kneebolster. Disconnectthe connectorsfrom the daytime running lights control unit. Inspectthe connectorand socket terminalsto be sure they are all makinggood contact. a lf the terminalsare bent,looseor corroded.repair them as necessary,and recheckthe system. a ll the terminalslook OK. make the lollowing input tests at the connector. lf any test indicatesa problem,find and correct the cause,then recheckthe system. lf all the inputtests proveOK, the controlunit must be faulty; replaceit.

4P CONNECTOR

8P CONNECTOR

YEL/BLK GNN/RED WHTiRED

WHT/YEL

RED/GRN

REO/WHT

View trom wire side

23-164

View from wire side

Tsst condition

BLK

Test: Desiled result

Underall conditions

Check for continuityto ground: Thereshould be continuity.

Under all conditions

Check for voltageto ground: There should be battery voltage.

. Blown No. 20 (10A) fus€ in the under-dashfuse/relaybox . An open in the wire

lgnitionswitch ON (ll)

Check for voltageto ground: There should be battery voltage.

Blown No. 18 (7.5A)fuse in the under-dash fuse/relaybox Faulty ignitionswitch An open in the wire

2 WHT/YEL

YEL/BLK

Combinationlight Check for voltage to ground: switch in "=D" position There should be battery voltage. RED/WHT

6

)

'1

Possiblecause it result is not obtained . P o o rg r o u n d( G 2 0 1, G 4 0 l ) . An open in the wire

Blown No. 48 (40A) fuse in the he under-hoodfuse/relaybox Faultycombinationlight switch An open in the wire

Combinationlight switch is OFF;connect a jumper wire between WHT/RED the YEL/BLKand WHT/REDterminals, then turn the ignition switchON (ll).

Left and right headlight(high beaml should be on but dim, and high beam indicatorlight should c o m eo n .

, 4 O 1 ,G 3 0 1 ) P o o rg r o u n d( G 2 0 ' 1G Blown bulbs Faultydaytime runninglights resrstor An open in the wire

lgnitionswitch ON (ll). brakefluid reservoir GRN/RED full, and parkingbrake levef oown

Connectto ground: The b.ake system light should come on.

Blown No. 25 (7.5A) fuse in the under-dashfuse/relaybox Blown brake system light An open in the wire

RED/GRN

Parkingbrake lever up

Check for continuityto ground: There should be continuity.

. Faulty brake lever switch . An open in the wire

23-165

LightingSystem CombinationLight/TurnSignalSwitch Test Removethe dashboard lower cover and steering columncovers{seepage23-721. D i s c o n n e c t h e 4 P a n d 7 P c o n n e c t o r sf r o m t h e switch. Checkthe connectorand socketterminalsto be sure they areall makinggoodcontact.lf the terminalsare bent, loose,or corroded,repairthem as necessary, and recheckthe system. in each Checklor continuitybetweenthe termanals switch positionaccordingto the table.

4P CONNECTOR

B D E

H

7P CONNECTOR

23-166

Combination Light Switch :

.,\

d

I

Lr"

OFF

G (Not us.d)

Terminal F

J

Position Headlightswitch

OFF

o o o

:m: LOW

=D

HIGH

o --o o

o o

o o

OFF

Passing switch

o

ON

o

Tuln Signal Switch :

LEFT

RIGHT

Terminal

B Position

I

RIGHT

o

o

NEUTRAL LEFT

o

o 23-167

Lighting System CombinationLight Switch Replacement

Daytime RunningLights Resistor Test (Canada)

'1. Remove the steeringcolumn covers.

CAUTION: The daytime runninglights resistor becomes vely hot when the daytime running lights arc on; do not touch it or the attaching hardware immediatelyaltel the lights have been tulned otf. 1.

the 3P connectorfrom the resistor. Disconnect

DAYTIMERUNNING LIGHTS RESISTOR

Disconnect the 4P and 7P connectorsfrom the combination light switch,then removethe two screws and lift out the switch.

;w;

V

View from terminalside

2 . Measurethe resistancebetweenthe resistorterminals (A and B) and the power terminalC. Resistance:1.4 O 1 O.O7o

,P CONNECTOR

23-168

Replacethe resistorwith a new one il any of the resistancesare beyond specification.

Headlight Description The low beamlightsare projector-typelightswhich are more compactwhile maintainingsufticientbrightness.Bundling the light rays reducesstray lightand yieldsa spotlight-effect which improvesvisibilityduringnightor foul weatherdriving. For easieraiming,the headlightsare equippedwith vertical and horizontalgauges. NOTE: As the outer lensesare made of a resin material,don't cover the headlightswhen they a.e turned on.

)

OUTERLENS CONVEXLENS SU8-REFLECTOR SECONDFOCUS INTERRUPTER PLATE REFLECTOR FIRSTFOCUS BULB

23-169

Headlight Adjustment Befole adiusting the headlights:

3.

a Parkthe car on level ground.

Turn the low beamson. lf necessary, alignthe vertical indicatorwith its "O" mark by turningthe vertical adjusterwith a Phillipsscrewdriver,and check aimingwith the chan on page23-171.

a Make sure the fuel tank is full. The driveror someonewho weighsthe sameshould sit in the driver'sseat. Loadthe trunk with the itemsyou usuallycarry(if you usuallypull a trailer,attach jt to the car). Push down on the front and rear bumpers several times to make sure the car is sitting normally. Wheninstallinga new headlightassembly,tightenthe four mountingbolts so that the indicatorin the verti"O" mark. cal gauge comes to the

lf necessary,align the horizontalindicatorwith its "O" mark by turning the horizontaladjusterwith a P h i l l i p ss c r e w d r i v e r a, n d c h e c ka i m i n g w i t h t h e charton page23-171.

ANGLE HORIZONTAL GAUGE HORIZONTAL ADJUSTER

'1. 2.

Open the hood. Check that both the horizontaland verticalgauge rcad "O" . a lf the gaugestead "O", checkheadlightaiming with the aimingchartson page23-171.(lf aiming isn't correct.refer to the frame repair chart in section20). a lf one or both gaugesdon't read "O", go to step

5.

Recheckthat the verticalindicatorbubbleis aligned with "0" t 1. lf necessary,adjust as describedin step 3. Turn the high beamson and checkaiming with the chartson page23-171.

23-170

Measurements (Standard): A: 9 ft 10 in (3000 mm) B: 23 in (585 mml C: 46.1 in (1170 mm) D: 33.5 in (85O mm) E: 1.2 in (31 mml

FLOOR

) HeadlightAiming Low beam:

High beam:

HEADLIGHT LOW BEAM CENTER

FLOOR

CAUTION: The outer lenses get very hot when the hoadlights ar6 on; do not cover th€m.

23-171

Headlight HeadlightReplacement 1.

Removethe front bumper(seesection20).

2.

Removethe mountingbolts,then pull out the headlight, and disconnectthe connectorsfrom it.

2P CONNECTORS

Bulb Replacement CAUTION: a Halogen headlights can becomo very hot in use; do not touch them or the attachinghaldware imm6diately after they have been tuh6d ott. a Do not try to replaceor cl6an the headlights with tho lights on. 1.

Disconnect the 2Pconnector(s) from the headlight.

HEADLIGHT

After replacement,the horizontaland venical aiming must be checkedusingconventionalmethods. Usethe aimingchartson page23-171.

2P CONNECTOR 2P CONNECTOR

Turn the bulb(s)counterclockwiseand removethe bulb(s).

23-172

Turn Front Parking/Front SignalLights

Replacement

Replacement '1.

Front Side Marker Lights

Removethe screw, and pull the front parking/tront turn signallights out of the front bumper.

CONNECTOR

1 . Removethe screw, and pull the tront side marker light assemblyout of the tront bumper. D i s c o n n e c t h e 3 P a n d 2 P c o n n e c t o r sf r o m t h e lights. Turn the bulb socket 45o countefclockwiseto remove it from the housing.

l.

FRONTTURN SIGNALLIGHT

D i s c o n n e c t h e 3 P a n d 2 P c o n n e c t o r st r o m t h e lights.

)

FRONTSIDE MARKERLIGHT

Turn the bulb socket 45o counterclockwiseto remove it from the housing.

/e*----

Ar)

fl I

23-173

Taillights(Hatchback) Replacement

Replacement

1 . Open the rear hatch.

Rearturn signal/Rearparkinglighis.

2 . Removethe rearpanelliningand the sidelining(see section 20).

1.

Openthe rearhatch,then removethe accesspanel.

2.

Removethe bulb from the bulb socket.

Disconnect the 5P connectorfrom the taillight. ACCESSPANEL

Removethe six mounting nuts, then pull out the taillight.

6P CONNECTOR

O : R E A RT U R NS I G N A LL I G H TB U L B( 3 2 C P ) L I G H TB U L B{ 3 C P ) @ : R E A RP A R K I N G Brake/Taillighr/Back-up lights: NOTE: a lnspectthe gasket.Replaceit if it is distortedor stays compressed. a After installation,run water over the lights to make sure they don't leak.

1 . O p e nt h e r e a rh a t c h . 2.

Removethe rear panel lining {see section 20).

( i ) : B A C K - U PL I G H TB U L B( 3 2 C F , (Dr BRAKE/TAILLIGH T L B( 3 2 / 3 C P ) BU

23-174 ----

Taillights(Sedan) Replacement I Taillight: '1 . Open the trunk lid, then removethe rear panel lining and side lining (seesection 20).

Inner Taillight: 1. Open the trunk lid.

2. 2.

Disconnect the 4Pconnectorfrom the innertaillight.

3.

Removethe four mountingnuts, then pull out the taillight.

Disconnectthe 4P connector from the taillight.

3 . Remove the lour mounting nuts, then pull out the innertaillight. INNERTAILLIGHT

I

:

-

TAILLIGHT

)

4P CONNECTOR

NOTE: a lnspectthe gasket.Replaceit if it is distortedor stays compresseo. a Alter installation,run water over the lights to make sure they don't leak.

1.., 23-175

Taillights(Sedanl Bulb Replacement Taillight: '1. Open the trunk lid, then removethe rear panel lining and side lining (see section 20).

Inn€r Taillight: '1. Open the trunk lid, then removethe bulb housing, 2.

2.

Removethe bulb from the bulb housing.

Removethe bulb from the bulb socket.

EULBHOUSING

BULB132/3CPI O: BRAKE/TAILLIGHT @; TURNSIGNALLIGHTBULB(32 CP) LIGHTEULB(3 CP) @: REARPARKING

23-176

O: BACK.UPLIGHTBULB(32 CP} /n. BRAKE/TAILLIGHT BULB{32l3 CP)

LicensePlateLights

GloveBox Light Test

Replacement

J

l.

Removethe glove box and disconnectthe 2P connector,

Removethe screws and pull out the licenseplate lights.

l.

Turn the bulb socket 45o counterclockwiseto remove it trom the housing.

2 . Checktor continuitybetweenthe A and B terminals in each conditionaccordingto the table.

\

Terminal

B

c""il-------l PUSHED {lidclosed) RELEASED {lidopen)

o-

/a v

---.o

BULB (3.4 Wl

t

ciot G401

23-177

Dash Lights BrightnessControl CircuitDiagram

tX"f

UNDER-HOOO FUSgRELAY 8OX

UNDEN.DASH FUSE/RELAYEOX

-.------^-;^*;;ilLrcrTswrc.

ffiwHT-lf-FEDGaN

, &TGEANPOSITION INOICATOR OIMMING CIFCUIT .ATTGEAB POSITION CONSOLE LIGHT . CRUISE COI,{TROL DIMMING CIRCUIT .CRUISECONTHOT MAINSWITCH LIGHT .GAUGELIGHTS .HAZAFDWABN NGSWITCH LIGHT . HEATER CONTROL PANEL LIGHTS . REARWINDOWDEFOGGER SWITCHLIGHT

23-178

J

NOTE: Be carefulnot to damagethe controllerand the instrumentpanel. '1. Removethe instrumentpanel from the dashboard (seepage23-126). Removethe dash lights brightnesscontrollerfrom the dashboard,then disconnectthe 3P connector.

3 . Inspectthe connectorand socket terminalsto be

View lrom wire side

sure they are all makinggood contact. a lf the terminalsare bent,looseor cortoded,repair them as necessary,and recheckthe system.

BLK

a It the terminalslook OK, make the following input tests at the connector. - lf any test indicatesa problem,find and cor rect the cause,then recheckthe system. It all the input tests proveOK, the dash lights brightnesscontrollermust be faulty;replaceit.

REO 3P CONNECTOR

)

CONTROLLEB

No.

Wire

BLK

Test condition

Underall conditions Headlightswitch ON

l -

2

REDiBLK

3

RED

Headlight switch ON

Test: Desired resull

Possiblecause if result is not obtained

Checkfor continuityto ground: . P o o rg r o u n d( G 2 0 1, G 4 O 1 l . An open in the wire There should be continuity. Blown No.30 (7.5A) fuse in the Check for voltageto ground: under-dashfuse/relaybox voltage should be battery There Faulty combinationlight switch An open in the wire Connectto ground: Dash lights shouldcome on full bright.

. An open in the ware

23-179 )

Ceiling/Trunk/Cargo Area Lights, Spotlights ComponentLocationIndex \

* 1: Sedan '2: Hatchback

CEILINGLIGHT Test/R6placem6nt.page 23 183

SPOTLIGHTS TesVReplac€ment,page 23-182

FRONT PASSENGER'S DOOR

swlTcH Test,page 23-158

*2 HATCHLATCH SwlTCH TesVReplacement, page23-186

DOORSWTTCH Test,page 23-158 .1 TRUNKLATCH

swrTcH

TesVReplacement, page23 186

TesVReplacement page23-185

\

23-180 l - -

GircuitDiagram FUSgRELAYBOX UNDEF.HOOD

,,**Er

-l

(Wilh moonrool)

WHT/FED

lSedan)

.-l TRUNK L]GHT

(sw)

I lb lff lh i T .F

LT ]NTEGRATED T CoNTROL I UNIT I

Lir -

23-141

Ceiling/Trunk/Cargo Area Lights, Spotlights SpotlightTest/Replacement 1

Turn the light switch OFF.

2

Pry off the lens.

3

Removethe two screws,then pull out the housing.

Disconnectthe connectorfrom the housing. 5 . Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.

Terminal ----l\

\

Hatchback:

BorB'

CorC'

;.ttr" CONNECTOR

LEFT

ON

o-

\:,,/

--o

o-

/-\

-o

OFF

RIGHT

ON OFF

lp

LEFIII lb

8' O

BULB

ll

RIGH]II ll B

CeilingLight Test/Replacement 5.

With moonroof:

Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.

1 . T u r n t h e l i g h ts w i t c h O F F . 2.

Pry off the lens. \

3.

Removethe two mountingnuts, then pull out the housing.

Teminal

t"",t*

-l\

OFF

DOOR ON

BorB'

ooo-

\-/ /:\ \:./ /:\ \:,/

c

D

--o --o --o

3P CONNECTOR

)

LENS

4.

From No. 43 l?.5 A) FUSE (ln the undeFhoodfuserelaybox)

Disconnect the 3P connectorfrom the housing.

I 23-183

Ceiling/Trunk/Cargo Area Lights, Spotlights CeilingLight Test/Replacement Without moonroof:

5.

Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.

1. Turn the light switch OFF. 2.

Pry ofl the lens.

3.

Removethe screw, then pull out the housing.

\

rermrnal

BorB'

Position OFF

DOOR ON

ooo-

/1 /A

/a\

\:,,/

CONNECTOR

HOUSING

4.

Disconnect the 3P connectorfrom the housino.

From No, i(} {7.5A} FUSE (ln the under-hood fuse/relay box) A

( {\> (

owt

!.

z ' \. OFF

0N D

l

f,o

B' To DOORI

23-1a4

l

c

D

--o --o --{.J-

--o

ti! Cargo Area Light Test/ Replacement(Hatchbackl

Trunk Light Test/Replacement {Sedan)

1.

Prythe cargoarealight lensout of its housing.

1 . O p e nt h et . u n kl i g h tc o v e r .

2.

Pry out the light assembly.

2.

Pry out the light assembly.

3.

Disconnect the 2P connectorfrom the housing.

3.

the 2P connectorfrom the housing. Disconnect

4.

Makesure that the bulb is OK. Checkfor continuity betweenthe A (+)and B (-) terminalwith the cargo arealight switchON.

4.

Make sure that the bulb is OK. Checkfor continuity betweenthe No. 1 and No. 2 terminals.

2PCONNECTOR

2P CONNECTOR

EULB(3.4W)

A l+)

B{ - t

trT ' t l 'l l

ll |

l

From No. a3 (7.5Al FUSE (lnthe under-hood fuse/r€laybox)

'

tt

r

)

'

23-185

Ceiling/Trunk/Cargo Area Lights, Spotlight Latch Switch Test/Replacement Sedan:

Hatchback:

1.

Openthe trunk lid. and disconnectthe 2p connector from the trunk latchswitch.

1.

Open the hatch, and disconnectthe 6P connector from the hatchlatchswitch.

2.

Thereshouldbe continuitybetweenthe A and B termtnats.

2.

Thereshouldbe continuitybetweenthe A and B terminals. 2P CONNECTOR

O O lf necessary,remove the three mounting bolts to pull out the hatch opener actuatorfrom the latch, then disconnectthe lock rod from the hatch latch switch and the actuator rod.

TRUNKLA

lf necessary, removethe threemountingboltsto pull out the trunk latch switch from the trunk lid, then disconnectthe lock rod from the trunk latchswitch. Disconnectthe trunk openercable from the truok latch switch.

TRUNKLATCH SWITCH

23-146

R e m o v et h e t h r e e m o v t i n g b o l t s t o p u l l o u t t h e hatch latch switch. ACTUATOR ROD

Back-upLights CircuitDiagram

IGNITION

swlTcH

FUSEi RELAY BOX UNOER.HOOD

YEL

I

EACK.UP LIGHT swtTcH / / onlhe \ r I ransnBgonI

SnoriARr*r.r r*i

)

(3;f;iil're' )V (oN posirion h

[E )

l"

I

GRN/BLK

GRN/BLK

I

GRN/BLK

zA arcx.up J LIGHTS

I P '

f

II

r:zce'21

I

TRAILER L]GHTNG CONNECTOR

BLK

I

I

II

G503

23-147

Back-upLights Test ManualTransmission:

Automatic T.ansmission:

NOTE:Checkthe No. 19 (7.5A) fuse in the underdash fuse/relaybox beforetesting.

NOTE:Checkthe No. 19 (7.5A) fuse in the under-dash fuse/relaybox beforetesting.

l.

Test the back-uplight switch by placingthe shift leverin reverseandturningthe ignitionswitchto ON f lr ) .

'1. Test the back-uplight swirch by shifting the shift leverto @ and turningthe ignitionswitch ON (ll).

2 . lf the back-uplightsdo not go on, check the back2 . lI the back-uplightsdo not go on, check the back-

up light bulbs in the taillightassembly.

up light bulbs in the taillightassembly. 3 . lI the fuse and bulbsareoK, disconnectthe connector from the back-uplight switch.

l f t h e f u s e a n d b u l b s a r e O K , d i s c o n n e ctth e 1 4 P connectorfrom the A,/Tgear positionswitch (backup light switch).

View from terminalside terminalside

A

B

C

D

E

F

G

A

6

SWITCH25 N.m (2.5 kgf-m, '18 lbf-Ir)

4.

This washermust always be replaced for the switch to tunction properly and 10 preventoil teaKs,

With the shift leverin reverse,check for continuity betweenthe A and B terminalswith the switch installed. There should be continuity. a It there is no continuity,replacethe switch (see s e c t i o n1 3 ) . a lf thereis continuity,but the back-uplightsdo not go on, check for: - P o o rg r o u n d{ G 5 0 3 } An open in the wire

Move the lever back and torth at the E position without touching the push button, and check for continuity between the C and D terminals.There shouldbe continuitywithin the rangeof free play of the shilt lever. a lf there is no continuitywithin the rangeof free play,adiuslthe positionot the A/T gear position switch {see section 14}. a lf thereis continuity,but the back-uplightsdo not g o o n , c h e c kt o r : - Poor ground {G5O3) - An open in the wire

BrakeLights CircuitDiagram )

'ry

UNDER.HOOO FUSE/RELAY BOX

WHTiGRN

BRAKE SWITCH (O,lI pushed)

WHT/GF

I

HONN INTEFLOCK

GRNA{HT

J

l GRNMHT

,#,.^{. LEFI BRAKE LIGHT (32CP)

il

: l i

l_t

INNEN TAIILIGHT

I 23-189

Brake Lights HighMount BrakeLight Replacement (LEDtypel

BrakeSwitch Test t.

lf the brake lights do not go on. checkthe No. 52 {20 A) fuse in the under-hoodfuse/relaybox, and t h e b r a k el i g h t b u l b si n t h e t a i l l i g h ta s s e m b l ya n d high mount brakelight.

2.

lf the fuse and bulbs are OK, disconnectthe 2P or 4P connectorfrom the brakeswitch.

Without c.uise control syst€m

t

l

tLatl

\c

\

TAILGATESPOILER

Wilh cruise control sYstem A

-/B

ran l - l

1. Removethe tour screws and the high mount brake light, then disconnectthe connectors.

B

FS-A ll ,t - -t ! L t

,Z-\ C

D

HIGH MOUNT BRAKE LIGHT {tED TYPE}

t

3 . Checkfor continuitybetweenthe B and C terminals. There should be continuity with the brake pedal pusneo. a lf thereis no continuity,replacethe switch or adjust pedal height (see section '19). o It there is continuity,but the brakelightsdo not go on, inspectfor: Poor ground (G5O3) An open in the wire

23-190

High Mount BrakeLight Replacement(Bulbtype) Hatchback:

Sedan:

1 . O p e nt h e h a t c h .

1 . Openthe trunk lid, and disconnectthe 2P connector from the high mount brakelight.

2 . Removethe two clips and the cover.

2 . Removethe two nuts, then removethe high mount 3.

R e m o v et h e t w o n u t s a n d t h e h i g h m o u n t b r a k e light,then disconnectthe 2P connecror.

brake light from the rear shelt.

2P CONNECTOR

Turnthe socket45o counterclockwise to removethe bulb.

3.

Installthe high mount brakelight in the reverseor der of removal.Cleanthe rearwindow qlassbelore installingthe light.

5 . Installthe high mount brakelight in the reverseorder of removal,and cleanthe rearwindow glassbetore installing. CAUTION: When installingthe high mount brake light, make sure the rubber seal fits against the reai window evenly.

)

23-191

Side Marker/TurnSignal/HazardFlasherSystem Component Location

TURf{ SIGNAL INDICATOFLIGHYS (ln the gaugoassembly) page23-122 EulbLocations, HAZARDWARNING SWITCH Replacement,pago 23-195 Test, pag€ 23-195

COMBNANONLIGHTSWTTCH Replacement.page 23-168 Test,page 23-166

FUS€/RELAYBOX

i l

r-.1uuij ffi-------r---

----------rn

tjt

+ _

t

LJJ

n u

l

l

?UBN SIGNAL/HAZARDRELAY Input Test,page 23-'194

I 23-192

CircuitDiagram UNDER DASH FUSE/FELAY BOX

UNDEB HOOD FUSUBELAY 8OX

COMEINATION LIGHTSWITCH

N0.41(100A) No.5l(l5A)

wHT---{.

V

rcr-

RED/GRN

rclrrtorswror

+WNT WHT/BLK

BLK/YEL

WHT/GRN

TRUNSIGNAL

swrTcH

F

(Notused)

GBN/ORN GRNioRN-

GFN/BLU

RED

tt ll

r l I

GFNBLUGRIVBLU

-]JJ GRNALU

GRN/BLU

I V V

t

GRNIELU TRATLER RN/YE L|GHTING I I CONNECTOR

t

*f --.f ,-+r*n"+ T B LK

GRN,YEL

t

I

OASHLIGHTS BFIGHTNESS CONTROLLEH

t t o l I RE,

lo'

8LK

8LK

I G201

)

G401

23-193

Side Marker/TurnSignal/Hazard FlasherSystem Turn Signal/HazatdRelay Input Test \

S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e SRScomponentlocations,precautions,and procedures in the SRSsection(23)beforeperformingrepairsor ser-

relayfrom the under1 . Removethe turn signal/hazard dash fuse/relaybox. 2 . Inspectthe relayandsocketterminalsto be surethey are all making good contact. a lf the terminalsare bent,looseor corroded,repair them as necessary,and recheckthe system. a lf the terminalslook OK, make the tollowing in put tests at the socket. lf a test indicatesa problem,find and correct the cause,then recheckthe system. - lf all the input tests prove OK, the turn signallhazad relay must be faulty; replacejt.

FUSE/RELAY UiTDER.DASH

aox

TURNSIGNAL/ HAZANDRELAY

t No. Telminal

Test condition

Test: Deaired result

Possiblecause it result is not obtained

Check for continuityto ground: . P o o rg r o u n d( G 2 0 1 ,G 4 0 1 ) . An open in the wire There shouldbe continuity. . B l o w nN o . 2 0 ( 1 0 A ) f u s e i n t h e l g n i t i o ns w i t c h O N ( l l ) Check for voltageto ground: and hazard warning There should be battery voltage under-dashfuse/relaybox . Faulty hazardwarning switch switch OFF . An open in the wire . Blown No. 43 ('10 A) f use in the lgnition switch OFF and Check lor voltage to ground: hazard warning switch There should be battery voltage. under-hoodfuse/relaybox . Faultyhazardwarning switch ON . An open in the wire . Poorground(G201,G301,G401, Hazardwarning switch Hazard lights should come on. is ON; connectthe B cs03) . Faulty hazardwarning switch terminalto the L . An open in the wire rermtnat. . Faultyturn signalswitch l g n i t i o ns w i t c h O N ( l l ) Right or left turn signal lights . An open in the wire and turn signal switch should come on. in right or left; connect the B terminal to the L rermtnat,

HazardWarning Switch Replacement CAUTION: Be carefulnot to damagethe switch and console panel.

HazardWarning Switch Test 1. Removethe hazardwarning switch. 2,

1.

Prythe hazardwarningswitch out of the centervent.

2.

Disconnect the 10Pconnectorlrom the switch.

Checktor continuitybetweenthe terminalsin each switch positionaccordingto the table.

Terminal

B

c

D

F

H

Position

o

OFF

o o

e) o

o

ON

oo

o o o

P!'t

O

HAZARD WARNING

1OPCONNECTOR

A B C D

I

oNt

I LEFI

r'**' (,0,,,

23-195

StereoSound System ComponentLocationIndex NOTE: The originalradio has a coded theft protection circuit. Be sureto get the customer'scode numberbetore - disconnectingthe battery. - r e m o v i n gt h e N o . 4 7 ( 7 . 5A ) f u s e f r o m t h e u n d e r hood fuse/relaybox. - removingthe radio. After service,reconnectpower to the radio and turn it on. Whenthe word "CODE" is displayed,enterthe customer's 5 digit code to restoreradiooperation.

STEREORADIO/CASSETTE PLAYER Removal,page23-199 Terminals,page23 200

RIGHTTWEETER page23'200 Replacement,

BIGHTREAR SPEAKER page23-201 Replacement,

DOOR SPEAKER Replacement,page 23-2OO

LEFTREAR SPEAKER Replacement,page 23,201

23-196

POWERANTENNAMOTOR Test, page 23-202 page 23-203 Replacernent,

Sedan:

STEREORADIO/CASSETTE PLAYER Removal,page23'199 Terminals,page23-200

* RIGHTTWEEIER page23-200 Replacement.

*: USA FRONTPASSENGER'S

ooon

SPEAKER Beplacement, page23-200

)

DRIVER'S DOOR SPEAKER page23-200 Replacement,

LEFT SPEAKER page23-201 Replacement,

Hatchback/S6dan: . ANTENNAMAST page23'203 Replacement, page23-204 Installation, . ANTENNATUBE page23-205 Replacement,

POWERANTENNAMOTOR Test,page23-202 Replacement,page 23-203

)

23-197

Stereo Sound System CircuitDiagram FUSE / RELAY BOX UNDER.HOOD No4l (100A)

No42(40A)

UNDER.DASH FUSE/RELAY BOX

WHT/RED

(7.5A) N0.30 FUSE

UNDER,DASH FUSE/RELAY BOX

f7

I

RED/BLK

t

W HTiRED

FRONT PASSENGER'S

oooR

r cV \

STEBEO RADIOi CASSETTE PLAYER

SPEAKER

RED/GRN

MAST ANTENNA

-ll

BLU,YEL

rn a

- t t l GRY/rrVHT

ANTENNA LEAD

LEFT REAB SPEAKER

;\ \:/

-ll

REO/YEL

ERNMHT- { t l

POWER ANTENNA MOTOR reraded lully) {wilhlheantenna 8LK

I

G503

23-198

BLK

I

G551

o

=4

x! \:/

RIGHT REAR SPEAKEB

Unit Removal NOTE: The originalradio has a coded thelt protection circuit.Besureto get the customer'scodenumberbefore - disconnectingthe battery. - removingthe No. 47 (7.5A) fuse in the under-hood fuse/relaybox. - removingthe radio. After service.reconnectpowerto the radioandturn it on. When the word "CODE" is displayed,enter the customer's 5-digit code to restoreradio operation. '1.

Removethe center console(seesection 20).

2.

R e m o v et h e c i g a r e t t el i g h t e ra s s e m b l y( s e ep a g e 23-2131.

Removethe four mountingscrews,then removethe front console.

FRONTCONSOLE

) Loosenthe two mounting screws.then disconnect t h e 1 6 Pc o n n e c t o ar n d t h e a n t e n n al e a d ,a n d D u l l out the stereo radio/cassetteplaver.

16PCONNECTOR

ANTENNASUB-LEAD

23-199

Stereo Sound System Stereo Radio/CassettePlayer

Terminals

Front Speaker/Tweeter Replacement Front Sp€aker: '1.

Carefullypry out the speakercover.

2.

Removethe three screws,then disconnectthe 2P c o n n e c t o rf r o m t h e s p e a k e r ,a n d r e m o v et h e speaKer.

\

FoTANTENNA LEAD

A / / 1

oItt FRMINAL

\

7

)I 2P CONNECTOR

a9- --

T€rminal

Wire

------->

A 16

Connecta to

AI

RED/GRN Frontpassenge.'s doorspeaker @

A2

BLU/GRN Driver'sdoorspeakerO

A3

RED/BLK Lights-onsignal WHT/BtU Constantpower(Tuningmemory)

A4 A5

YEL/RED ACC {Mainstereopowersupply)

A6

YEL/GRN Radioswitchedpower1Toantenna)

A7

BLU/YEL Left rearspeaker@

A8

RED/YEL Rightrearspeaker @

A9

BRNiBLK

A10 A11

GRY/BLK Driver'sdoorspeaker O (notused)

A13

{notused) (notused)

A14

BLK

1.

Removethe door panel and disconn€ctthe tweeter 2Pconnector.

2.

Removethe two screws,then removethe tweeter ano cover.

G r o u n {dG 5 5 1 )

GRY,ryVHTLeft rearspeakerO

A16

8RNAVHT

23-200

Tweoter:

Frontpassenger's door speakerO

A15

Rightrearspeaker O

SPEAKER COVER

2P CONNECTOR

Rear Speaker Replacement Sedan:

Hatchback: l.

Removethe speakercover.

1,

Removethe three screwstrom the trunk side,then femove the speakercover.

2.

Removethe three screws,then disconnectthe 2P connectorfrom the rearspeaker.

2.

Remove the four screws,then disconnectthe 2P c o n n e c t o rf r o m t h e s p e a k e r ,a n d r e m o v e t h e speaker.

LEFTREAR SPEAKER

OUARTERTRIM PANEL

I

z>-

I

SPEAKERCOVER

|

I.EFTREAR SPEAKER 2P CONNECTOB

2P CONNECTOR SPEAKERCOVES

)

REARTRAY

I 23-201

Stereo Sound System Powel Antenna Motor Test 1 . Removethe quartertrim panel(Hatchback)or trunk side trim panel {Sedan).

ANTENNAMAST

Disconnect there 3P connectorfrom the motor, and removethe connectorfrom its clamp.

3 . Checkfor power to the motor at the connectorlerminals: a There should be battery voltage between the WHT/RED { + ) a n dB L K{ - ) t e r m i n a lasl l t h e t i m e . a There should be battery voltage between the YEL/GRN(+) and BLK(-) terminalsonlywiththe ignitionand radio switched ON. Test motor operation: EXTEND:Connect battery power to the "A" and "B" terminalsand groundthe "C" terminal.

c

lwith tho anronn6rotractodlully)

"B" RETRACT:Then disconnectpower from the terminal. StickingAntenna: The antennasticks in either the up or down position. WHT/RED

BLK

Ttffili u/^

1.

Usingthe antennawrench,removethe antennanut. spacer(seepage23-203).

2 . Cleanthe antennamast housingthreads,and reinstall the spacer.

YEL/GRN

PLASTICSLEEVE

lf the motor lails to run or does not run smoothly, replaceit.

ANTENNA MAST

Tighten the antenna nut with the antenna nut wrenchto 2.3 N.m {O.23kgf.m, 1.7 lbf.ft}.lf you overtightenedthe nut, the antenna may slick. lf stickingoccurs, back the nut off a little, then turn the radioon and off to raiseand lower the antenna again. Repeatuntil the antennamoves lreely.

\

J

PowerAntennaMotor Replacement 1 . Removethe quartertrim panel(Hatchbacklor trunk side trim panel (Sedanl.

2 . Disconnectthe 3P connectorand antennaleadfrom the motor.then removethe antennanut and motor bracketnut.

Antenna Mast Replacement Removal: NOTE: The antennamast alonecan be replacedwithout havingto removethe power antennamotor. 1.

Removethe antennanut and spacer.

2.

Carefullywithdraw the antennamast while extending it by turning the radio switch ON.

ANTENNA NUT 2.3 N.m {0.23 kgf'm, 1.7 tbf.trt ANTENNANUT SPACER

ANTENNA MAST DRIVE CABLE ANTENNA NUT WRENCH

07JAA-001000C

\..

3P CONNECTOR

) 2.3 N.m (0.23kgf.m,1.7 lbf.ftl

DRAIN HOSE

3 . Remove the motor and antenna as an assembly. NOTE: Tighten the antennanut, then tighten the motor bracketnut.

POWERANTENNA MOTOF UNIT

I 23-203

Stereo Sound System Mast Antenna Installation Carelullydirectthe teeth of the antennamast drive cableas shown, and insertthe drive cableinto the antennahousino.

6.

Tightenthe antennanut. 2.3 N.m (0.23 kgf.m. 1.7 lbf.ftl NOTE: Therearetwo types of antennanuts - those with an O-ring(new type) and those without an Oring(oldtype) - which requiredifferentspace.s.To preventa leak, make sure that - thereis no antennacollarsealin the antennacollar when usinga nut with an O-ring.lf necessary, removethe seal. - there is an antennacollarsealinthe antennacollar when usinga nut without an O-ring.It necessary, installa seal. - the spacermatchesthe type of antennanut.

With an O-ring:

Without an O-ring:

ANTENNA NUT__.\

a€^1 .i*-lr

Diroction ol th6 teeth

ANTENNA NUT

6d{ .i*-.-r

O-RING

SPACER

(Q\ Checkfor engagement of the cableteethto the drive gear by caretullymoving the cable up and down. Cleanthe antennamast housingthreads.

ANTENNA

Vorr.""o _/coLrjlR t'o'6

Turnthe radioswitch "OFF", and let the motor pull the drive cable insidethe antennahousing. Installthe bushingand spacer.

7 . Checkthat the antennamast extendsand retracts fully when the radio switch is turned ON and OFF repeatedly.ll you overtightenthe nut, the antenna may stick. lf stickingoccurs.back the nut of{ a little, then raiseand lower the antennaagain.Repeat until the antennamoves freely.

s

23-204

J

1 . Removethe antsnna mast (seepage 23-2031.

With an alignmant m!*:

2 . Removethe antennatubs/motor assembly(seepage 23-2031. Removethe tube clampingscrew, and pull the antenna tube out of the motor. 4.

Removethe plasticguideand plasticinsulatortube, and installthem in the new antennatube.

ALIGNMENT MARK

CLAMPING SCREW

CONNECTOR HOLDER Wilhout an allgnmont hark: PLASTIC INSULATOR TUAE

) ADJUSTTHE SO THAT THE COLLARFITSTHE CONTOUBOF THE BODY.

PLASTIC GUIOE

5 . lnsert the new antennatube.

WHEN THE ALIGNMENT MARK IS CORRECT, TUBEAND MOTOR.

With an alignm6nt ma.k: - Insertthe new antennatube into the motor, and align the mark on the tube with the screw that is used to clamp the tube to the motor, Without an alignmont markr - Insen onlv the tube, and installthe tube/motor assemblvin the car. - Adjust the tube so that the collar lits properly againstthe body. and mark the tube and motor. - Removethe tube/motorassemblyagain. - Align the mark on the tube with the mark on the motor, and tighten the clampingscrew.

o.

Installthe tub6/motor assembly in th€ car (see page 23-203t.

7.

Insertth€ mast into ths tube (seepage 23-204).

I 23-205

Clock CircuitDiagram CAUTION: a Prv the clock out at the left side. a Be careful not to damagethe clock and the dashboard when prying the clock out.

BATTERY

1.

Pry the clockout from the dashboard.then disconnectthe 4Pconnector. 4P CONNECTOR

UNDER,HOOD FUSE/RELAY BOX

WHT/BLU

WI-]T/BLK

I

A

/ BAT

wHT 8LU lalSTEREO BADIOi CASSETTE PLAYEF

CLOCK

TION I 1GN

-|" -v

No3o(7.sA)

Y*"t

Terminals

F'nrrn l

I

BLK

G201 G401

23-206

BLK

Ground r G 1(Main clock power sup-

B

YEL

c

RED/BLK

D

Constant power WHT/BLU (Time memory)

pry, Lights-on signal

Ho rn

J

ComponentLocationlndex S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e SRScomponentlocations,precautions,and procedures in the SRSsection{23)beforeperformingrepairsor servtce,

HORN Test,page23 211 HORNSWITCHES Test,page 23-209

{---=-\s ":=',-i=

CABLEREEL page23 322 Replacement, UNDER-DASH FUSE/BELAY BOX

i l -rrj

_LJLi

.r ----------;-t -----,-------

lJJJ

I

-

- tL I t---

HORNRELAY I Wire colo6: WHT/GRN,WHT/GRNI and BLU/REO LBLU/GRN, I Test,page 23-70

)

23-207

UNOEF.HOOD FUSARELAY BOX

CRUISE CONTROI SET/RESUME SWTCH ($/-ihc.uteconrol)

23-208

\-J

I

Switch Test SRScomDonentsare located in this area. Reviewthe SRScomponentlocations,precautions,and procedures in the SRSsection(23)beforeperformingrepairsor servtce.

Removethe dashboardlowercoverand kneebolster (seepage23-71). Disconnectthe cable reel 3P conneclorfrom the main wtre narness.

NOTE:The originalradiohasa codedthett protectioncircuit.Be sureto get the customer'scodenumberbeJore - disconnectingthe battery. - removingthe No. 47 (7.5A) fuse from the under-hood fuse/relaybox. - removingthe radio. After service,reconnectDowerto the radio and turn it on. When the word "CODE"is displayed,enterthe customer's 5-digitcode to restoreradio operation 1.

Disconnect the batterynegativecable,then disconnectthe positivecable,and wait at leastthree minuIes. Disconnect eachairbagconnector. Driver's Side: a Removethe accesspanelfrom the steeringwheel, then disconnectthe 2P connectorbetweenthe driver'sairbagand cablereel.

)

Front Passenger'sSide: . Removethe glove box, a Disconnectthe 2P connectorbetweenthe front passenger's airbagand SRSmain harness.

CABLEREELSUB.HARNESS 3P CONNECTOR

Checkfor continuitvbetweenthe No. 2 terminal of the cable reel sub-harnessand body ground with the horn switch Dressed.

-t-

r-P r 1 1 2 3 l terminalside

I I

It thereis continuity,the horn switchis OK. a lf thereis no continuity,go to step6.

(cont,d)

23-209

Horn Switch Test (cont'd) Removethe driver's airbag assembly(referto the SRSsub-sectionin section23).

lf all tests prove OK, reinstallthe driver's airbag assembly(re{erto the SRSsub-sectionin section23).

Checkfor continuitybetweenthe No. 2 terminal of the cable reel sub-harness3P connectorand horn Dositiveterminal.

9 . Reconnectthe driver'sairbagconnectors,and reinstallthe accesspanelon the steeringwheel.

1 0 . Reconnectthe front passenger'sairbag connector, and reinstallthe glove box. HORNPOSITIVETERMINAL

1 1 . Connectthe batterypositivecable,then connectthe negativecable. 1 2 . Atter installingthe airbagassembly,confirmthat - the SRSindicatorlight shouldcome on for about six secondsand then go off with the ignitionswitch oN 0t). - the horn soundswith the horn buttonpressed.

a lf there is no continuity.replacethe cablereel. a lf there is continuity,replacethe horn switch.

23-210

J

HornTest 1.

Removethe front bumper(seesection20). Disconnect the 1Pconnectorfrom the horn.

lP CONNECTOR

BOLT MOUNNNG IBODYGROUND}

Test the horn by connectingbattery power to one terminaland groundingthe body ground.The horn s h o u l ds o u n d . lf the horn failsto sound,checktor: - taultyhorn assembly. - faulty mountingbolt.

GigaretteLighter CircuitDiagram

UNDER.HOOD FUSURELAY 8OX

3o{75A) J-

Y

Lit*is***/

BLK

I

r'

OASHLIGHTS ERIGHTNESS CONTFOLLER

G201 G401

23-212

J

1 . Removethe two ashtraymountingscrews.Thenpull out the ashtrayfrom the front console panel.and disconnect the 4Pconnector.

2 . Disconnectthe thermofusecase from the socket end. Remove the thermal protector, and pull out the cigarettelighter socket. CIGARETTELIGHTER LTGHTt1.4 Wl ASHTRAY LIGHT

t 1 . 4W l

EULBCASE

FRONTCONSOLE PANEL

THERMOFUSE CASE RINGNUT

THERMAL PROTECTOR

scREws ) ASHTRAY ILLUMINATION RING

CrcANETTELIGHTER

socxET

When installingthe cigarettelighter,align each lug on the face panel, illuminationring, and cigarette lightersocket with the grooveof the hole.then positionthe bulb housingon the thermalprotectorbetween the stops in the consolepanel. 5 . Make sure that the ground wire, bulb socket, and thermofusehousingare seatedto the cigarettelighter assembly.

l \ 23-213

Rear Window Defogger ComponentLocationIndex UNDER.OASH FUSE/RELAY BOX

r-'luijij

u

l

NEARWINDOW DEFOGGER SWITCH Removal,page23-217 Test,page23 217

REAR DEFOGGER REI-AY Test,page 23-69

Description The rear window de{oggeris controlledby the integratedcontrol unit. Pushingthe detoggerswitch in the Instrument panelsendsa signalto the defoggertimer in the integratedcontrol unit, and the defoggerstays on for 25 minutesor until the ignitionswitch is turned off. The indicatorlight in the switch comes on when the defoggerworks.

23-214

CircuitDiagram CNTION

UNDEFHOODFUSE/RELAY BOX No41(100A)

swrTcH

N0.42(40A)

+ WNT/BLK

/ 8AT \

T ",7-l

WHT

II II

--l

ELKGRN

BtK/GRN

BLI(RED

1 A T L-]

REAR

wtNDow

DEFOGGER SWITCH

REAR WiNDOW DEFOGGER

l l t l

BLK

J

t l

I

t l -

II

DASHLIGHTS B RC H T N E S S CONTROLLER

l

Hatchback:G771 Sedan iG503

G201 G40l

G201 G401

23-215

RearWindow Defogger Troubleshooting NOTEr The numbersin the table show the troubleshootinoseouence Item to be inspected

o

=

s ; ! i 6

< : o

F

';i

!

O

.9

Symptom

.E

>=

;

; €

ao

9 c

{ o

a 5

3tr

,

ta

OJ

' - c

o)

o i f

u-

O =

c

o

o

Defoggerworks, but indicator light does not go on. Defoggerdoes not work and indicatorlight does not go on.

BLK/YEL or BLU/YEL

Defoggerdoes not work, but indicatorlight goes on. Operationtime is too long or too short (normaloperationtime is 25 minutes).

23-216

G201 G401

3 1

,]

2

3

YEL,BLU/YEL or BLK/YEL

G 77 1 BLU/YELor BLK/YEL G 5 0 3 BLK/GRNor BLK/WHT

Switch Test

Switch Removal )

CAUTION: Be carelul not to damagethe heater control/centerair vent. 1. Carefullypry the switch out oI the heater control/centerair vent. 2.

Disconnect the 6Pconnectorfrom the switch.

NOTE: Be careful not to damage the heater control/centerair vent. '1.

Carefullypry the switch out of the heater control/centerair vent.

2.

Checktor continuitybetweenthe terminalsaccord ingto the table.

\

Terminal

6P CONNECTOR

PUSHED

RELEASED

c

B

pLN-_\

/:\ \:./

o ooo-

\:/ /:\ \:,/ /:\ \:./

D

-o o-

E

F

-o -o

_o -o

REARWINDOW DEFOGGERSWITCH

.

l

Removethe indicatorbulb (turn the socket 45o bulb. andremovethe illumination counterclockwise), REARWINDOW SWITCH DEFOGGER

I

INDICATORBULB (o.84 W)

23-217

RearWindow Defogger FunctionTest

DefoggerWires Repair

CAUTION: Be caretul not to scratch or damage the defogger wires with the tester probe,

NOTE: To make an elfectiverepair,the brokensection must be no longerthan one inch.

1. Checktor voltagebetweenthe positiveterminaland body groundwith the ignitionswitch andthe defogger switch ON. There shouldbe battery voltage.

1.

Lightlyrub the areaaroundthe breakwith fine steel wool, then clean it with alcohol.

2.

Carefullymaskaboveand belowthe brokenportion of the defoggerwire with cellophanetape.

lf there is no voltage,check for faulty defoggerrelay. - faulty defoggerswitch. - faulty integratedcontrol unit. - an open in the BLK/GRNwire.

I

OPEN

lf there is battery voltage,go to step 2.

NEGATIVETERMINAL

POSITIVETEFMINAL CELLOPHANE TAPE

BBOKENWIRE

3,

Usinga smallbrush,applya heavycoatof silverconductivepaintextendingabout 3 mm (l /8 in) on both sidesof the break.Allow 30 minutesto dry. NOTE: Thoroughly mix the paint before use.

2 . Turn the rearwindow defoggerswitch OFF.Check for continuity between the negativeterminal and body ground. a lf there is no continuity,checkfor an open in the defoggerground wire. a lf there is continuity,go to step 3.

3 . Touch the voltmeter positivelead to the halfway point of each deloggerwire, and the negativelead to the negativeterminal. Thereshouldbe approximately 6 V with the ignition switch and defoggerswitch ON, a lf the voltageis as specified,the defoggerwire is OK. a lf the voltageis not as specified,repairthe defoggerwire: lf it is more than 6 V, look for the damageon the negativehalf on the grid. lf it is less than 6 V, look for the damageon the positivehalf of rhe grid.

23-214

Check for continuityin the repairedwire. Apply a secondcoat of paint in the same way. Let it dry three hours before removingthe tape.

I

Moonroof

. J

Component Location Index

)

J wire colors:GRN/BLK,] IWHT, GRNand BLK I Test, page 23-68

I 23-219

Moonroof CircuitDiagram \ ,

UNDER,HOOD FUSEiRELAY8OX No41 (100A)

IGNITON SW]TCH

N0.42(40A)

BLK

M MOONROOF M0TOR(Harchback)

MOONROOF M0TOR(Sedan)

G201 G401

23-220

ElectricalTroubleshooting NOTE: The numbersin the table show the troubleshootingsequence.

Item to be insDected

c P E

' o6 xc : Ya b p o

s

qE: b=6'9 * d-9 * i 9

?3;

.:3

o 6 b

Moonroof does not move, but motor turns. Moonroot does not move ano motor does not turn {moonroof can be moved with moonroot wrenchl.

ln all switch positions

E 3 g

< ! H 6

xi

-9 o

B

E

t ? c

3 € Symptom

!

6 \

q i : 6

o c

F

c.9

1

o 6

1

E

G401

WHT, GRN/BLK, GRN,BLK

With OPEN swttcn

GRN/RED

With CLOSE swttcn

GRN/YEL

I 23-221

Moonroof FunctionTest 1 . Remove the dashboard lower cover. and if neces-

3 . Checkfor continuitybetweenthe No. 2 terminaland body ground.

sary, remove the knee bolster.

a lf there is no continuity,check for - a n o p e n i n t h e B L Kw i r e . p o o r g r o u n d( G 2 O 1 G , 4O1). a lf there is continuity,go to step 4. 4.

Checktor voltagebetweenthe No. 4 terminal(+ ) a n d N o . 2 t e r m i n a{l - ) w i t h t h e i g n i t i o ns w i t c hO N (ll). There should be battery voltage. .

lf thereis no batteryvoltage,checkfor - b l o w n N o . 4 9 ( 3 0A ) f u s e i n t h e u n d e r - h o o d f u s e / r e l a yb o x o r N o . 2 4 1 7 . 5A l f u s e i n t h e fuse/relaybox. under-dash - an open in the wires (GRN/BLK, cRN, WHT)or looseterminals. - faultymoonroofrelay. . lf thereis batteryvoltage,go to step5. 5 . Connectthe No. 4 terminalto the No. 3 terminal, andthe No. 1 terminaltothe No. 2 terminalwith jumper wires. The moonroolshouldopen when the ign i t i o ns w i t c h i s t u r n e dO N ( l l ) .

KNEEBOLSTER

lf the moonrool opens, check the moonroof swttcn. lf it doesn'topen,removethe headliner andcheck the motor.

LOWER COVEB

2.

Carefullypry the switch out of the left side air vent panel,then disconnectthe 4P connectorto remove the switch.

CONNECTOR MOONROOFSWITCH

.

F-_1

,

1 1 2 l

r t 10 l 1 3 View from wire side

Switch Test

Motor Test

Removethe dashboardlower cover.

1 . Removethe headliner(see section 20).

Carefullypry the switch out of the left side ajr vent panel,then disconnectthe 4Pconnectorand remove the switch.

2 . D i s c o n n e ctth e 2 P c o n n e c t o rf r o m t h e m o o n r o o f moror. Checkthe motor by connectingpower and ground accordingto the table.

Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.

NOTE: Motor clutch test is in section 20. Terminal

\

B

;'..b;--\

CF O-

OFF

OPEN

D

--o -_o o- -_o _O

o-

CLOSE

c

Terminal ll\

\

B

Conditbn

OPEN CLOSE

o o

o o

o -o

MOONROOFSWITCH

)

{Hatchbackl

{Sedanl

View from terminalside

lf the motor tails to run or does-: run smoothly, reptace rt.

I

OPEN

,l \ { J O F F \,, CLOSE

?

)

23-223

Power Mirrors Component Location Index

POWERMIRRORS T€st,page 23-228 Replacom6nt,s6ction20 Mirror Actuator Repl6cemenl,page 23-229

FOWERMIRRORSWTCH FunctionTest,page23-227 Test.page23-226

I 23-224

I

CircuitDiagram UNDER.HOOD FUSE/FELAY BOX

YEL

-+-----t I.I-Zu',x I

UNDER,DASN FUSE/RELAY BOX

POWERMIRRORSWITCH

LEFT -

l_L______ ___l.l /t\--------

--lt\

YEURED.

( ):Hatchback

)

23-225

Power Mirrors Switch Test 1 . Removethe driver's door panel (seesection 2O). 2 . Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.

MirrorSwitch Terminal

\

Position

o-

OFF

UP

DOWN

o-

D

G

c

oG

LEFT

RIGHT

DOWN

o-

RIGHT

-o -o -o -o -o -o -o -o

oo-

o- -o

oooo-

-o -o

-o

o-

L LEFT

-G

o-

OFF

UP

-o

ooo-

F

-o

o-

R

23-226

E

\

-o -o -o -o

aaaaaaaa A-------->J

FunctionTest NOTE: To test, removethe driver'sdoor panel(seesection 20), then disconnectall of the connectorsfrom the ooor panet. vrllBtxt YEL/RED' aa*\

Left miror inoperative: Connectthe BLK,^/EL terminal of the 1OPconnectorto t h e Y E V R E D 1 t e r m i naanl d t h e Y E L / V H T( o r Y E L / B L K 1 ) terminalto body groundwith iumperwires. The left mirror shouldtilt down (or swing left)when you turn the ignitionswitchON (ll). a lf the mirrordoesnot tilt down (ordoesnot swing lett). check for an open in the YEL/WHT {or YEL/BLKr} wire betweenthe left mirrorandthe switch.lf the wire is OK, check the lett mirror actuaror. a lf the mirrorneithertilts down nor swings left, repair the YEL/REDrwire between the letr mirror and the swtlcn. a lf the mirror operates properly, check the mirror swttcn.

Right mirrol inoperative: Connectthe BLK/YELterminal of the 10Pconnectorto the BLU,^/VHT terminal and the YELMHT {or BLU/BLK) terminalto body groundwith jumperwires. The right mirror should tilt down (or swing left) when you turn the ignitionswitchON (ll). a lf the mirrordoesnot tilt down (ordoesnot swing left), removethe right door paneland checkfor an open in the YEL/WHT(orBLU/BLK) wire betweenthe rightmirror and the switch. lf the wire is OK, check the right mirror actuator. Mifior Test NOTE:Checkthe No. 17 {7.5A) fuse in the under-dash fuse/relaybox beforetesting. One or both inoperative:

a lf the mirrorneithertilts down nor swings lett, repair the BLU/WHTwire betweenthe right mirrorand the swrtch. a lf the mirror operates properly, check the mirror switch.

Checkfor voltagebetweenthe BLK//ELterminaland body groundwith the ignitionswitchON {ll). Thereshouldbe batteryvoltage. . lf thereis no voltage,checkfor: * Blown No. 17 (7.5 A) fuse in the under-dash fuse/relaybox - An openin the BLK/YEL wire . lf thereis batteryvoltage,go to step2. Checkfor continuitybetweenthe BLK terminaland body ground. Thereshouldbe continuity;checkfor. * An open in the BLKwire - Poorground(G501(sedan),G502)

)

23-227

Power Windows ComponentLocationIndex

UNDER.DASH FUSE/RELAY BOX

a

POWERWINDOWRELAY Test,page23-69

rrrr'---rnnrn

---t----,

Tl

.----r-

Ll

WINDOWSWITCH FRONTPASSENGER'S Test, page23 238 page23 239 Replacement,

POWERWINDOW MASTERSWITCH (Hasbuilt-incontroluniti InputTest,page23-234,236 Iesr, page23-23'1 ,238 page23'239 Replacement,

FRONTPASSENGER'S WINDOWMOTOF Test,page 23-240 RIGHTREARWINDOWSWITCH(Sedanl Test,page 23 238 page23-239 Replacement, RIGHTREARWINOOW MOTORlsedanl Test,page 23-240

\( \

DRIVER'S Test,page 23-240

LEFTREARWINDOWMOTORisedan) Test, page23 240

LEFTREARWINDOWSWITCH{Sedan) Test,page23 238 page23 239 Replacement,

23-230

CircuitDiagram(Sedan)

UNDEF.HOOD FUSE/RELAY BOX

UNDEF DASH FUSE/NELAY BOX

IGNITIONSWITCH

)

BLUIREDI swrrcH

BLK'

:. ,:5S rricot

)

RIGHTREARWINOOW MOTOR

LEFTREARWINOOW MOTOF

!c-:F

FRONT PASSENGECS WINDOWMOTOR

23-231

ir

Power Windows Circuit Diagram (Hatchback)

I'

FED/BLU

DRIVER'S WINDOW MOTOR

23-232

Troubleshooting NOTE: The numbersin the table show the troubleshootingsequence

Item to be inspected

E

dr€ .q

3 ; !

a 3

-9

E - !

3

z =

;

N

N F

Symptom

9 c

o i

z 3 6

d ) =

z ; 6

z ' 6

3

z

.= 3

B

;

E 3

.= 3

E ;

.E 3 !

.g i

o g

E B .g

;

@

3 E

oi

.z

!

o

o-

3

B

c

B

oG201 G401 G5 0 1 G502

2

Driver'swindow does not work.

2

Driver'swindow does not work in AUTO. Passenger's Rightfront windows do *Left rear not work. *Right rear

2 2

1

1 'l

t

?

c 6

o)

All windows do not work. 1

I

BLK/YEL WHT/RED

5

WHT/YEL

3

BLU, BLK/WHT

5

BLU/BLK

4

5

GRN/BLK

4

5

YEL/BLK

*: Sedan

)

t 23-233

Power Windows Master Switch Input Test (Sedan) NOTE: The control unit is built into the Dowerwindow masterswitch, and only controlsdriver'sdoor window oDeratrons. 1.

Bemovethe driver'sdoor panel,and disconnectthe 16Pand 1Pconnectorsfrom the masterswitch.

2.

Inspectthe connectorand socket terminalsto be sure they are all makinggood contact. a ll the terminalsare bent,looseor corroded,repair them as necessary,and recheckthe system. a lf the terminalslook OK, make the following inout tests at the conneclor. - lf a test indicatesa problem,find and correct the cause,then recheckthe system. - lf all the input tests proveOK, the power window masterswitch must be faultV;replaceit.

GRN/BLK

LT

i

BLK'

Vlew from wire side View trom wire side

23-234

Po$siblecause if result is not obtained

Test condition 1

BLK' and BLK3

U n d e ra l l c o n d i t i o n s

Check for continuityto ground: . P o o rg r o u n d( G 5 0 1 ,G 5 0 2 ) . An open in the wire Thereshould be continuity.

3

. Blown No. 24 (7.5A) fuse in the Check for voltageto ground: There should be battery voltage under-dashfuse/relaybox BLU/BLK . BlownNo.7, 8, 10or 11 (20Al fuse in the under-dashfuse/relaybox GRN/BLK . Faultypowerwindow relay YEL/BLK ' An open in the wire . Faultydriver's window motor connect rhe wHT/YEL Check the driver's window . An open in the wire a n d R E D / Y E Lt e r r m i n a l s , motorl I RED/BLU a n d t h e R E D / B L U l a n d It should run (the window and BLK3terminalswith jum- m o v e so o w n ) . RED/YEL1 per wires, then turn the i g n i t i o ns w i t c hO N ( l l ) . . Faultyfront passenger'swindow Connectthe BLU/BLK check the front passenger's motor andBLU/GRN t e r m i n a l s , wtnoow molor: BLU/YEL . An open in the wire It should run (the window and the BLU/YELand and BLK' terminalswith jum- m o v e s d o w n ) . BLU/GRN per wires, then turn the i g n i t i o ns w i t c hO N ( l l ) .

5

Connectthe GRN/BLK and GRNterminals,and GRN/YEL the GRN/YELand BLK, ano terminalswith jumper GRN wires, then turn the igni t i o n s w i t c hO N ( l l ) .

Check the left rear window motor: It should run {the window m o v e sd o w n | .

Faulty left rear window motor Faulty left rear window switch An open in the wire

6

Connectthe YEL/BLK and YEL/GRNterminals, YEL/GRN A N dt h c Y E L A N dB L K ' and terminalswith jumper YEL wires, then turn the ignit i o n s w i t c hO N ( l l ) .

Check the right rear window moror: It should run lthe window moves oownl.

Faulty right rear window motor Faulty right rear window switch An open in the wire

7

Connectthe WHT/YEL and RED/YELrterminals, BLU a n d t h e R E D / B L Uarn d and BLK3terminalswith jumBLK/WHT per wires, then turn the i g n i t i o ns w i t c h O N ( l l ) .

Connectan analogohmmeterto terminalsBLU and BLK/WHTI The meter needleshould move back and fonh ahernalelyas the driver's window motor runs.

Faulty pulser Faulty driver's window motor An open in the wire

WHT/YEL lgnition switch ON (ll) 2

)

I

J

23-235

Power Windows Master Switch Input Test (Hatchbackl NOTE: The controlunit is built into the power window masterswitch, and only controlsdriver'sdoor window ooerations.

POWERWINDOW MASTER SWITCH

1 . Removethe driver'sdoor panel,and disconnectthe

10Pconnectorfromthe masterswitcn. Inspectthe connectorand socket terminalsto be sure they are all makinggood contact. a lI the terminalsare bent,looseor corroded,reDair them as necessary,and recheckthe system. a lf the terminalslook OK, make the following input tests at the connectorterminals. - It a test indicatesa problem,find and correct the cause,then recheckthe system. - lf all the input tests proveOK, the power window masterswitch must be taulty; reDlaceit.

No.

Wile

Test condition

BLK/WHT BLK' BLKI

RED/YEL RED/BLU

BLU/GRN

BLU/BLK

View from wire side

Tgst: Desired result Check for continuityto ground: There should be continuity.

Possibls cause if result is not obtainsd Poorground(G502) An open in the wire

. Blown No. 24 (7.5A) fuse in the Check for voltageto ground: There should be battery voltage under-dash fuse/relaybox ' Blown No. 10,or No. '11(20A) fuse in the under-dash fuse/relaybox . Faultypowerwindow relay . An open in the wire . Faultydriver's window motor Connectthe WHT/YEL Check the driver's window . An open in the wire and RED/YELIterminals, motor: and the RED/BLU1 and It should run (the window BLK3terminalswith jum- moves oownl. per wires, then turn the i g n i t i o ns w i t c h O N ( l l ) . lgnition switch ON (ll)

Connectthe BLU/BLK and BLU/GRNterminals, and the BLU/YELand BLK2terminalswjth jumper wires, then turn the i g n i t i o ns w i t c h O N ( l l ) . Connectthe WHT/YEL and RED/YEL1 terminals. BLU and the RED/BLUIand and BLK3terminalswith jumBLK/WHT per wires, then turn the i g n i t i o ns w i r c hO N ( l l ) .

23-236

Check the passenger'swindow motor: It should run (the window moves oownl.

. Faulty passenger'swindow motor . An open jn the wire

Connectan analogohmmeterto . Faulty pulser . Faultydriver's window motor the BLU and BLK/WHTter. An open in the wire minals: The meter needleshould move back and forth alternatelyas the driver's window motor runs.

Master Switch Test (Sedanl 't 1 . Removethe driver'sdoor panel (see section 20).

Front Passenger'sSwltch:

,,

\

D i s c o n n e ctth e 1 6 Pa n d 1 P c o n n e c t o r sf r o m t h e switch. CheckJor continuitybetweenthe terminalsin each switch positionaccordingto the tables.

Terminal Position

I uain \ I Switch

J

\

OFF

UP

ON

s swtTcH OFF LEFT REAF SWITCH

G_ G*

ON OFF

MAIN SWITCH

DOWN POWERWINDOW MASTER SWITCH

ON OFF

L€ft Rear Switch: Terminal \ I Main \ Position I Switch \

o-

--o oo- --o G

OFF

)

RIGHT REAR SWITCH

J

UP A

B

C

D

E

F

ON OFF

G

ON

ooo-

DOWN OFF

o-

G- _O

--o

E

OFF

swtTcH

o --o --o --o

o-

ON PASSENGER'S

o

G

F

o

o- o --o o- --o --o --o o--o --o o- -o -o

H I J K L M N O

Right Rear Switch: Terminal \

o

Posirion | 35ii.r \

o

G-

ON OFF

o-._,f

OFF

.)-]--------{-) UP

ON OFF

I

J

Drivsr's Switch: The driver'sswitchis combinedwith the controlunit so vou cannot isolatethe switchto test it. Instead,run the master switch input test proceduresNo. 1, 2, 3. and 7 on page 23-234.lf the tests are normal, the driver's switchmust be faulty.

DOWN

ON

oFF

1

o c-l

___i--

--o

--o

o-

:----o

23-237

Power Windows Master Switch Test (Hatchback)

Passenger'sWindow Switch Test

Removethe driver's door panel (seesection 20).

Front: '1. door panel(seesectaon 20). Removethe passenger's

Disconnect the 10Pconnectortrom the switch. Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.

2.

Disconnect the 5P connectorfrom the switch.

3.

Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.

POWERwtNDOW PASSENGER'S MASTERSWTTCH swtTCH

\

Terminal

'*';__\

/ +\'ir=i;l,r \\ r

o- --o

OFF

'

.JJ#iill

ryfi'\

o- --o

UP

DOWN

Driver's Switch: The driver'sswitch is combinedwith the controlunit so you cannot isolatethe switchto test it. Instead,run the masterswitch input test p.oceduresNo. 1, 2, 3, and 5 o n p a g e 2 3 - 2 3 6 .l f t h e t e s t s a r e n o r m a l ,t h e d r i v e r ' s switchmust be iaultv.

c

o- --o

D

o- --o

o-'o o-

Real (Sedan): 1. Removethe inner handle(see section 20). 2.

Disconnect the 5Pconnectorfrom the switch.

3.

Checktor continuitybetweenthe terminalsin each switch positionaccordingto the table.

Passenger'sSwitch:

\

Terminal t"t-*

\

OFF

UP

DOWN

23-238

c

o- --o o- -_o

o-

D

--o

o- --o --o o--o o-

Master Switch Replacement -

I Hatchback:

Passenger'sWindow Switch Replacement Front:

1.

Removethe driver's door panel (seesection 20).

1.

doorpanellseesection20). Removethe passenger's

2.

Disconneclthe 10Pconnectorfrom the switch.

2.

Disconnect the 5Pconnectorfrom the switch.

3.

Removethe threemountingscrewsand the switch.

3.

Removethe two mountingscrews and the switch.

swtTcH Rear (Sedan);

)

.J

Sedan:

1.

Removethe inner handle(see section 2O).

1. Removethe driver's door panel (see section 20).

2.

Disconnect the 5Pconnectorfrom the switch.

2 . D i s c o n n e ctth e 1 6 Pa n d 1 P c o n n e c t o r sf r o m t h e swrtcn.

3.

Removethe two mountingscrewsand the switch.

3.

Removethe two mountingscrews and the switch.

wtNDow swrTcH

POWERMIRROR

swtrcH

5P CONNECTOR

I

scBEws

IN ER HATOLE

23-239

Power Windows Driver'sWindow Motor Test Motor Test:

Passenger'sWindow Motor Test 1 . Removethe passenger's doorpanel{seesection20).

'1.

Removethe driver's door panel (seesection 20).

2.

Disconnect the 4Pconnectorfrom the motor.

2.

Disconnect the 2P connectorfrom the motor. NOTE: a Frontpassenger's door is symmetricaltodriver's door. a The illustration showsthe rightreardoor.left rear door is symmetrical.

(

I

2P CONNECTOR

View from terminalside

4PCONNECTOR 3.

Test the motor in eachdirectionby connectingbattery power and g.ound accordingto the table. Terminal {B)

B {At

UP

o

@

DOWN

@

o

\ Direction

Viewfromterminalside 3.

Test the motor in eachdirectionby connectingbattery power and ground accordingto the table. Terminal

\

O'*"r*-T

B

UP

o

@

DOWN

@

o

CAUTION: When the motor stops running,disconnect one lead immediately. 4.

lf the motor does not run or fails to run smoothly. repracerI.

PulserTest: 5.

Connectthe test leadsof an analogohmmeterto the : and D terminals.

6. Run the -nororby connectingpower and groundto t h o A a n O8 : e r r n i n a l s . Thg ohmrneterneede shouldmove back and forth alternately,

23-240

CAUTION: When the motol stops running,disconnect one lead immediately. lf the motor does not run or fails to run smoothlv, repracerI.

Power Door Locks Component Location Index -) RIGHTREARDOORLOCKACTUATOR{Sedanl Test, page23-247 DOORKEY FRONTPASSENGER'S CYI-INDER SWITCH Test,page 23-248

HATCHKEYCYLINDER SWITCH(HATCHBACK) Test,page 23-250 LEFTREARDOORLOCKACIUATOR (Scdlnl Test,page 23'247

DOORLOCKACTUATOR FRONTPASSENGER'S lest, page 23-247 Replacement, soction20

HATCHL(rcK ACTUATORIHATCHBAC(I Test, page23-250

FRONTPASSENGER'S DOORLOCKSWITCH Test,page 23-249

)

J DRIVER'SDOOR KEYCYLINDERSW]TCH Test,page 23-248

OOORLOCKACTUATOR Test, page23-246 Replacement,section20 DRIVEB'SDOOR LOCKSWITCH Test,page 23-249

oooRLocK CONTNOLUNIT InputTest,page23-244

I

J

Forthis model,a new door lock svstem has beenadootedto imDroveconvenienceand salety. lf the key is insertedinto the driver'sdoor kev cvlinder.turned to the unlock position,and pulledout immediatelythereafter,ONLY the driver's door will unlock. However,il the key is kept in the unlock positionfor one secondor more, ALL doors will unlock.

23-241

Power Door Locks CircuitDiagram UNDER.HOOO FUSEiRELAYBOX N0.41(1004)

@*"

No.s4(40A)

DR]VER'S 000RLocK SWITCH

WHT/GRN

DFIVERS DOOR KEYCYLJNOER SWITCH

L_____

ooon rocxxroe I l f7 V

I

E

Y

DRIVER'S DOOR LOCK ACTUATOR E

LOCK

o

POWER DOOR LOCK CONTROL UNIT

K

FRONT PASSENGERS DOOR LOCK ACTUATOR

T--=-l -4{il^

* LEFT REAR DOOR LOCK ACTUATOR

A

,@-

t--l t=J

KEY

* RIGHT NEAR DOOR LOCK ACTUATOH

NATCN KEY CYLINDER SWITCH

-4{.ill^

LTGRN

HATCH LOCK ACTUATOR

LT BLU

T-:-l fl.|.{-

i

A t l

.LK

BLK

l

l

A

A

t

:

-

l

l

G501 G2r. G502 ercl

23-242

BLK

I

G503

T-t l - l KEY

8LK

BLK

A

,l'

-l G501 G502

G5o1 G502

Troubleshooting ,t

I NOTE: The numbersin the table show the troubleshootingsequence Item to be inspected

B : B

g

I

(,o

-c

o

5

I !

t_:___JKEY

lf qa

:ll

HATCH OPENEH ^ l l RELAY

3. ELUMHT

t

YEURED

[S-l*0,., f/tl | \ I o P E N E Fl t . l

l

. -o n :r o- s.r U

I ? l'*n'" +_i t l 8LK

t

tt .

G503

Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the table.

BLK

t:

HATCH I OPENER ACTUATOB

-

Terminal

c

F

1

UNLOCK LOCK

l

l

-----t1 shownon pagel9l.

1

c70!

-..--.-{[ i"?*i,h Male terminal

J

O,'

- i":!f$l ?:T"'i,.i,. F,":,2 f

.---#

Numberot photo in backot book showingcomponent locationon car.

c484

FUEL GAUGE SENDING UNIT

Thermistor

SeeGauges

Splice ----------)f

rr(

"*l

Brokenwi.e means

-{ ffir"i:'ffi:[:l''" elsewhere as directed oyttt" not" n"n to [. Ground---{

I I

SeeGround Distribution. page14'4.

S€e Ground Dstrb(rtlon page 14 .l

u.* f G30t

o,a

)o

)wer IJrstnDullon DistributionScnemallcs SchematicsPower showhowpoweris suppliedfromthe positivebatteryterminalto schematics PowerDistribution sectionto geta moredetailedpicture variouscircuitsin the car.Referto the PowerDistribution to the circuityou'reworkingon. of howpoweris supplied From Battery to lgnition Switch, Fuses, and Relays however, lndividual circuitschematics beginwitha fuse.Thefirsthalfof PowerDistribution, betweenthe batteryandthe fuses. showsthewiring"upstream"

!'

- - - - - - -ro-unE,-"*l

- - - -f ---?

i,"-")il"i"v-g& o"

FUSE15

,

Page10'7

1

\

hTt""r--.r

T L--Jr LJ-------

. v - E . , zi r u : r E re r o Ia ruse I ruse t PowER sEAr /

ELECTRTCAL ) rc

)

gs-r-qqrg! | {ELD)Ul'{r

l'*

iOA6".'-'-

?

! I (REcuNrNG) I

I *

I

'f t"' l*.r::: *-lll3l Distribuiion, f ;1 ALTERNAToR tL_Jii1:"": pago 1G7.

)a

SLK

BLK

BATTERY

t

4----t

STARTER

l

STARTER SOLENOID

I I + G1(BODY)

r I I I

t

7.ta

, _l_

l---r+J

) o

FUSE9

FUSE1O 754

SeePower Distribution. page10-5.

Se€Power Distribution. pag€10-5.

SgePower Distribltion, page10-5.

Sa€Power Distribution, page10-6.

tt

HowTo UseThisManual PowerDistributionSchematics

ol

From Fuses to Relays and Components Thesecondhalfof PowerDistribution showsthe wiring"FromFusesto Relaysand Components." Thiscanspeedyourtroubleshooting by showingwhichcircuitssharefuses.lf PowerDistribution showsthatan inoperative circuitandanothercircuitsharea fuse,checka component in the othercircuit.lf it works,you knowthefuseis goodand poweris available to the inooerative circuil.

I I

FUSE15

UNDER-OASH FUSE/RELAY BOX

FUSE23

204

10A

\ \

I

/

3rc802

8

I "*

|

1?c-.7

I

',I "ro. -

f

|

O (

-

l--

YEL

YEL

.:r- I

1 MooNRooF

:*.l sHrFT r LOCK I I I

13"'^TI",

L-J,iiio'i'

L-

I

SOLENOID J Page138

L -J

PHOfO2T

-l

. I I

lFEt[,o' SWITCH (Automatic Transmission) P a g e1 1 0 - 1 3 PHaro62

I YEL I 2 3 C216

r-.l c408

3 g cl20 YEI

I

L -J

r l5"f,TE'" I (N,4anual L Transmission) P a g e1 1 0 - 1 3

HAZARD

I t3'S[t''i" L-

J P a g e1 1 0 , 8

:I-

c564 1 AUTOMATIC I SEATBELT I CONTROL J UNIT L____________J Page146

r------

I

z I czra r -.lclocK

,

L-J

l"i1:"':o

c7t3

ti:*'"T8* 8 1 .a n d8 9

ol

)a

'ounoulslnoulron ScnemarlcsDistributi Schematics Ground thal sharetwo showsall of thecomponents schematic ThissamDleGroundDistribution groundpoints.

RIGHT RIGHT LEFT REAR REAR REAR SIDE RIGHT TURN RTGHT TURN LEFT stoE LEFT MARKER BRAKELIGHTS/BACK-UP SIGNAL BACK-UP SIGNAL BRAKELIGHTS/ MARKER LIGHT LIGHT TAILLIGHTS LIGHT LIGHT LIGHT TAILLTGHTS LIGHT Page110-7 Page110-7 P a g e 1 1 0 - 7 P a g e 1 1 0 -P8 a g e 1 1 0 -P5a g e 1 1 0 -P8a g e 1 1 0 ' 5P a g e 1 1 0 - 7 LEFT REAR

t \

)a

r--r t*-r

r--t r--r

t-\ \./

t-l \/

t-t \./

\/

r--r

r-\

r--t

\/

JL

POWER ANTENNA MOTOR Page151

LIGHTS LICENSE Page110'6

I I

l"uo,

O

O

l*"''*L.J

:E_, t l

,-t

l l

!-.1** REAR

FUEL PUMP Page23-1

FUELTANK UNIT Pages74 and 81

wtNDow WIPER MOTOR Page92

HIGH MOUNT BRAKE LIGHT Page110-9

l t

t t

t l

t

l l

l l

l l

iIn*

1 Y C652 c530 -irg puoro | tzt

l

t

l

c603

106

a-

I

ra

a-al

I

c549

T

) o

+ Gs21

T

!. G601

E

HowToUseThisManual ComponentLocations To seewherea component or connector is locatedon thecar,lookup its photonumberin the Component Location sectionin the backof the book.Thephotowillalsotellyouthecolorof theconnector. andhowmanvcavitiesit has.

'r"' VEHICLE

t t

r -.I |

r

L-J

GAUGE | ASSEMBLYI

t

0,,I

l SPEED l SENSOR (VSS)

il"l,* r -'l CoNTROL I l

.I CRUISE

l

L-

i"u,t',:.. l

To see where connectorsand parts are located,look up their photosin the Component Locationsection.

ENGINE

l CONTROL UNIT(ECM l PHOIO 8A

lf thereis no photonumberbelowor besidea connector, ground,or terminalnumber,lookup ground,or terminalnumberin the appropriate thatconnector, Connector ldentification Chart. you Thechartwilltell thecolorof a connector, howmanycavitiesit has,whereit'slocated, andwhatcomponent or harnessit connectsto.On the pageoppositethatchartyou'llfindan illustration of the relatedharness.

O,

Connector ld6nlillcallon and Wire Harness Rouling tconrd)

SEATWIFE HAFNESS

lf a connectoron a schematichas no photonumber,look it up in the Connector ldentification chart.

203-14

c712 c297

203-15

ot t-

t

)

for In'Lineand FuseBox Connectors Circuitldentification in separate use thechart(onpage204,samplebelow)to helpdiagnosemultiplesymptoms circuits' by those problem in a connect,oishared circuitswhichcouldbe causedby a single Here'showthatchartcouldhelpyoufindsucha problem: for thatcircuit' andlookup the schematic 1. Pickoneof the multiplesymptoms (includepagenumbers). in thatschematic 2. Makea listof all in-lrneandfuseboxconnectors on yourlist to see if circuitsrelatedto the other 3. Then,in the chart,lookup eachconnector for the problem. runthroughoneof them.lf theydo, inspectthatconnector symptoms don'twork.Listall in-lineandfusebox Thehorn,A,/C,andthe rightheadlight Example: in the horncircuitandthencheckthe chart(samplebelow).YoufindthatC211is connectors circuit,so you inspectc211andfindthe problem: commonto the A,/Ccircuitandthe headlight bentterminals.

Connector (6 or more cavities)

Numbel of Cavities - Color

Wire Harnesses

Circuits Ant!lockbrakesystem(ABS),Cruisecontrol, {uelinjection system(PGM-FD Programmed

1O-GRY

Main/ | ComPer 'rorc.ntrols,lgnitionsystem I I I Dashboard I I

Fans, Antilockbrakesystem(ABS),BIowercontrols, Wiper/washer

12-GRY

!ngrnei lvlain

system lgnitionsystem,Starting

Headlights' controls, Compressor Engine/ | Blowercontrols, Wiper/washer Main I Horns,Vehiclespeedsensor(VSS), system(PGM-Fl)' fuelinjection Programmed Startingsystem

)

HowToUseThisManual Symbols Wire Color Abbreviations The followingabbreviations are usedto identifywire colorsin the circuitschematics: BLK.... BLU.... B R N. . . . GRN.... G R Y. . . . L T B L U. LTGRN. ORN.... PNK.... P U R. . . . R E D. . . . wHT... Y E L. . . .

.........btack . . . . . . . . .b t u e . . . . . . . .b r o w n . . . . . . . .g r e e n . . . . . . . . .g r a y ..... tighrbtue ....ljghtgreen . . . . . . .o r a n g e ..........pink . . . . . . . .p u r p t e . . . . . . . . . .r e d .,.......white . . . . . . . .y e o w

Wires A wavylineat theendof a wrremeansthe wireis brokenby the bindingof the bookor by a "choice" bracketbutcontinues on the nextpage.

A brokenlinemeansthispartot thecircuit is notshown;relerto thecircuitlistedfor the complete schematic.

",.I *.1

SeeGround Distribution, page14-1.

ar

1G101

Whereseparatewires join,onlythe spliceis shown;for detailson the additional wiring, referto the circuits listed.

BLK

CrulseControt, Qaal Gauges, Indrcarors

UNDER. DASH FUSE/ RELAY BOX

i-l{:i

;["

Q,

! YEUBTK I

I Wirechoicesfor optionsor differentmodelsarelabeled andshownwitha "choice"

Wireinsulation can be onecolor,or onecolor withanothercolorstripe. (Thesecondcoloris thestripe.)

bracketlikethis\

Manual Transmission

*J

Thiscircuitcontinues on anotherpage.(Thearrow showsdirection of current flow.)Tofollowthe RED/ BLKwirein thisexample, youwouldturnto page23-5 and lookfor the "2" aftow.

Q,

*"1"'*"1""0

*'ffil:,

Thismeansthe branchof the wireconnects to another circuit.Thearrowpointsto the nameof the circuitbranch wherethewirecontinues.

Thisbrokenlinemeans bothterminals arein connector C134.

"""1 Name of Circuit

I cl34

H

a,l

I I

"C" Connectors The cavities(and wire terminals)in each connectorare numberedstartingfrom the from upperleft,lookingat the maletermlnals female (or at the looking the terminalside thewireside.Bothviewsarein termhaiSTiom the numbersare the the same direction-so even same.)All actualcavitiesarenumbered, in them. if theyhaveno wireterminals WireSide ol FemaleTerminals

Terminal Side ol MaleTerminals

one Thissymbolrepresents busbarinsidethecapof A ... a junctionconnector.

Lrh.t'-=*nn".torcap \

I

A containsseveralbusbars, \ -butonlythe oneaflecting thatcircuitwillbe shown. f-

tabson Thedotsrepresent al wire that the thebus ,2

il;;;;';;;;;;:;i; /// wiresto Remaining

c103

I

seeGauses

t l

thesamebusbars by arerepresented a brokenline.

l 1

Splices

)

cavitynumberis listednextto Theconnector The eachterminalon the circuitschematic. shownbelowis #6. cavitv/terminal

areshownas a dot.Theirlocation SDlices andthe numberof wiresmayvary on the harnessmanuJacturer. depending

*-l

".^** I *-l*-l*-l *-l *"1 *,,1 a--- a--- a--- a---a

-o

Components A solidborderlinemeansthe is shown. entirecomponent Female Terminal

Thismeansthe connector conneclsdirectlyto the componenl.

II

l

--a

)

Thismeanstheconnector to a lead(pigtail) connects wireddirectlyto the component.

A brokenborderlineindicates l thatonlypartof the component t rssnown. The nameof the appearsnexl component to its upperrightcorner followedby notesabout itsfunction.

l l

BRAKE

swrTcH

Closedwith pedaldepressed.

HowToUseThisManual Symbols

Q,(

Ground - "G"

Switches

Thissymbolmeansthe endof thewireis attached(grounded) I to thecarframeor to a metal \ I partconnected to theframe. \I orol

Theseswitchesmove together; the brokenstraight linebetweenthemmeansthev aremechanically connected.

m

,

Eachwireground(G)," -/ numbered for reference.

Othertypesof switchesare controlled by a coilor a solid statecircuit.Unlessotherwise noted,all switchesareshown in theirnormal(rest)position, with poweroff.

Thisgroundsymbol(dot and3 lines)overlapping the component meansthe housing of the component is grounded to the car f rameor to a metal partconnected to the frame. Thissymbolrepresents the busbarinsidea ground connector. Thedots a

Solid-state

.,.L i"r*"""*nn"l,':" I I I

-'--'-:t"'--------< lermtnalsconnectto. : Gsoo Thegroundsymbol(largedot) is theconnection betweenthe busbarand metal(grounded) partof the car.

- "T" Terminals Each'T" terminal(ringtype) is numbered for reference ano location. A "T"terminalis securedwitha screwor bolt.

Fuses Thismeanspoweris supplied whenthe ignitionswitchis in ON (ll).

Q,

\t,,,

n

Shielding

Thisrepresents RFI (RadioFrequency Interf erence)shielding arounda wire.The shielding is always connected to ground.

ffi

Diodes

:'iL.-!

L-_+i !",* I

A rectifier diodeworkslikea one wayvalve.lt allowscurrentto flowonlyin the dlrection of the arrow. A Zenerdiodeblocksreverse justlike currenlat normalvoltages a rectifier diode.At highvoltages, however, a Zenerdiodeallows currentto flowin reverse.

'l'

F ive-StepTroubleshooting

1. VerifyThe Complaint in the problem Turnon allthe components of the customer circuitto checkthe accuracy Do notbegin Notethe symptoms. complaint. or testinguntilyou have disassembly area. narrowed downthe Problem

l o

2. AnalyzeThe Schematic for the problem Lookup theschematlc the circuitis how circuit.Determine to workby tracingthecurrent supposed pathsfromthe powersourcethroughthe to ground.Also,trace circuitcomponents circuitsthatsharewiringwiththe problem circuit.Thenamesof circuitsthatsharethe samefuse,ground,or switch,andso on' are Tryto to in eachcircuitschematic. referred you operateanysharedcircuits didn'tcheck in steo1. lf the sharedcircuitswork,the sharedwiringis OK,andthe causemustbe in thewiringusedonlyby the problem circuit.lf severalcircuitsfailat the same time,thefuseor groundis a likelycause. andYour Basedon thesymptoms of the circuit'soperation, understanding identifyoneor morepossiblecauses. 3. lsolateThe ProblemBy TestingThe Circuit Makecircuitteststo checkthe diagnosis youmadein step2. Keepin mindthata is the keyto logical,simpleprocedure Test efficienttroubleshooting. for the most likelycauseof failurefirst.Tryto maketests at pointsthatareeasilyaccessible.

TestEquipment CAUTION: devices. Mostcircuitsincludesolid-state in thesecircuitsonlywith Testthevoltages digital or higherimpedance a 1o-megaohm Neverusea test lightor analog multimeter. meteron citcuitsthatcontainsolid-state to the devicesmayresult. devices.Damage TestLight and DVOM devices,usea On circuitswithoutsolid-state A testlightis voltage. for light to check test pairof leads with a volt bulb madeup of a 12 grounding lead, touchthe one After attached. points alongthe circuit otherleadto various wherevoltageshouldbe present.Thebulb willgo on i{ thereis voltageat the pointbeing tested.lf you needto knowhowmuch voltageis present,usea digital (DVOM). volVohmmeter TestLight and DVOM Selt-Powered testlightto checkfor Usea self-powered is madeup of a lightbulb, This tool continuity. To test it, touchthe leads. battery,and two the lightshouldgo on. leadstogether: testlightonlyon an Usea self-powered the First, disconnect circuit. unoowered battery,or removethe fusethat feedsthe circuityouareworkingon.Selecttwo points in the circuitbetweenwhichyouwantto Connectone leadol the checkcontinuity. test self-powered lightto eachpoint.lf there thetestlight'scircuitwillbe is continuity, andthe lightwillgo on. completed,

4. Fix The Problem Oncethe specificproblemis identified, makethe repair.Be sureto usepropertools andsafeprocedures.

I

5. MakeSureThe CircuitWorks in the repaired Turnon all components circuitin all modesto makesureyou've fixedtheentifeproblem.lf the problemwas a blownfuse,be sureto testall of the circuitson that{use.Makesureno new problems turnup andtheoriginalproblem doesnotrecur.

TESTLIGHT SELF.POWERED

HowTo UseThis Manual TestEquipment

Troubleshooting Precautions

you needto knowexactlyhow lf, in addition, muchresistance thereis betweentwo ooints. usea digitalvolVohmmeter (DVOM). In the"oHMS"range,the DVOMwillshow resistance betweentwo pointsalonga circuit. Lowresistance meansgoodcontinuity.

BeforeTroubleshooting

Diodesandsolid-state devicesin a circuitcan makea DVOMgivea falsereading.Tocheck a reading,reversethe leads,andtakea secondreading.lf the readings differ,the component is affecting the measurement. JumperWire Usea jumperwireto bypassan opencircuit. A jumperwireis madeup of an in-linefuse holderconnected to a set of testleads.lt shouldhavea tiveamperefuse.Never connecta jumperwireacrossa shortcircuit. Thedirectbatteryshortwillblowthefuse.

1. Checkthe mainfuseandthefusebox. 2. Checkthe batteryfor damage.stateof charge,andcleanandtightconnections. CAUTION: . Do not quick-charge a batteryunless the batterygroundcablehasbeen disconnected, or youwilldamage the alternatordiodes. . Do not attemptto crankthe enginewith thegroundcabledisconnected or you willseverely damage thewiring. WhileYou'reWorking 1. Makesureconnectors areclean,andhave no looseterminals or receotacles. 2. Makesuremultiple terminalconnectors are packedwithdielectric (silicone) grease. PartNumber:08798-9001 . Packwith dielectric(silicone)grease

Short Finder(ShortCircuitLocater) Shoftlindersareavailable to locateshortsto ground.Theshortfindercreatesa pulsing magnetic fieldin the shortedcircuitwhichyou canfollowto the locationof the short.lts use is explained on page15.

Whenconnecting pushit untilit a connector, clicksintoolace. Do not pull on the wireswhen disconnectinga connector.Pull only on the connectorhousings.

SHORTFINDER

To orderanytestequipment shownabove, contactyourlocaltoolsupplier. Fora listof suppliers andtoolnumbers, referto Acura Required SpecialToolsand Equipment ServiceBulletin.

Qr(

Mostcircuitsincludesolid-state devices.Testthe voltagesin these circuitsonly with a 1o-megaohm or higherimpedancedigitalmultimeter. Neveruse a test light or analog meter on circuits that contain solid-state devices.Damageto the devices may result.

l"(

ra

Tests Troubleshooting Testingfor Voltage

Testingfor Continuity

Whentestingfor voltageat a connector withoutwireseals,youdo nothaveto thetwo halvesof the connector. seoarate fromthe back lnstead.orobethe connector Alwayscheckbothsidesof the connector andbentterminals becausedirty,corroded, contact= cancauseproblems(noelectrical an open).

at a connector Whentestingfor continuity withoutwireseals,youdo nothaveto separatethe two halvesof lhe connector' fromthe back. lnstead.orobethe connector of the connectol sides Alwayscheckboth bent terminals and becausedirty.corroded. problems (no contact= electrical cancause an open).

1. Connectoneleadof thetestlightto a knowngoodground,or,if you'reusinga (DVOM),placeit in digitalvoltohmmeter range,and DC volts the appropriate connectits negativeleadto ground.

the negativecablefromthe car 1. Disconnect battery.lf you'reusinga DVOM,placeit in the lowest"OHMS"range. test 2. Connectoneleadof a self-powered part of the lightor DVOMto oneendof the circuitvouwantto test.

connecthe,e[fl5Bi'

:lL:'#*-'\L{.t

ro

-'-----{

i'L----'t.r- El'*''"" ".,f Qli'""'"":*soLENo,D Connecthere I

I

l lll

ljlu I 3f,3JiEx\",*

Connectthe otherleadto theotherend. Connecttheotherleadof thetestlightor DVOMto thepointyouwantto checK. lf thetestlightglows,thereis voltage presenl.lf you'reusinga DVOM,notethe voltagereading.lt shouldbe withinone batteryvoltage. voltof measured A lossof morethanonevoltindicates a oroblem.

I

NOTE:Alwaysusea DVOMon high A testlightmaynot circuits. impedance glow(evenwithbatteryvoltagepresent).

testlightglows,thereis lf theseltpowered l{ you'reusinga DVOM,a low continuity. readingor no reading(zero),means goodcontinuity.

HowToUseThisManual Troubleshooting Tests Testingfor VoltageDrop

Testingtor a Short to Groundwith a Test Lightor DVOM

Wires,connectors, andswitchesaredesigned to conductcurrentwitha minimumlossof voltage.A voltagedropof morethanonevolt indicates a oroblem.

1. Removethe blownfuseanddisconnect the load.

1. Placethe digitalvolvohmmeter (DVOM)in the appropriate DCvoltsrange.Connect the positiveleadto the endof thewire (orto theconnector or switch)closestto the battery.

2. Connecta testlightor digitalvolvohmmeter (DVOM),switched to theappropriate DC voltsrange,acrossthefuseterminals to makesurevoltageis present.Youmight haveto turnthe ignitionswitchto ON; checkthe schematic to see.

TESTLIGHT ol OVOM

EEO

'p;


:[:J"'" s;.o"*o'o 3. Closeall switchesin thecircuit you'retesting.

HowToUseThisManual Troubleshooting Tests(cont'd) 4. Turnon theshonfinder.Thiscreatesa pulsingmagnetic fieldaroundthewiring betweenthefuseboxandthe short.

tr(

5. Beginning at thefusebox,slowlymove the shortfinderalongthecircuitwiring. The meterwillshowcurrentoulses throughsheetmetalandbodytrim.As longas the meteris betweenthefuseand the short,the needlewillmovewitheach currentpulse.Onceyou movethe meter pastthe pointof the short,the needlewill stopmoving.Checkthewiringand connectors in thisareato locatethecause of the short.

Li(

Fuse/Relay Information - Under-dashFuse/RelayBox

t4

FrontView c55't (Todashboardwireharness) c801 OoSFISmainharness)

c922 (Toignitionswitch)

c441 (Tomainwireharness)

c661 (Torootwireharness) c442 flo rra n wireharness)

-)

n. Fl r"r r'r rl r-l r-r ri r'1 Tl rl r-1 23 24 25 26 27 2a 29 30 31 32 33

t_-.1 u u !

tJ LJ Ll t. Ll tJ l. tJ

- r-l n T'l T-l r't T-1T-t r-l T-t r-l r'1 .12 13 14 15 16 17 18 19 2A 21 22

LI tJ LJ LI tJ I.J t-J tJ IJ IJ IJ I.J

c92s

r-r Tl l;t T'l T-l T'1rn r-l T-t r'l T1 Tl r'1 n . 1

2

3

4

5

6

7

I

9

10 11

.

Oo power window relay)

.

t-l LJ LJ LJ LJ [J t-t LJ Ll LJ t_l t-J Lr u

c928

(Notused)

RearView c504 (Torearwireharness)

c503

(To rear wire harness)

c440 {Torrainwireharness) c439 (Tomainwireharness)

6

. : Spare fuse r : Not Used O : Option (+B) O : Option (Dash lights) O : Option (ACC) O : Option (lG2)

Fuse Number

or circuitProtected component

Amps Page j 1o-2

FuseName (POWER DOORLOCK)

Powerdoorlockcontrolunit

10-2 | Rearwiper

(RRWIPER RRWASHER) R _ HEADLIGHT HIGHBEAM

I

Rightheadlight tto-e i onLcontrolunit(Canada),

L _ HEADLIGHT HIGHBEAM

light, (Canada), Highbeamindicator i 110-8 i DRLcontrolunit i Leftheadlight Notused 10-1

(POWER WINDOW RR-L)

| 1zo-zI I

Leftrearwindowmotor

| 120-2 I Rightrearwindow molor

I

| (lGNcolL)

|

15

passenger's windowmotol i120(H/B) Front 120-2 iot

(POWER WINDOW FR-R)

l(Sedan) windowmotor i120(H/B) Driver's l 0 : 1 2 0?

(POWEB WINDOW FR-L)

(Sedan)

'lo-2

TURNLIGHTS 13 14

FUELPUMP (SRSUNIT)

19

t

mainrelay,SRSunit 1O-2 | PGM-FI I

I J

coNTRoL)| 7.5 I (cRUlsE ALTERNATOR SPSENSOR

Hazardwarningswitch

10-3 | Cruisecontrol ECMor PCM('00Model),ELDunit, 10-3 Alternator, A/f), Modelwith TCM('98-'99 PGM-Fl, Gaugeassembly, Vehiclespeedsensor

7.5

i REARDEFBOSTER i i RELAY i A/C I HEATER : RELAY

10-6 i ABScontrolunit,Rearwindowdefogger

ucxr I z.s II tnururutruc I otrt av\

10-6 I DRLcontrolunit(Canada)

I BACKUPLIGHTS | 7.s (RUNNTNG LTGHTS) i

Blowercontrols, Airdelivery, controls, fuC compressor Fans.Powermirrors

|

10-4 I Back-uplights i DRLcontrolunit(Canada)

(cont'd)

6-1

FuserRelay Information - Under-dashFuse/RelayBox (cont'd) Fuse Number

FuseName Amps Page Componentor Clrcull Protected Rightheadlight i R HEADLTGHT i 1 0 i i i LOWBEAM i 1 1 0 - 8 Leftheadlight ! L _ HEADLIGHT I 1 0

I roweenu

I ro

(sRs) 24

i

I

SRSunit

I P/IVRELAY

I 7.5 I t

| METER

|

l(suNRooFBELA!l 25

r 26

t

7.5

t

|

10-4 | Powerwindowrelav.Moonroof l 10-5 | Clock,Gaugeassembly, Integrated controlunit,Interlock

lsystem,Maintenance reminder unit

i FRW|PER

Frontwiper/washer

I FRWASHEB

27 | crcnnerre

lighter Cigarette

i LTGHTER

28 2e

player i RApro i 1 0 i 10-s i Stereoradio/cassette | (RRFoc LtcHT) | z.s !

30

I INSTRUMENT | 7.5 | I LIGHTS t l

3'1

STGNAL i STARTER

32

LtcHrS I i LTCENSE i TAILLIGHTS i

| I

6-2

(rNrER LocKuNrr)l I

114 | Dash& consolelights,Integrated controlunit 21,21-11 ECMor PCM,Integrated controlunit,PGM-FI mainrelay

i 1 0 0 1i

Licenseplatelights,Parkinglights,Taillights

Interlocksystem

- Under-hoodFuse/RelayBox FrontView T102 Ooenginewireharness)

T1 [ro battery)

D3r-t

r'1

tr tr

IJ IJ

r'1 51

LI

r-1

[J r"l 56

IJ

57

LI

*: NotUsed

RearView

c905 [ro F/C compressor) clutchrelay)

c2l5 To mainwireharness

Llo

c2t8 [fo main wire harness)

Oomainwire harness)

(cont'd)

6-3

Fuse/Relay Information - Under-hood Fuse/Relay Box (cont'd)

Fuse Number

FuseName

Amps

Componentor CircuilProtected

Page

BATTERY

Powerdistribution lgnitionswitch

LIGHT 1 7.5 1 10-7 I DLC,Ceilinglight,Powerantennamotor(Hatchback), I INTERIOR I I Trunk/cargoarealight I Fl E/lvl

15 | 10-7 I PGM-FI mainrelay Not used

POWERWINDOW 47

Powerwindowrelay

I BACKUP (RADTO)

7 . 5 | 10-8

I HEADLIGHT i DRLOCK,

40

I 49

|

I RRDEFROSTER

i I

Moonroof

I Rearwindowdetoggerrelay platelights, I Dashandconsolelights,License parking Rear lights, Taillights I 10-9 | Brakeswitch,Hornrelay

+ B SMALL STOP I HORN, i HAZARD 40 I HEATER MOTOR I 20

6-4

| 10-8 | Headlights,Interlocksystem(A/T)

10-9

i suNRooF

Clock,ECMor PCM,Maintenance reminder unit,Stereo radiocassetteplayer,TCM('98-'99ModelswithA'/T)

('00Model),Hazardwarningswitch i Gaugeassembly to t Powerdoorlocks,Security system(option) | I I t 0-1 I Blowermotorrelay clutchrelay,Condenser fanrelay I 10-1 ; A,/Ccompressor 10-1 Radiator fanrelay i

rio

- Under-hoodABS Fuse/Relay Box

c213 (Tomainwireharness)

*Il f.*l f*-l f*-l

c903

OoABSpumprnotorrelay)

CI .' IC

T5 (Tobattery)

Fuse Number

FuseName ABSMOTORFUSE

Componentor CircuitProtected ABSpumpmotorrelay ABS fail-saferelay

ABS82 ABS UNIT

| 10-10 | Notused I Notused i ABScontrolunit

rJO 6-5

Ground-to-Components Index NOTE:All groundwiresareBLKunlessotherwise noted. Ground Page

Componentsor Circuit Grounded Battery(BLIVYEL)

-

-

G101

t

' t.+

and 14-1

I

Valvecover(BRN) Daialinkconnector (BRN/BLK), Engineor powertrain controtmodule(pct andpG2 BLK; are LG1and LG2areBRN/BLR,IABcontrotsolenoid valve(GS-B), lmmobilizer receiver unit('00Model)(BRN/BLR, PGM-Ft mainretay,Radiator fan switch,Transmission controlmodule('98. 99ModelswithMD (2 BRN/BLK wires), Vehiclespeedsensor,WEC pressureswitch(GS-R,Type-R) Shielding between the ECMor PCMandthesecomponents (allhaveBRAIDED wires): CKFsensor,Primaryand secondaryheatedoxygensensors,Knocksensor(GS-R, Type-R), TDC/CKP/CYP sensor Shieldingbetweenthe TCM('98-'99Models)or PCM('00Model)andthesecomponents (allhaveBRAIDED wires):Countershaft speedsensor,Mainshaft speedsensor

G 1 s 1i

i Condenserfan motor Blowermotorrelay,ELDunit,Badiatorfan motor,Rightfrontparking/turn signallight, Rightfrontsidemarkerlight,Rightheadlight.....plus groundedthroughG401 everything ABSfail-saferelay,ABSpumpmotor

G401

14-3

Brakefluid levelswitch,Cruisecontrolactuator,Leftfrontparking/turn signallight,Left frontsidemarkerlight,Leftheadlight,Powersteeringpressureswitch(USA),Rear windowwashermotor(Hatchback), Windshield washermotor,Windshield wipermotor

14-4 ano

A,/Tgearpositionswitch,Cigarettelighter,Clutchswitch(M,/T), Ctock,Ctutchinterlock switch(MfD,Combination wiperswitch(2wires),Cruisecontrolmainswitch,Cruise controlunit,Dashlightsbrightness controller, Datalinkconnector, Daytime running lightscontrolunit(Canada), Frontpassenger's doorkeycylinderswitch,Front passenger's doorlockswitch,Gaugeassembly (2wires),Gloveboxlight,Heater controlpanel,Heatertan switch,lgnitionkeyswitch,Integratedcontrolunit,Interlock controlunit(AfI), Maintenance reminderunit,Modecontrolmotor,Moonroofrelay, Moonroof switch,Parkingpinswitch(AfD,Powerwindowrelay,Rearwindowdefogger switch,Service checkconnector, Turnsignal/hazard relay.....plus grounded everything throuohG201

l4-c

Driver's doorkeycylinderswitch,Driver's doorlockactuator, Drivelsdoorlockswitch, powerdoor Driver'sseatbeltswitch,Fuelpump (BLI(/WHT), Fueltank unit(BLI(/WHT), lockcontrolunit,Powermirrorswitch,Powerwindowmasterswitch(2 wires) Hatchkeycylinderswitch,Hatchlatchswitch,Hatchopeneractuator,Hatchooener switch,Leftand rightback-uplights,Leftand rightbrakelight/taillights, Lettand right rearparkinglights,Leftandrightrearturnsignallights,License platelights,power antennamotor,Trailerlightingconnector..... pluseverything grounded throughG751 '14-8 G503 (Sedan)

6-6

Highmountbrakelight,Leftandrightback-uplights,Lettandrightinnerbraketighv taillights,Leftand rightouterbrakelight/taittights, Leftand rightrearparkingtights,Left andrightrearturnsignallights,License platelights,Rearwindowdetogger, Trailer lightingconnector, Trunklatchswitch

t-,O or CircuitGrounded Components player Stereoradio/cassette ABScontrolunit(GND1andGND2areBLK;GND3andGND4areBLKWHT) grounded pluseverything Highmountbrakelight,Rearwindowwipermotor..... i 14-7 i through G503

G801

i Rearwindowdelogger SRSunit(2GRNwires)

l u s l

UO

rio 6-7

PowerDistribution - From Batteryto lgnition Switch,Fuses,and Relays T1

,

STARTER Pages21and21-1

FUSE4t

BATTEFY

PHOfa 27

I

BATTEAY tmA

I

STARTER

| soLENorD

|

t

L--J

l

I

--------J

I I

BLKTYEL

L

G1

I-

I : I I

ELECTNICAL LOAD DETECTOR (ELD}UNIT Page22 PHOTO 23

L-----?

FUSE42

FUSE43

FUSE44

tGt

IMTEFIOB LIGHT 7.5A

FI E/M 15A

FUSE46

FUSE47

FUSE48

FUSE49

FUSE50

AACKUE (RAOTO) 7.la

NEADLIGHT

DA LOCK,

OEFFOSTER

su{BooF

I rusesr I +BsuaLl I

304

\

I I

c216 WH'/BLK

SeePowerDistribution, page10'7.

c432

SeePowerDistribution, pages1Ggand 10-9.

I

lff-(".BLK/WHT 'I

r-r

tili*

\

lff* r

acc {r)

c432

".__",x' Mff

BLK/wHr

"a*t"t

--':'[E

If I

i

'o *"'f,""f#

c922

"ooi'* i .t

I I

L-----STARTER CUTRELAY Page21-1

t

t

J

r+t

t

r

l

l

L--J A/T GEAR POStTtON swtTcH Page21

FUSE16 AEAA OEFFOSTEA FELAY 7.54

FUSEI8 (aurxf{G IIGHT RE!AY) 7.54

FUSE27

FUSE28

C|GAAETTE LG}T'ER 104

RADIO

f.--

(Not Used)

PHA|A 7A

ToFuse31,tor details,seeStartingSystem, pages21and21-1.

10

rl*,)(

SeePower Distribution, page10-6.

SeePower Distribution, page |0-5.

UNDER-HOOD

I \ \ .

FUSE52

FUSE53

8OFN, STOP

HAZARO

t)-

BOX I FUSE/RELAY I I I

J

1102 SeePower Distribution, page10-9.

T101 I'_'I ALTERNATOB | | Pase22 | L--J

I I

t

|

PHoro31

FUSE55

FUSE56

HEATEF MOTOB

(CoNDENSEA FAtl) 204

!I L--J i

!

lF"'s?60I I rdq€

I RELAY I L - - J Page63 L--J

@

eudrozz

-l

tanfiton

,. ( t--)

".r\l:'S7ili"'l l;9c*(

lsiwitctr

'-'

oa"t 0) 0

lf

I

ltttt

J

a------rl-

COOUNGFAX 204

c9)6 RADIATOR

r^- -:I

!"o"'""' !| Etto" Page63 or 63.2 !

I RELAY Page62

."-'1tr;' L--J

Pqofo ?2

--

.l STEERING i I LOCK

I I I

FUSE57

FUSE 54 {oFnon)

c90s c904 c907 r--1A'/CCOMr--'t BLowER r - - 1 c o N \. tContactlMO-IOR I ContactlDENSERI ContactlPRESSOR RELAY ! IFAN : ; CLUTCN

-

i I ruser

' rusez

'rusEo

L-J- ---

se€Power Diskibution.

lLg%-

\\

{tG

\

nn

-'l

I

UNOER-

if99Ff.

l[:'^. ubEu/

J..9Yl--:1,-

l[:'^, uJcv /

3!I$f"tot (+B)

UNDER.DASH BOX FUSE/RELAY

c922

\

-

i ) &*'s"-,,lil?l, , $?'"r I ii,At: ? j page10-2.

t # st FusE3 iI t\ FUSE dcr{ \ rFRwtPE WIPEF

UNDEB. HOOO FUSE/ RELAY BOX

PHOfa 58

FUSE12 FUSE13 TUfN LIGTITS r0A

FUELPUTiP (sB6 UNrr)

fis., fllo"o.".",

FUSE'I5

FUSE19

FUSE24

ALlERNATOf, sP sENSoa 7.tA

BACKUP UGHTS t.5a

REIAY

€rrNBooF NEIAY)

FUSE 25 II€TEF 7.5A

,rar ra ! FF WPEB FA U'ASHEN 204

?.3A

I 4y--J---J --

SeePower Distribution, page10-2.

SeePowerDistribution, pages10-2and 10-3.

SeePowerDistribution, pages10-4and 10"5.

10-1

PowerDistributiol (cont'd) - From Fusesto Relaysand Components

FUSE9

FUSE12

FUSE13

oGNCO[] r5a

TURN uGt{Ts

(sFsuNrr)

I I \ \

I I

I -l- C.'138

C551 (Not

c504

c439 1

c801

GFN

q

:*f-----""^* c516 (ln-line connector; may nol oe present In all cars.)

a!

wHr/GBN I

uA"u, 11"1! a l'l PHO ll

BLu,'r/vHTI

138

1 I cs31 lI : t I r--_t r--]

t I

t t t t

L--J HATCH OPENER RELAY Page 134

I

l

t--J HATCH LATCH Page 134 pHora138

c526 106

c506 c755 GFN

cs63 1

I I

REAB

wtNDow WIPER MOTOR Page 92

',lo-2

I I

coMBr-

NATION WIPER

swtTcH Page 92

J

'|10-2 o-4

5

r

I I

c446

t--J PGM-FI MAIN RELAY Page23 ('98,99) or 24 ('00)

7 |' C804

l l

l l

L--J SRS UNIT Page47 PHoro6z

I I

i

FUSE 15 alTEaxAron

FUSE 14 (cFUlsE corrEoLl

\

8P SEt{904 ?.54

\

I I 8

c504 c440 '12

C551

PHO|O 62

floro 5A

(Not

14

12

c551

18

used)

c417

i#r'

c560

I l' C555

t l

t t

l l

L--J L--J CRUISE CRUISE CONTROL CONTROL MAIN UNIT Page34 SWITCH Page34 PHaro s5

BLK I Y E LI

4 g c510

ii.',LI Il

L--i

:

t

:

!i

: l1' ,,JTI . 1 r " ' L l

o r A ccz7gs s 3 ,zll "c zr zr q

|

;

I

" " . % ' , 3! , . |

;

: ii

I I

z, 4 A c" r' g. 0 q

.,lo

;

r

I L--j

i:

V

| r z[

;i

:i

,2,A1c[1s' t12 1 'i2z2s5 X - - ' : - A c^4-2- 0- ::'l| f :1fA^c-2-r:8]

, !--r : ; ,

VENTSHUT VALVE Page23-5 (f98Y o - 99) w/ or, .24 u e J \5v v('00) /

, ' i ,|

, SOLENOTD VALVE p a q e2 4 - 5 | pdato p H a r o1t32 32 :

PHOfO 139

l--33. -j

, YEL

;i

i| - -||l i:r it l- - |ll :'i liI - - lI| i:: it l- - - - - l!l :i' :;i l!a!i 'l- - l L--.r

I er-xi

; i

:. 1' f',,,I"T# 5 . " 1 ! ; I ;

: L-----r

VEHICLE : TRANSMISSION ' CONTROL SPEED SENSOR fiCM) 9F,lIioR ''' MODULE l|oDtllEficM)

': (vss) bvpads aoNThoL i rAat33 soLENolD caNlsTER ; bor.!n.o1 ' Page pHora

PHoro 136

i

ii i'L

r

EVAPORATIVE' IHTAXC EVAPORATIVE EMISSION EMISSION , AtR BypASS :; iiiirss ie.vfDF!Afl,-.

VALVE Paoe23-5 (96-99) orz+-3(uul or24-5(00)

:

l

It

:" 1 ' I^ -^ -i " " ! " ," ,. c127 ''

SECONDARY HEATEDOXYGEN (H02S) SENSOR Page23 5 ('97-98) or 24-5('00)

I

pHoto5l ,

r [ - ; : i - j : t

":'.!. ^- - ^

|

t'to" ".-.,..f, i' Y -..-",-. I

: C421

,

12 g c301

8lK lt Y E LI

l l

ALTERNATOR Page22

GAUGE ASSEMBLY Pages22-1 and80-2

BLK/^YEL

9 4

c440

PHOfO 58

BLK/WH'

BLl( YEI

[| l

UNDER. DASH FUSE/ RELAY BOX

26

,i i r-=l

c410

: l :r tl

, EIEqTRICAL

: :

; , ' ;:l (ELD)-uNlr ': i LTl9.r.?f ' : :: I Ptloro l.?^s_"^l? 23 | , :,4 - J ;' L--'IUNDER-HOOD ':FUSE/RELAY Fus

|

,t

Pase 3s1 ', euo,o,, ,

:; ; :' : ' !! !o49 !%9 -

:, : , BOX

PHOTO21

: - - e e - lsvso d -e-l :sl - - - . u s A- - -

, , '-

I I

POWERTRAIN CONTROL MODULE (PCM) Page39-5

'00 Model with

Model

10-3

PowerDistribution - From Fusesto Relaysand Components(cont'd)

FUSE'I9

FUSE23

FUSE24

AACXUP LIGHTS

lSiS)

Pfl RE-AY SEIAY) Gutroof

i:tif,H-q: \

PHOTO 6A

16

L 10

c55l 17

C801 (Not PffOtO 60 Used)

c440

YEL

c439 11

I

c438

(Not Used)

'---------J

2

c66t

GFN

All except USARS

SECURITY SYSTEM CONNECTOR (oPTroN)

],ifij L 36

l l

A/T GEAR POSITION SWITCH Pages 1 1 01 , 10-1, a n d1 1 8

10-4

l l

BACK-UP LIGHT SWITCH Pages 1 1 0 1, 1 01 , a n d' 1 1 8

r

|.

sRs

MOONROOF RELAY Page122

I I

UNIT Page47

I I

I I I I

FUSE26

FUSE25 IIETER ?.5A

\

FRWASHEF 204

I I

INTEGRATED CONTROLUNIT Page70

t

I

UNDER. DASH FUSE/ RELAY BOX

I

't0

--'-r---i:--L " : ,c;% lf: "tio$, r ' i ii i 'r.u".u|

: i

i,

:

i

l

i

Czt38

(Not Used)

5

t-

l

-"'",,*j*" I i'sn+.1* !

;

i !.--l

l

:

i

I , : ;

SHIFTLOCK SoLENOIO ; Paqe13B( 98-99) , or 1381 ('00)

I

PHQ|O 124

"::]

":-[

GBN/BLK

'I"0,, I r--1

:

*-' 33r'$$'o"

Pase 1ss

I

I

;

- - - - - - o , n- - - - - , - - -Y

iliirinars r-ar

YEL/BLU pHoro,4 I

c55t ?

I I

L--J CLOCK Page154

1|'

Cs57

I I

L-------J GAUGE ASSEMBLY Pages80, 80-2, 81, 83, and 89 PHOIO 47

4

c559 .l

I I

,T'*' I -u.,*""1t-**" ,Iu* 1

I I

L--J t--J MAINTENANCE COMBI. NATION REMINDER WIPER UNIT Page 83 SWITCH pHoros2 Page 91

r--1

r-1

l

1

WIND. SHIELD WIPER MOTOR Page91-1

STEREO RADIO/ CASSETTE PLAYER Page150

(cont'd)

10-5

PowerDistribution - From Fusesto Relaysand Components(cont'd)

@ F U '1E6

UNDER-DASH FUSE/RELAY BOX

Err*rril

nEAR

oEFFosrER

tFurflnc ,:

\ tEArEn

:

\

{ flfo"t-t

i

{ l'rtTr 7.5a

7.5A

I

f f i - . ^ , ;

:

I

:! ,l

l : l

L - - L __ _ _ J_ _ _ _ _ J __ _ _ I _ __ _ J _ _ 16J9:91L _L _ _ _:i 'tr 'tr'F"Xlg",

' f F;03,, ' lf ;'"11'" ' : 331'$A"'o* {H!, " " " " ' i f t"X13,, (rcrt'--'-'

F"?%,, eLxaLul

":1",-:ri;:t i ll".",:{.tFz'€; lll".,. I rt i'--t rt i--t i ;i--i i I

r

:

_

l

I

r

16z

l

t__J t__l r__J !._-J !

BEAR wrNDow oEFoccER SWITCH Page64

ABS coNTRoL uNrr Page44

REAR wtNDow DEFoccER RELAY

pHoro1oo Page64 PHoro111\sedan) pHoro5a

POWER MtRRoB swtrcH paoe141

' : ; ,

t*', "JI.f

-.

)t

:

DA\.TIME ; RUNNTNG LtcHTs CONTROL :

' Uttf Page110-9 j

[ !

t*rarffi'

:

I

i t__.t i

II I It I

or i41-t

i

!

u..^""1

:

| l - - c a n a d a . i-

r*,. .,1,

BLK,YEL

c677 BLK,YEL

ml'" L--J |.--J L--J A/C MODE HEATER THERMOSTAT CONTBOL CONTROI. Pages62-1 MOTOR PANEL and63.1 Paqe61 I Paoes61. PHO|O zJ

psiro aa

62--1 and 63'1

]"*.

r'--?1

r;^;'r

r-A?1

rF^;'l

BLOWEN MOTOR BELAY Page60

L--J L--J CONDENSER NADIATOR COMPRESSORFAN FAN CLUrcH RELAY RELAY BELAY Page63 Pags63 Page62 or 63-2

t*"1 t l

Pttofo 22

t * l t l

t * " l t * " 1 t t t l

Atc

PHA|O)3

PHO|O22 ------J

i

UNDER-HOOD FUSE/RELAY BOX PHQ|O2l

10-6

HOOD

I

43 FUsE

r{rEFroi 7

,

5

A

6lr-----

""'"'.I!E-

a FUSE/

.' I ruse+e

I ruseao I lFliY

rsA .( at i!i,-

/a LlI M

S;,;;

Llcrrr LrGtfT

I

t

"o"*-- laox S i,vr-,iiroirv

lpHara2l

-T---=(?:;t",'

i

i

t-----------1----ll[qi:".1* | I ! "-J-E'11,.o"o,,o

-';[""..."'lj ] LljF*ff: t*"" n%--'""'"f ::It*"xt*"' '--l I f '5l5j*,,, ""** .==.i *","."|-i ***tr-i "' I *HTFEDI

!

t

l

i

I

' $rx:- f ,*t,*""o"""",",, ;#,ii3J'" t ,n",".o

,^lJr^r coNNEcroR

:18;?'alJ)"") '::t:::-. ,

*","."!il""!,l""lroio'"*"'

!

I |

im-*,1,* -"'"."N ","'"."[ 'n*'"'ol 'n*'"."[ [ [,

[

r - i i l l l f ffirT"-',-'l i-"'"."1 i-"'"."1 ,1.,,, i i"-""{ I li#""i ',;,["ff;,,'*""'*',{=., :

i i

'

iwnrneol

:

!

wHrREol wHrFEDl

:

[

i i ,I*.,

I

l !'i;-""t'l r*"--l

!

a ai

,'I=rTt':.ih*r*

; !--J SpOTLtcHTS' eaoelti-z I',

!--J CEIL1NG LtcHT faQe eige 114-2 tt+-z

L--J TRUNK/ CARGO AIIEA AREA

I

|

' '--

I

ll

a a :

:

,

I

[

:

|

:

..

.^ I

I

*",n..

I

I

|

ti |

tl'cii

Page114-3

With i i / l o o n r o o -f - '

I

| I

L--J pOWER ANTENNA M(J | \rrl MoToR

Floil'sr

pHoro1as

''-'---a - '3 l ? 3 " 1 ? . a PHoro^o I

L-----J UNDER-DASH FUSE/RELAY Box PHoro 58 .

-

To Fuses7, 8, iO, and 1.|,

tor dotailsse€PowerWindows, p a g e l 2 } o (1 2 0 - 2 .

(cont'd)

10-7

PowerDistribution - From Fusesto Relaysand Components(cont'd) r' 'l l FUSE48

\

HEAruCHT {la

::]:I

\ \

I I

-------J

c217

c216 . - All except USA RS - r

-'..

'

BLU

SECURITY SYSTEM CONNECTOR (oPTroN)

,SECURITY SECURITY : .SYSTEM SYSTEM , : CONNECTORCONNECTOR (oPTroN) (oPTtoN) , : I PHA|A 124

PHA|A 48

'

,

3

i r : l

:, I ! , :

WHT/BLU

I (RS7)

, I c452

wHr/BLU

WHT/ALU

z 7

4 A C56( C566

l l

i

1 A C568

t t l t

l l

l

t

l

!

N

t wnlalu I

t

r

'LJ___ -18JF#

: 1 6r - -

t t

T

I

t t

2 lt c415

t l'i i--t I l: l I

t--J t--J POWERTRAIN ENGINE i or ENGINE CONTROL, CONTROL MODULE , I (ECM) MOOULE (PCMor ECM) Paqe23 : pr6ro,, Pages24 , and39-4

PHO|O 14A

Y€L

I

t t

i l : l i_J_

tn"r,o"" I

o,[ "uu' ,,,.!,"ou, ,o.!,"oo,'

t r tL - - J t

tFUSE20 \ (BUNNTNG I u_qHrc)

l

t wrrier-u

r - - 1 r - - . | r - - 1

STEREO MAINTENANCECLOCK RADIO/ REMINDER Page154 CASSETTEUNIT PLAYER Page 83 Paqe150 Page

10-8

'98-' 99 N,4odels

'00 Model

aru f

BLU

UNDER-DASH FUSE/RELAY BOX

:

olwrme

RUNNING LIGHTS CONTROL

uNrT

Page1'10-9

. - . Canada

i

li:

'*9,'ot, "*r,o"" I rrr 1 l t l t l STEERING LOCK Page138 ('98-99)or 138,1f00)

--'- Nr --

i [--.

, COMBI. . NATION : LIGHT

; swrTcF , Page101

UNDER-HOOD FUSE/RELAY BOX FUSE 49 DRrOC( SUNNOOF

FUSE50

FUSE5I

FUSE52

RF

+a$ 16A

HOR',|, STOP 20A

o:FnostEF

LL

I I I

J

WHT/GFN

WHT/GFN

WHT/GRN

WHT/GFN

1'l (RS 10)

'13 ?

L

c452

c440 PHOfO 62

1 UNDER. I DASH i FUSE/ : RELAY I BOX

i - -'00 |\,4odel

c418

==:==t-

58 IPHOTO J

c661

WHl/GFN

WHT/GRN

c662

c448

(Cruise2) 'l o I caeo

t

1 t

coMBr. MOONROOFREAR wtNoow NATION RELAY DEFOGGER LIGHT Page122 RELAY Page64

SWITCH Page100

1

c431

l

BRAKE swtTcH

ia---;,;"] t l L------J HORNRELAY Page40

Pages23-6 ('98-'39),24,6 ( 00), 34-1,39 (98,' 99), 39-4(00),44, t 1 0 6 , 1 1 0 - 71, 3 8 ('98-'99), and 138-1(00) PHOTQ129

WHT/GFN

i -1-[- "ru, _t - i iF*, 1

c563 12

cseoi z

L------J GAUGE HAZARD WARNING ASSEMBLY page80 swtTcH Page110-2 or110'4

(cont'd)

10-9

PowerDistribution - From Fusesto Relaysand Components(cont'd) FromA on page 10.

WHT

t FUSE61 \ ABS MOTOR

f [Y* l c9o3 r-:-1 I uonracrsI i . j L___

FUSE62 ABS 81 204

154

A B SP U M P MOTOR RELAY Pase44 3

c2t3

c20a

ABS FAIL.SAFE RELAY Page 44-2

10-10

FUSE63 ABS 82

srr----i

(NotUsed)

UNDER.HOOD ABS FUSE/RELAY BOX

GroundDistribution - G 1 ,G 2 ,G 3 ,a n dG 1 0 1 * : '98-'99Models

NOTE:Wiresshownwithoutcolorcodesareblack. BATTERY VALVE Page10 COVER

'n' r-'r t l l

l

I I

I I

PGM-FI MAIN RELAY Page 23 ('98-'99) or 24 ( 00) TRANSMISSION

I I

T3

I

I I T4

t t

i---------\

l l

L-J

L - - - - - - - - - J-;-;.11, (- 10)r-(- 23) 10

.-- GS-R TYPE.R .

.. '

VEHICLE SPEED SENSOR

RADIATOB FAN SWITCH

Page 33

and 63 2

I I

t t

(vss)

II

I I

L-J

l l cl08

c3o1

*-*rl 10

I

I

!

^ _ F,to,o

l

1io,o,o* PHATO6IIITJ

14

'9899 GS.R l/odel

i n r r a r e r r ni

II

II

(c408.)

;

* = '98-'99L4odels

or ENGINE POWERTRAIN MOOULE CONTROL (PCMor ECM) Paqes - 23-2and23'3('98-'99) or 24-2and24-3('00) PHOTO// f98 99 Models) PHA|A 144 100 Made)

r

\

l

I

--".--

PBA|O 51

MAINSHAFT ano COUNTER. SHAFT SPEED SENSOR SHIELD Page 39-1 ('98-'gs)or

L----J

26' I c4s7 BBN/BLK

PRIMARY HEATEO OXYGEN SENSOR (HO2S) SHIELD Page 23-4 ('98-'99)or 24-4 ('00)

SECONDARY HEATEO OXYGEN SENSOR (HO2S) SHIELD Page 23-5 ('98-'99)or 24-5 f00)

r::)t r::) l l t l t

t

k--'a

ill

BRN/BLK

l l

l

39-s[oo)

CRANKne_F . - ii'pilp -i SHAFT SPEED FLUCTUA- ' K N O C K

T|ON (cKF} CKP/ SENSoR SHTELD CYP SENSOR paoe23-2 SHIELO ( 9 6 -9 9 )o r Page 20 24 2 (OOt

(- ,:o

k::!

B R A T D EI D W I F EI

BFAIDED WIRE

1 l

i: (::) : : l , 'I

SENSOR (KS) SHIELD Page23'6 ( 9 8 - 9 9o)r : 24-6(' 00)

: . , ' '

l::i iL:l

.---a--,--o

I ""","j-.!, "oo.

BFAIDEO WIBE

DATALINK (DLCI (DLC) coNNECTOR Page23-7('S8-'99) or 24-7('00)

c:)l r::) I l I I

t l

k::: . k BNAIDED

c102

'l TDC/ CKP/ CYP SENSOR SHIELD Page20

BNAIDEO

I a

PHO|O20

CRANKSHAFT SPEED FLUCTUATION (cKF)SENSOR SHIELD Page23-2(98-99) ot 24-2(00)

(::)

l

t

l

l

kIt:: BFN/ BLK

I I

iiffil

f::l i(::)

AFN/BLK

PBIMARY HEATED OXYGEN SENSOR (HO2S) SHIELD Paqe23-4 ('96-99) or 24 4 ('00)

A/T.--,

TRANSMISSION CONTROL MODULE(TCM) Page39-1

l

---------J

&------

'98' 99 l\4odels

BRAIOEO

. KNOCK , SENSOR

AF

,(Ks)

,SHIELD

or | 1se:'ss; , 24,6('00)

ir::) I : l ; l

I

:kll:: ' BFAIDEO

MAINSHAFT SPEED SENSOR SHIELD Page39-1 ('s8-'99)or 3e-s('00)

COUNTERSHAFT SPEED SENSOR SHIELD Page39-1 ('98-'sg)or 3e-5f00)

(::)

t l

l l

(:::: BFAIDED WIFE

14-1

GroundDistribution(conrd) - G201and G202 NOTE:Wiresshownwithoutcolorcodesareblack.

BADIATOR FAN MOTOR Pages63 and63-2

l t

l l c206

RIGHT FRONT SIDE MARKER LIGHT Page110-11

RIGHT HEADLIGHT Page110-8

IA

RIGHT FRONT PARKING/ TURN SIGNAL LIGHT Pages110-3, 1 1 05 , a n d 110-11

Ai

'l'J"'' (

)

LY___!jj 1 Y C204

UNDER-HOOD FUSE/RELAY BOX .----

U S A- - - - '

PHAfa 21

BLowER

--'

MOTOR RELAY Page60

:

; ' '

aoAb

PIIOTO22

.

PHOTO2S

DETECTOR (ELD)UNIT Peq'e22

r - - 1 . | . - - 1

|

|

: t

I

[g"ri i; l--J 2 Yc$7

t'c218 a

;Y;,;-i---l---J

G201

14-2

Pll;**

ABS FAILSAFE RELAY Page 44-2

ABS PUMP MOTOR Page 44-3

PHO|A 7

PHOIA 5

|.--1r--1

I I

t t

t t

I I

L--J L-.J 4 I' C208 2Y C210

- G301 NOTE:Wiresshownwithoutcolorcodesareblack.

- - - u s A- - . POWER

LEFT FRONT SIDE

LEFT HEADLIGHT P a g e1 1 0 - 8

MARKER LIGHT P a g e1 1 01 1

LEFTFBONT PARKING/ WIND. TURN SHIELD SIGNAL WIPER LIGHT

Pages110-3, MOTOR 110-5. 1 1 05 ,and Paqe91'1 Page 91 110-11

(

I I I I

)

i sreentlc :

WINDSHIELD WASHER MOTOR Page 91

t

l

l

2Y c320 |

BRAKE . ' FLUID ' LEVEL SWITCH : Pages44-1,, 71,and71-1 '

PRESSURE ; (PsP) SWITCH Page23-6 I ('98'99o )r : 24-6('00) ,

PHOTO35

'

r--1

; r--1

I t

t

|

PHATA 33

: l ; l

l ; t :

2 Y C317

c308 3A

-'

I nean : , wtNoow ;

CRUISE CONTROL ACTUATOR Page34'2

l

Hatch' - back

, WASHEB . MOTOR : Page92 I

: l t : : t I i

l

I 2Ycai8:

ly a

G301

14-3

GroundDistributior(cont'd)

- G401

NOTE:Wiresshownwithoutcolorcodesareblack. FRONT PASSENGER'S . - . A , / T- . . DOOR ; KEY FRONT ' PARKPtN ' SWITCH CYLINDERPASSENGER'S SWITCH OOORLOCK ' Paqe138 Paqe130 SWITCH I (ge ggtor or130-2 Paget30 ; 138-1C00) PHafao6 or 130-2 | pHaro12a

!.--.!

I |

tT'

, r--1

r--1

; l ; t

| | | I

| | t^-.--i^-

'"IY k ^^^91i

z

l t

t'or'

a';"'" I

| |

' INTERLOCK SERVICE : CHECK CONTROL CLUTCH i CONNECTORUNIT swtTcH , Pages Page138 Page34-3 23-6( 98-99), PHoro5z i--t : 24,6('00),

: ;

, LrJ : tY'"*u"": ' I'zi :

:

'I*-'l*"'l**

iifiii;"'! !

PHOTO 76

r

I

l

:

l

I

-

- o-------

Canada

c403

DAYTIME \YTIME RUNNING LIGHTS CONTROL UNIT Page110-9 Page ) ;

tI tI

l l 't Y c41 c41(

STEERING LOCK Page73

'i!Y-',

a

14-4

o

139""i#;3a, cLUrcH

ig.ii,oor.--" TNTERLOCK PAIA,LT$ 89, 138(rss99t

i ffi."ro* ;p,'nron Switch I Page 23-7

!i:;iSii' !'---'' | . ii ;;":,;i; Llrri.i

- l l

A/T GEAR POStTTON SWITCH

12 Y C406

i'#!".., 'lgl::""

and 138-1{ 00)

PHO|OTo

r--1

l t

l-J

lwlTcH Page zl-l

PHOfa 130

r--1

t t

t l

t--J

2

|

l l

'Y 9:t:,2."rc428 I

t

I

o

l l

I

"1i,. I | .l

IE

L__J

t t

,

L

t

* = '98-'99 f,4odels REAR

GAUGE ASSEMBLY Pages80-1,80 2, 8 1 - 1a, n dB g

CRUISE CONTROL MAIN

swrTcH

wtNDow DEFOGGER SWITCH Page 64

Page 34

DASH LIGHTS MOONROOF BRIGHTNESS RELAY CONTROLLERPage122 P a g e1 1 4

I I

J

L-------J

c662

All . - - e x c e p t- . , R S CIGARETTE LIGHTER Pages114-1 and 155

: , ' I

GLOVE BOX LIGHT P a g e1 1 4

' l : l

l

MOONROOF swtTcH Page 122

t l

l t :

:F.

t

;

l l 2 Y C664

I

Oerminals 5-10)

c661 PHOfA 58

TURN SIGiIAU HAZARD RELAY paoes11G2 ani tt0-+

POWER WINDOW RELAY Pages120 and120-2

?HOTO'O

PHOTO@

UNDEROASII FUSE/ BELAY BOX

INTEGRATED CONTROL UN|T PNO|O 62

r - . 1 r - - 1 | . - - 1

t t

l l

c926

t l

l l

1Y C92s

14 ------J

c439 COMBINATION WIPER SWITCH Pages9l-'l

92 I coHuecron ' : Page , ((oPTtoN) o P n o N ) ; , r - - 1

i s Y cc 4r 5s o l: l l

r--1

t l

I

l l

L-.J 5 Y C437

-l G401

14-5

GroundDistribution(conrd)

- Gs02

NOTE:Wiresshownwithoutcolorcodesareblack.

' - 31""0, r, - ., PowER

j

OOORLOCK CONTROL UNIT Page130-1 or 1303

DRIVER'S DOORLOCK ACTUATOR Page130-1 or 130'3

; , . : ;

Pnofo u

PFofo $

|

r--1

r--1

l I

t I

t I

t |

oRven's

DOORKEY : CYLINOER : SWITCH Page130-1 or 130-2 : PtaQfoS5

FUEL PUMP P Page 23'1 Pi ('I ('97,'98)or 24 1 ('00) 2'

ORIVER'S SEAT BELT

swrTcH page73 !'--1

|

; t t : : t | :

l t

pr 7

l t

tT'

tl tl

l l

:

T

z ! csoz"t "oto f ".^ ' '----

;i

: : ; :

FIFFTo

s e . i a -n- - - - -

POWER WINDOW MASTERswtrcH Pages120-2. 120.3. 1204. and120.5

lI * *

r, l i l F l i i ,

f I I I

uNtT F"g"" u+ ano er photass

' : t : : t

t ; l t l : l t " L - - - - - J , l L - - J

I I

lTl'lili;-fl lla ---o----a

a-- a--

c506

1 4 -6

--

l._il__-_--

I

!

--o----a

csoz

BLlv

BLK/

98

- G503(Hatchback), G751 NOTE:Wiresshownwithoutcolorcodesareblack. LEFT BRAKE LIGHT/ LEFT TAIL. REAR LEFT LIGHT TURN neln Paqes SIGNAL PARKING LEFT LIGHT LIGHT BAcK-uP 110-6 and Paqe LIGHT Paoe tto*-s ttd-tz P a o e1 1 0 1 1 0 ' 1 2

1-) (_r 1-\ \_r

(-) r---' \-/ r--r

RIGHT BRAKE LIGHT/ RIGHT TAILREAB RIGHT LIGHT TURN REAR PAgCS SIGNALPARKING RIGHT LIGHT LIGHT BACK.UP 110-6 and Page Page LIGHT 1 1 0 - 3 1 1 0 ' 1 2 P a g e1 1 0 1 1 0 - 1 2

1-\ \-,, \-,, 1-)

REAR wtNDow WIPER MOTOR Page92

f-) \.'/ t--t

t

l

LLIJ L-L.I PHOTO108

PHOTO148

HATCH LATCH Page114-3

t . I lt

l

l

POWER ANTENNA MOTOR Paoe 151 pu6rctos |.--1

| I

LICENSE PLATE LIGHTS P a g e1 1 0 - 1 2

| |

l-t r-t \-., \-,,

t t

I I

l l

L ALU

cnv I 1 g

HIGH MOUNT BRAKE LIGHT Page110'6

HATCH OPENER ACTUATOR Page134

HATCH OPENER SWITCH Page134

c52a

U T;,. I iHi'$t"" I I I

:3:.:ll: ^ -:-"^

1 g c756

| ':::2"'

1 REO

atu/

I 1

I

PHA|O 137

PHOfO 106

HATCHKEY CYLINDER

swtrcH

Page130

. l

I

t t * l t I -

I

l

'l le:3?.,,,

(GSand

I GS-R)

c530

c527

r

l

'

:I

.

tGS 'YF/o% :*^ a 1lz

BLU

1

c529

l l lt - l

c525

I

!

cTsl

14-7

Ground Distributioh(cont'd) - G503(Sedan) NOTE:Wkes shownwithoutcolorcodes are black. LEFT I NN E R BRAKE LEFT LIGHT/ BACK-UP TAILLIGHT LIGHT Paqes110-7 P a q e1 1 0 , 1 a n d 1 1 0 - 1 3

r-,r

RrcHr

!'rqlt-

TRUNK LATCH

!iTfi^. iilt[i", iff#"" ii3:3 b:::1,0.

swtTcH

Page114-3

:i3::lts'

(:) (:) rllr

,--r r-

\_,,

l!-c.{r

-,

t t

L.J LIJ

l l

2 Y C535

RIGHT BACK-UP LIGHT P a g e1 1 0 1

/

\

RIGHT INNER BRAKE LIGHT/ TAILLIGHT Pages110-7 a n d1 1 0 - 1 3

(

)

L.J

cs22

c534

TRAILER LIGHTING CONNECTOR P a g e1 1 8

LEFT REAR TURN SIGNAL LIGHT Page110-5

LEFT REAR PARKING LIGHT Page 110-13

/

\

LEFT OUTER BRAKE LIGHT/ TAILLIGHT Pages1'10-7 a n d1 1 0 - 1 3

(

)

'98-'99 Model (Not useo)

REAR

wrNDow

DEFOGGER Page 64

HIGH MOUNT BRAKE LIGHT Page110-7

t l

14-8

l

l

G771,and G801 G151,G551,G7O2, NOTE:Wiresshownwithoutcolorcodesareblack.

CONDENSER FAN MOTOR Page 63

t

l

ABSCONTROL UNIT Page44'1

STEREO RADIO/ CASSETTE PLAYEB Page150'1

t l

l l

14

PHO|O 100 PHO|O 111 (Sedan)

REAR WINDOW OEFOGGER Page 64

SRS UNIT Page 47 PHoro67

r--1

t t

-L - - - - - - -:v -------J czoe z v-

l l 1 i'-

-.;lt

c704

Y c771

cl5s

!

ctst

!

cssr

,.}

G702

G7?1

PHOfO 116

+-

G80l PHOTO67

14-9

lgnitionSystem

I

NorE: Forservicecheckconnectordetails,seepage23-6('98-99Models)or 2zl-6('00Model).

I

POWERTRAIN '-"

rDc

cKp

sensor inout input ! g"ocet I L--:----_"4_____:_

cyp

sensor inout input n !cj a

at

"a

@

Vo.i Swhch

HiDEF Swltch

D6lro3t Ssltch

I I I ,

I

I

"lf

ttto o

BLK I

o'o'''"'on' | !3!"u;;110

".*l

1'

W,rl61-1

Air Deliver| (cont'd) - How the Circuit Works Theairdeliverysystemdirectstheflowof air used by theheaterandairconditioner systems. ModeSelection Modeselectionis controlled by the modeswitchesin the heatercontrolpanelandthe modecontrolmotor. Whenyou selecta specificmode,voltageis applied through thedimming controlcircuitto theLED,which comeson,indicating themodeselected. Groundis providedto the modecontrolmotorthoughthat modeswitch.Themotorthenrunsuntilthe air controldoorreachesthe properposition. Fresh/RecirculationSelection Whenyoupressthe recirculation button,a ground signalis sentfromthe heatercontrolpanelto the recirculation controlmotor.Themotorlhenruns untilthe recirculation doorreaches theopposite Whenthe recirculation Dosition. buttonis in the RECposition, batteryvoltageis appliedthroughthe dimming controlcircuitto the recirculate LED,and theLEDcomeson. Referto theServiceManual(Section 21,Heate0for procedures. specif ic testsor troubleshooting

61-2

A/CGompressor Controls @

r-T------.I I t FUSE17

UNDER-DASH I FUSE/RELAY

I

l--*

|

) LBEL, r.uo

I :

I {--t

I

^lee _ Power

(GoNDEXSEAfAN) 204

I :

Diskibdion.

L_I_fiT_.! I C439

Y "'oto u' ".^,tr. | ll erx,.ver a ---i

FUS€55

t19T^..

UNDER.HOOO FUSE/RELAY BOX

SeePower Dislribution, page1G'l.

36€ Power Distribution, pagetO-0.

BLX/YEL I

" IFi:,u.^ NC COMPR€SSOR CLUTCH REI.AY Ptloron

-Y c905 -*---------

-f - '98199modelswithA/T - - - r -^ ^-^:'l TRANSMTSSTON CONTROL rr!P!I.. : ^;;', : MoDULE

|

L-Z-J

| (rcM)

24 Y C420 BLK/RED

POWERTRAIN or ENGINE CONTROL MODULE (PCMor ECM) ly'CONinDut

PHOfO 77 (94 99)

{ACS}

L--,S"s-i

(98-99 s) Y (C4o8'98-'99) 27 tl C409

",-r,"ao I

I aLuneo ar
-1!-1'

!-o3!!-------J.FromC437on rnrspage.

Intermittentwlpcr Rclty Circu l

------------r

c914

F'r:i-' ".',I

----r

I

! |

SeeGround Distribution, page14-5.

V

BLK

rd

I 91-1

Wiperffasher (contd) - How the Circuit Works Whenthe ignition switchis in ON (ll)or START(lll), batteryvoltageis appliedto lhe windshield wiper/washer wiper switch,andthewindshield motor. Low Speed Whenyouturnthewiperswitchto LO,thewiper throughthe motor'slowspeedwindingis grounded BLUwireandtheLO speedcontacts of thewiper switchat G401,andthewipersrunat lowspeed. ParUOfi WhenyouturnthewiperswitchOFF,theintegrated controlunit(PARKinput)grounds thewipermotor throughthe BLUMHTwire.Thecamswitchon the motorsignalstheintegrated controlunitthatthe thecontrolunit wipersarein the PARKposition; thenremovesgroundfromthe motor,andthe wipersstopin the PARKposition. HighSpeed Whenthewiperswitchis in Hl,the highspeed windings wipermotorare ol thewindshield grounded throughthe BLUI/ELwireandthe Hl contactsof the wiperswitchat G401, andthe wipersrunat highspeed. Intermittent Whenthewiperswitchis in lNT,batteryvoltageis appliedthroughtheYEUBLUwireto theintegrated wiperON input).The controlunit(lntermittent integrated controlunit(lntermittenvPark Wiper grounds the lowspeedwindings of the Control) wipermotorandthewipersmakea singlesweep everyfewseconds(SeeLowSpeedabove).When thewiperreturnsto the PARKposition, thepark switchappliesbatteryvoltagethroughthe BLUMHTwireto the integrated controlunit(PARK input),andthewipersstopin the PARKposition.

91-2

Mist Whenyoupullthewiperswitchdownto MIST position, the highspeedwindings of thewipermotor throughtheBLU//ELwireandthe aregrounded of themistswitchat G401,andthe closedcontacts wipersmakeonepassacrossthewindshield at high thentakesoverand speed.The PABKOFFtunction thewrpersstopin the PARKposition. Washer Whenyoupullthe wiperswitchtowardyouto turnon the washerswitch,batteryvoltageis appliedto the washermotor.The motorpumpsfluidontothe windshield untilyou releasethe lever.On models the withcombinedwiper/washer operation(Canada), washerON input) integrated controlunit(windshield sensespoweral the BLI(GRNwireterminaland runsthewashermotorwhenever thewioersrun. 23, Electrical) Reterto theServiceirlanual(Section procedures. for specific testsor troubleshooting

RearWiperMasher UNDER.DASH FUSE/RELAY BOX PHO|A 58

I

:- -

c442

---J

c504 GFN/AIK LT GFN/BLK

GRNAiTHf

c5r6 GRN/BLK

(ln-line connectort may not be presentin all cars.)

lT GFN/BLK

c526 GFN/6LK

LT GFN/BLK

4

1 GRN/BLK

c755

LTGFN/BLK

REAR wtNDow WIPER MOTOR

GFN

2

GFN

8LK

c526

Or-(

GRN

c516 GFN

5 GFN

1

4

(ln-lineconnector;may not be present in all cars.) c422 PHafo 56

!

c435 PHOTO 48

Rear wtndow wiper/ Washer Swltch BLU BLU/BLK

8 (RS12)

I

G751

.I COMBINATTON I WIPER : swtTcH | I !

I

ALK

2

3

c435

LT GRN/BLK

c302

BLK

BLU/6LK

c3r8 REAR

wrNDow WASHER MOTOR

SeeGround Diskibution, page1+3.

?f*'u"* Y f

BLK

L_______l '------=,cgot.< PHA|O 11

92

SeeGround Oistribution, page1+7.

SeeGround Distribution, page'l4-5.

LTGRN/BIK

HeadlightSwitch --.I

FUSE 4a

UNDERHOOO

t rusesr i russr

HE^nrrcr{r 1|oA

REL +BsMArL sMArL ! RELAY \ +e l1.5e I Box

Head. I TroN lloht a LIGHT

s; ch! swrrcH --)otl*o1--)*r

"*

o.t

\,)

I PHaro 144

I

------m**;-----";;r--"."-4"*' HEAD PAFX

I

pmx

I raax

I

J

RED/BLU

,;:-: i *

"'"'"lI:'*.

+ V i:l I

' i ;;;;;l

i i" L_jHsl,,,, -'- - - - - -- ------- -!-I9:::"'" FUSE5

FUSE2I

R - IIEAD UGHT IOW BEAI' 104

L_ HEAO LIGHT NIGH BEAiI 10A

UNDERDASTI FUSE/ RELAY BOX

FUSS4 R . NEADUGH' H|G8 'loA AEAB

c438

!Jg3i (Not Used)

FED/BLU

Canada - - -

;l

FED/BLU

o5/

2|

I I I

J

100

LEFT HEADLIGHT Page 110-8

C205

REO/ BLU 6 BED/ BLU

c30t c307

r I I

.I DRL

I REsrsroR

I Page110-9

FromA on lacingpage. !J

v

i

neorcnn I ;l ' a -=--J -: I

N

B E o / q R N 3 ^SECURITY -SYSTEM coNNEcroR (oPrloN) cG

'

---- O'iify -.----" Phoro ttt

___ :l-ll c44i "to'o"n

UNDER-DASH FUSE/RELAY BOX

7 A p1ora59

r--1 INTEGRATED I LiohtsI CONTROL :oN : UN|T I inDut I rYioTO62

ToEon nelcpage. 't7

OPTION CONNECTOR (DASHLTGHTS)

15 Y C551

c440

FED/ BLX

----;

_I *Tf c4.4 li,irlffi",;:^l 'f,9"*

","! .uu.*-[------]f ".o 1:?[ "*

-.'l'--,,ili # ilJ I ",

"-+: * iI

"fow; edoro6e I

"ao,i

t t

il;

8ff"ttt;tt

FED/BLK I

, I .r.. l l

l l

HAZARD WARNING swlTcH Page114-1

I

"u.0"'*li ;l:;;,i:'::' . l"uu, !.'l"*, l l

(-) ii--l

: i Paeett+ : : nttexcept l i -

coNTRoLLEB Pase114

| neor

|

|

sLK

CRUISE CONTROL MAIN

swtTcH

Page114-1

10

: i--l

i!*ij",i t*r.i* +i.iHt+ifl

HEAIER CONTROL L PANEL F;;;' Page 1ii-1 1 1 41

|

t GAUGE ASSEMBLY P a g e1 1 4

l

REAR

wtNDow DEFOGGER swtrcH

CIGARETTE LIGHTER Page114-1

Page114

USARS

(cont'd)

100-1

HeadlightSwitch (cont'd) -.I FromB on pr€viouspage.

't8

c302

2 |' C319

LEFT FRONT SIDE MARKER LIGHT P a g e1 1 0 - 1 1

100-2

3 l'

C320

LEFTFRONT PARKING/TURN SIGNALLIGHT Page110-11

RIGHT FRONT SIDE MARKER LIGHT Page110-l1

RIGHTFRONT PARKING/TURN SIGNALLIGHT P a g e1 1 0 - 1 1

UNDER.OASH FUSE/RELAY BOX

c516

(ln-line connector; maynot be present in allcars.)

".o".*l 1 J

.Z[\

:

I

Cs22

*""*[-q I"'"-[='ilI i ,-t i.j

t-t

i,i

neo ar-x I

:

i'gdi.Ite^- [ i*;Plgl il

I

F*+'.i""* !

ifii:|l$''il

.Fl "-'-Fl ;ilI

**

*""*!

r\ . /- - \ ( LEFT NENN i'rCiirlc f-iCii Paoes rrd-rz and110''13

-t

LEFT ARNXELICXT/ irir-t-iGii (Hatchback) L E F IO U T E R BRAKELTGHT/ TAILLIGHT {sedan) Pagesi to-tz a n d1 1 0 ' 1 3

I

---

---

t\ . /\ RIGHT NEIN PARKTNG LIGHT Pages 110-12 and110'13

;-

(

i; l'

I"---

)

RIGHT BRAKELIGHT/ ralLLlcHT (Hatchback) RIGHT OUTER BRAKELIGHT/ TAILLIGHT (sedan) Pages110-12 a n d1 1 0 - 1 3

:(

r-s

!I

:

l

LEFTINNER : ' BRAKELIGHT/ ' TAILLIGHT Page110-13 : ;------

:

t : ti9'1'3,,,i :

t

j

ato*ufl

t

: ,.-

!

'

!

I l 'tut;%,,,

jr.or.*tr

t

I:

I

:l8iill,%'' 4 1l^--;"o;oi;:'s"o*'il 914 _ cAcszr :[ ---j rseoani)[;ffi13;?3,"*"", (sedan3) n38:1'r,".".",. ! I

:

[

|

(

)

RIGHTINNER BRAKELIGHT/ TAlLLlGtlrPage110-13

i : i :

100-3

Back-upLights - Hatchback -.I

I

UNDER.DASH

I FUSETRELAY

I ruSr rs

* ! 1;" ," uo"'. I F"?T" i |

| I

L-J-----J

'oY "c,fl13.,

YEL I a-

*'l

Automatic Transmission

s€e powsr Distribution,

YEL

page10-4.

l\4anual Transmission

"'i U"ro' ':;^::;:"

.=L=r-. """1:i*#J;;;" !.frl_.j "1"''1,! A/T GEAR POSITION

swtTcH

aacr-up r# swrrcH I 1 | LrcHT tra.lsm,ss,on _\ It | l]"^#1,;:. "notot'

o"n,".*F

","'"J, fi ";o'8" """,J; fi F;%,,

9,:%,, """JIft ""-".t[

t*'

fi f,f.l,l" "onn"",o.,

o"n".*!ffi;-'l ,lF;,;,,,

0,"""", *" *_ ilil,?:lli I

:l::.

canre.*l

i$itdq

""g#'"'c'o*

@ l.:{;*-,"

Y eLr

"Tt "*, .II-II'

eaororoa

I

o"n".*f

@ BLK

I

erx

,fffi:,*

arrrr-
------+-

* = '98-'99l,4odels

110-2

I\r-l

!F[ ,**t,** pase. -----11I

t

csoo RIGHTTURN SIGNAL I}IDICATOR UGHT

GAUGE ASSEMBLY

@i{FH'"'

COMBINATION LIGHT

l!rn Signal Swllch

'T

L-

c434

From B on facing page.

v

i GRN/BLU

t6

GFN/ BLU

GFN/ BLt'

vt

GFNffEL

I

9:"4,2," t Jl "",u"%* . Jl "",%%* u ______e-t

H

I I

From C on tacrngPage.

"r""* I

GFN/BLU

I

swtTcH

UNDER-DASH I FUSE/RELAY

iF,oJ","

c504

I:: [ff Used)

c504

15

PhoTa 62

10

GRN/EIU

o"nrtaa I

----+

CRN/ALU

GBN/BLU

I

;T:]*

a

GFN/YEL

c516 (ln-line connector; maynot be present in allcars.) RED/BLK

See Parking Lights cFN/ BLU

3

1 /-l'_'\\ T lo q

\:9./

---.I

LEFTFBONT /A I b T PARKING/TURN

srcNALLrcHr v/

c320

[,*

lerr nean

SIGNAL I TURN LIGHT

Y

"t"

BLK

I

ALK

SeeGround Distribution, page1+3.

,[r",..

BtcHTFRONT /-m --fF--36="1?tto" (oPT|oN) ;;;

g,%03^FS2;"6t$2rg '24

_rJt gp:,s". BLU/ REO

ALU/

YEU BED

(NotUsed) ORIVER'S DOORLOCK ACTUATOR

c506 YEUFED 4

yEqFEo

c421

YEUBED

ll

Prrolo 50

"..".o

Y E LR E D |

9,0:1",,

veuneo

YEUFED 'I WHI/FEO

YEURED

WHT/REO

2

I

cs28

YEL nED

| r Aces+ tn"#r, onoto'' .,.. ,rar"ao ".,-".o "aa"ao ".of,t 'r FRoNT lerr Rell rfi

c633

Y,%?i,u Ptloro 36

RIGHT REAR DOOR LOCK ACTUATOR

h[},p*i'HfSf^'". WHTFEO II

"',%13,u c4ot

PHoro7s WHT/FED

5

\ro:L,"

WHTFEO

gu^q1, t iaoros' 'f

c633

WHT/RED

'fi

2

'i,t::|",,

2

WHTREO wHTREO I lt 3 !'l(c s 2 7 3 PHoro8e wHrFED I U

wHrlF€D

c6s9 c528

wHrFED

a

wHr/REo 11 c506 WHT/FEO

o

130-3

lmmobilizer System('00Model) POWERTRAIN ol ENGINE

- - - -F^-E; -'j -;,6ri iriE' !;.-. *;; ; I H3BB" (Pclvlor EcM) i I 1,'r._,..--: !.i3!.* f F ( rri-*." ",ono. \ rua ruur lsnsurrll Firser I i \ o_e,n \ xrano I FUsEi

CONTROL

ig-r

i

fl^.ee,ntesra,ed fi;rl,u,:l i "u'* iEioii f

"'-

l

'*"

iEEf'

!:"'ll,l' ! L---g-_'ry_+J-:_E.:gil il.^=---=I-= -i;;eo'' io"-r, I B:i,fffil pase lo-e. !4.1ry.. : RELAY

".,"":r------*-";T ^

WHI/GRN

;{---------61'c446

t

""i;i ,.""..1 i*':,:""# -:":fr'*,, I | ,"!::.,"

o'"u'u"'on l i ;;6;;;uno

!

'= PHoro2s

yffi

[f,"i;. I ".--rr

|

I

! (9

|

GAuGE

ilSi'"ito"

I

i"Yffii

-'-=--l ,""o",.,r.*

t;ia;;----'

I "ffi;f:'- ,.!,"ouu ""-II

"." l N 'lr**"" ,,tr*, ,ffi".,, ILF"l';I".., "..".* i I I

l"#fl;llF#'*"

-;:*+ -l 7;:F, isx,fi^ ,-Tr,u-,"*"tilt, 'no" codeinput enabref I [-;*tn-

i--!r, I *.**il iltlw IJ

ul.:ii'o (LGr)

20 c4s7 enrerxtr, |

-J

\ I \ iilfli:lT*, itf$Egf ( P C Mo r |

2------J

|

t g"-:,Bn'*,l l guW """".-U:i' BFN""l--i

:

132

PHafag4

i:-f,:g:,,

! s." crouna

Yffi:

:,"#,.,

- How the Circuit Works to preventthe systemis designed Theimmobilizer carf rombeingstartedwithouttheowner'signition key. lf an attemptis madeto startthe car without systemwilldisable thecorrectkey,the immobilizer thecar'sfuelsupply. systemconsistsof the ignitionkey, Theimmobilizer indicator receiver unit,immobilizer immobilizer pump, the PCM and relay, fuel main light,PGM-FI or ECM. switchin ON (ll)or START(lll),the Withtheignition unitandthe PCMor ECM receiver immobilizer on"signalthroughfuse44 and receivean "ignition the PGM-FImainrelay.ThePCMor ECMthen through sendspowerto theignitionkeytransponder then receiver unit.Thetransponder the immobilizer sendsa codedsignalbackto the PCMor ECM the unit. lf thesignalis correct, throughthe receiver thecar'sfuelsupply PCMor ECMwillenergize the PGM-FImainrelay.The systemby grounding indicator lightflashesa codeto indicate immobilizer thatthecorrectkeyhasbeeninserted.lf the the PCMor ECM keysignalis notcorrect, ignition thecar'sfuelsupplysystemby not willnotenergize grounding the PGM-Flmainrelay.Theimmobilizer thatan lightthenflashesa codeto indicate indicator keyhasbeeninserted. incorrect 23, Referto the ServiceManual(Section for specifictestsand BodyElectrical) procedures. troubleshooting

132-1

SecuritySystem NOTE:Wiresthat look likethis --::= factoryharness connectors.

are partof the optionalSecuritySystemharnessinstalledbetlveen

-----f.-u'?;l

!-l-'*;;-| ) Ho-BN.srop | |

1."^ {---------------

"\W27**^

LJ--------.J4---------9----JP4oto21

-"hlT'jZn8:,*[:*ift

SeePowerDislribulion. rZ )z----page10-9.

, f]3,"0u,

HBB'J'

I FUSE/ ) B..l\-cj^qp | lTl"'", I RELAY | Box l'*

page1o-8.

!--T-'u-"-"-13X3"'*| I FusE, ) Flg!!!p I I

I RELAY lBox

a ;'lx'" -^ l

L-Ja----JPHoro,3

:.1::t*' a+

*', "r:l''"' "t' ** ------,C 1.*" ;;;" "1,f";"3"*",J"11-------;'ff wnr I t"o'o 'o

I

tn"r ".u | |

".. | |

*n'

seepower Distributjon, page104.

' '

t"ffBr+T' mli [F=]F;"#,.. "T['*kfl EilHr{" E c4s1

"."".:X-:-S]""'ll

ll

ffi'-"*FL_____r*F_ l^y^ :l-il* "-l ,"":l :::lb.i[ri?n'a'fl:. r..rn?.,n

Horncontrol i a Drsarm/varet rq I Groundswitch input switch input inprlt r.JllXi'lJ;,L s'ivitcn !:L - Ground -----;

Security indicator

Battery

control

-----,;]1

toy--T|f-

lgnilion lgnition

Antenna I 'nPut \

------J

B r Kl l r r G R N l l LrBLU - - - - - -;-:t l l 7 Yi- -;-ltc426

r

|

",,I

ttu' . c4so

'eru I z:L cqgz

KevReminders

*'*'i'f,F;l'o"

i{",;::* rh d.,til i;-fr H{jfJ. I Ed'"""" LliCir'l':i "t--,i[;"" ":it*t*' I

"..1 -.1 I 133

I I

See Ground Distributron. pages14-4and 14 5.

G401

rRANsMlrrER

I

a ) ' -

-----'!rex^ER

I 1

illt#lP$3"'s'J39" H^-

li33,i

I

i i

F;t':"' i*.,;-, l_.,*_______,fr_j ,.llF-------il(coo+ r Inpw

lnpu

;

I a.rn;o I

i

I

9 l, C2j6

t iidr'o az

'

".*-",i

u.^,".o I

T

, ol - - ----------J 'o f er-rcneol ""

seetuwer

3;*1tB:

ii----l I

"',f""3,,

f

Ptioro )4

wHr I

I eL,"v*r I

.'.- r - - ------l6-f ------J^.^.

lPHarc2'

I

-qh9i"," "o,,

LIGHT FLASHER

aix,wxr arx,wxrl !

I f-------.Jln:SY,,

-:-[;^. -";][-. }-hf[ ;LT-ffi *"*:iL_____::lL_ ""'"n i

r zA - _ - " 1

'1"

ll ar.x.n:o

J

tl

I

sA__--

|

","',' GRN'YE *.llll

,ll

ELKwHrll

ll

I \.

!1ft"c*39,,, ij:g+ ''-

-1A-----------19 tl

- - ---

-_--9J.t----

Loc*output

output unrock

[

ill

".o,o"n I T

!

- - -1! ]ZJ{ -----:1

sEcuRrrr i!

fiirn[|. ! Eg,f"o. ,gil,", ildib., ! t

siren contror

ffi,U',:. pase'ro*l'

i I

-----:[:-;nT:===;.TIf ithT#'**l!$gs : ;s__+_______+';,;.... i ! i,,#;'*'iF.ifl, -;;-q

A------

9 t|'-

Hoodswirchinput

- - - - - - -

- -^:1t-

i I T1"'

:

""".lnro.

sEcuRrrY rtl

nooo

fl tts,'Jt;; l/.1:#[%

u

"; Y'ioic"n

r c44i

5e PHOrO

;'lf

3,'],o,,0 ',,u"if,F"l%oo

,

7

.* "'r"J

'ft*"'l*u.u"o "ro

i Ljry-i '

L-*'-----

;

"to".^f,

i'

neoeLxf

I cdHead'isht

IgJ'e*.,

t:;:['fig"' i I t r "*l ilu"#:31 i ".-f i I iatr'f'ni"xl II **1

-i o,o'i

+

(cont'd)

133-1

Security System(contd) NOTE:Wiresthat look likethis 5--------5 are partof the ootional Security Systemharnessinstalledbetweenfactoryharnessconnectors. UNDER.

r.I-.;.-,:1

I { i":"",'# | !.o.^o-g I J t$ri ;Eiii

c"itrns

I

L^*-^lt-jF,i[,, i lg5 aY cz.tz

wHr RED ll

P&?ir rz

sEcuRrrY I coNrBoL

Door

fffJ ||rrrur

ro 6___z_|f__________Jlf

I .- -

8,'"'hT"

ll

rnpur iv,j:]'",, I','#llitT oPcn ]

see Trunk o"n*i l LidOpenor

ll

,, VP,'::.^

t"t*

."*":['*'*lH'T,'*i'*" ;;:, llll *""& dlffi'r,'*ir*' t-l,",,*,"""^'"*f,'''o" ffi .*"*1*, 1 ll [*l "l1",., >-a

L= Jsts.""ll .,"""ffi:;:91., ,l"u.u .L:-.ntt ll ':L--:SI{ "" 'I:;"12* H4rqH _I,&:1*,"","11 I

."""'o.L----

P,olos6

a,o"n ".oI r----{--

!

'NDER-DAsFI

-='1=rr^,."-"" l"''qi:'':* i |.l;H,I!il"" ll ilSl:il,:f,-,. "*' I FUSE;BELAY

,. I "oo.

li!qr,,n.t !fiJ"'' >1 r ru;;i.L----V-J L'"---J_.i L---ilr-J

ll

iI

lll r

I

14 c44e lr ---:{j1'-----l ----1---

lFhalchooen '

I

ll

---:Ij1'-----l

:tl-------i "if 1 gg ccss2288

I|

"-l'nnn'''o--,..^,.^ "-l I| _"""o,ouno "". _''.""o,"""0 'rr{ or{ oisiriourtn. oLtrioutron,

'":;1"_. *o'o' ;t'"*." gn:+rf+J ""^l.:fit*t" """ ".u ll cnNe.uI

illl

*"{l-o

"." ll

," I ",,,

-*ll

11""" ||

cFNBLu

V

ll

""",. $s,*2. """",u! """ "'u.i. -:-

open

DRTVER S

| 1 IDooR

3lill8T,* lr-\ |ooor op"". H -

133-2

eiafaaT pHoro 88 (sedan)

pase u,

pase 14-8'

u.*|

l#

99,to;t,u

:iio_,_o.0,,

u cnr neo I

-Gc--

-

-t-

Indicator

"uo, l-lFl

".*l

'cnrneof

s""

HPrata' te

LrcFNRED

ll.,\

(ln-lineconnector;, ',.,o""".0! .,o"n",'![:U;,1"" ____l::.*"! i cars.)

cs12 l-rlF,l

I i

FRONT

i, .1,"rr,

'll-l-tt I passENcEns

.1,;;,

LEFTREAB l-rt-l

I ooon

| {

RtcHr

| neanooon

lr-\ 1333*i"Y,l'"" i, lr-\ Iil3llSi* lr-\ I 3lillET,,' |+-f oo- op"n o* op"n ts E-J i*i opu1 -

plotoyT pHoross (sedan)

photoa2

:

_ - Sedan .

prratag,

J

r-----TI

STEERING l g n i t i o n LOCK

r----T--"-==-1

| | | | I I

f--r i[!,iii[ir" lswncn Pase10 , sraRr

-/ !'gcK
w H E NA D D T NoGR F E P t A c t NTGH Ec o 0 L A N Tu, s E 5 0 , / 5 0s o L U ro N o F ' H o N D A AN ND TD I S T L L E DW A T E F ' R E C O M M T NG DEN D U I NAEN T- F R E I Z E , / C O O t A T ,R I H E L I F EO F T H EE N G I NMF A YB E S E R ] O U S L Y > N E V E fDl I L U T TEH EC O O t A N O SHORTENTO. S R 2 0 0 . 0 0k0m ( 1 2 00 0 0[ , |L t S ] ' > T H E C O o L A NM T U S TB E B E P L A C EADT I 2 0 M O N T H O r T E v E F Y6 0 [ r o N T H so R 1 0 0 . 0 0k0m ( 6 00 0 0[ i l L E s ) ' rnirilrren, B€pLAcE TE A N KN . O TT H ER A D I A T O F ' > C H E C (O R A D DT H EC O O L A NAIT T H ER E S E R V SA N U A L ' R .E A DT H EO W N E N 'M NR FORMATO I ONN] H E C O O L ] NSGY S T E M > F O RF I , J R T HI E AE A L E R , ICHECK W I T HY O U RH O N O D

I SO U . S .E P AN L E V T H I SV T HC t E C O N F O F [ T YTAs ] ODEL LO E 2 O OM R E G U L A T I OANPSP L ] C A B T EA F F SA I I DC A L ] F O R N I A N E WT L T VP A S S E N GC ] O O EYTA E R AN PS P L I C A BTLOE2 O OM REGUTATIO EA RR S . N E WT L E VP A S S E N G C

N : 0 . l / 1 0 . 0 2m m VATVE LASH (COLD) E X | 0 1 9 i 0 0 2m m 1.2-1.m 3 m GAP S P A RPKL U G EDTO, I O O T H EARD J U S I M E N I S

HONDAl/0T0R c0. , LTD

ll,5lil,5;i;,'iX;';'

I H N X V O8I1, 3 F I HNXROO99AAK O 8 OI I C E R I I F I E D 1.81

P72-401

50 STATETIER 1 SO U . S .E P AA N D C A L I F O R T H I SV E H I C L C E O N F O R MT TO 2OO1MODELYEAR APPLICABLE NIA REGULATIONS CARS. NEWPASSENGER 50 STATETLEV+ NLEV (UNRESTRICTEDI: E O N F O R MTSO U . S .E P AN L E VR E G U L A T H I SV E H I C L C TO 2OO1MODELYEAR NEW TLEV TIONSAPPLICABLE A EGULATIONS PASSENGEC R A R SA N D C A L I F O R N I R N E W T L E VP A S . Y E A R M O D E L T O 2 O O 1 APPLICABLE CARS. SENGER CANADIANTIER1 TO CANADIANTIER1 STAN. CONFORMS THISVEHICLE D A R D SF O R2 O O 1M O D E LY E A R N E W P A S S E N G E R

1-4

1HNXV01.4 83E

Model Year 1:2001 Manufacturer HNX: Honda

Type Car V: Light DutyVehicle/Passenger Displacement SequenceGharasters

EvaporativeFamilY: Model Year 1:2001 Manufacturer H N X :H o n d a Type R: ORVR GanisterWork CaPacitY(gramsl SequenceCharacters

1 HNX R OO99AAK

RevisedComponentTerms \

Beginningwith '01 models,the followingcomponentterms havebeenchangedto conformwith the standardsin SAEdocu m e n tJ 1 9 3 0 l.f y o u f i n d a t e r m o r a b b r e v i a t i oinn a ' 0 1 m a n u a tl h a t i s u n f a m i l i atro y o u ,c h e c kt h i s l i s t .l f a t e r m i s n o t l i s t e d b e l o w ,i t d i d n o t c h a n q e . '00 and EarlierModels Description

HONDAAbbreviation HO2S

Description

New Abbreviation SAE Recommendation

Arr ruet llalto )ensor

A,/FSensor

B r a k eS w i t c h

B r a k eP e d a lP o s i t i o nS w i t c h

B P PS w i t c h

C l u t c hS w i t c h

C l u t c hP e d a lP o s i t i o nS w i t c h

H e a t e dO x y g e nS e n s o r (forsome models)

D i s t r i b u t o rl g n i t i o nR o t o r

Dl Rotor

F l u c t u a t i o nS e n s o r

D i s t r i b u t o rR o t o r EngineSpeedFluctuationSensor

R P M F l u c t u a t i o nS e n s o r

EvaporativeEmissionControlCanister

E V A PC o n t r o lC a n i s t e r

E v a D o r a t i vE e m i s s i o nC a n i s t e r

E V A PC a n i s t e r

E v a p o r a t i v eE m i s s i o nC o n t r o lC a n i s t e r VentShutValve

E V A PC o n t r o lC a n i s t e r Vent ShutValve

E v a p o r a t i v eE m i s s i o nC a n i s t e rV e n t ShutValve

E v a p o r a t i v eE m i s s i o nP u r g eC o n t r o l S o l e n o i dV a l v e

EVAPPurgeControl SolenoidValve

E v a p o r a t i v eE m i s s i o nC a n i s t e rP u r g e Valve

E V A P C a n i s t e rV e n t S h u t Valve E V A PU a n i s t e rP u r g eV a l v e

E x h a u s tG a s R e c i r c u l a t i oV n a l v eL i f t Sensor

E G RV a l v e L i f t S e n s o r

ExhaustGas Recirculation Valve Position Sensor

EGRValvePosition Sensor

E x h a u s tG a s R e c i r c u l a t i o C n ontrol S o l e n o i dV a l v e

E G RC o n t r o S l olenoid Valve E G RV a c u u mC o n t r o V l alve

E x h a u s tG a s R e c i r c u l a t i oV nalve V a c u u mC o n t r o lS o l e n o i dV a l v e

E G RV a l v e V a c u u m C o n t r o l S o l e n o i dV a l v e

E x h a u s tG a s R e c i r c u l a t i oV nalve V a c u u m C o n t r o lS o l e n o i dV a l v e

E G RV a l v e V a c u u m C o n t r o l S o l e n o i dV a l v e

E x h a u s tG a s R e c i r c u l a t i o V n acuum C o n t r o lV a l v e

\

'01 Models

R a d i a t o rF a n C o n t r o lM o d u l e

FanControlModule

F u e lT a n k E v a p o r a t i v eE m i s s i o nV a l v e

FuelTankVapor/LiquidSeparationValve

O R V RV e n t s h u t V a l v e

FuelTankVaoor ControlValve

ORVRVaoor Recircuration Tube

FuelTank Vaoor Recirculastion Tube

F i r s tl d l e T h e r m o V a l v e

l d l e A i r C o n t r o lT h e r m a lV a l v e

F u e lI n j e c t o r

Injector

F u e l I n i e c t i o nA i r C o n t r o lV a l v e

F I A C o n t r o lV a l v e

I n t a k eA i r B y p a s sC o n t r o lV a l v e

Fuel InjectionAir ControlSolenoidValve lntakeAir BvDassCheckValve

FIAControlSolenoidValve I A B C h e c kV a l v e

IntakeAir BypassControlThermalValve I n t a k eM a n i f o l dR u n n e rC o n t r o lV a c u u m CheckValve

IMRC Vacuum Check Valve

IntakeManifold RunnerControlActuator

I M R CA c t u a t o r I M R CA c t u a t o rW i r e

Intake Manifold Runner Control Actuator Wire ntakeAir BypassControlDiaphragm

I A BC o n t r o D l iaphragm

I A CT h e r m a lV a l v e

Intake Manifold Runner control Actuator Diaphragm

ilvrr1u rapnragm

I n t a k eM a n i f o l dR u n n e rC o n t r o lM o d u l e

I M R CM o d u l e

IntakeManifold RunnerControl Solenoid Valve

IMRC Solenoid Valve

I n t a k eA i r B y p a s sC o n t r o lS o l e n o i d Valve

lAts Control Solenoid Valve

I n t a k eA i r B v p a s sV a c u u mT a n k

I A B V a c u u mT a n k

IntakeManifold RunnerControlVacuum

I M R CV a c u u m R e s e r v o i r

IntakeAir BypassValve Body Assembly

I A B V a l v eB o d y A s s e m b l V

IntakeManifold RunnerControlValve

I M R CV a l v e

B r e a t h e rC h a m b e r

O i l / A i rS e p a r a t o r

F u e l P r e s s u r eR e g u l a t o rC o n t r o l S o l e n o i dV a l v e

P r e s s u r eR e g u l a t o rV a c u u m C o n t r o l SolenoidValve

Air Control Valve Check Valve

SecondaryAir In.jectionControl Vacuum C h e c kV a l v e

A i r C o n t r o lV a c u u m C h e c k Valve

A r r C o n t r o lV a l v eV a c u u mT a n k

SecondaryAir InjectionControl Vacuum Reservoir

A i r C o n t r o lV a c u u m Reservoir

A i r C o n t r o lS o l e n o i dV a l v e

S e c o n d a r yA i r I n j e c t i o nC o n t r o lV a l v e Vacuum ControlSolenoidValve

A i r C o n t r o lV a l v eV a c u u m C o n t r o lS o l e n o i dV a l v e

Air Pump A i r C o n t r o lV a l v e

SecondaryAir InjectionPump

Air Pump A i r C o n t r o lV a l v e

S e c o n d a r yA i r I n j e c t i o n P u m p C o n t r o l Valve

A r r r u m p t s r e c l n cu u r r e n t b e n s o r

S e c o n d a r yA i r I n j e c t i o nP u m p E l e c t r i c CurrenS t ensor

A i r P u m p E l e c t r i cC u r r e n l Sensor

S h i f t / C l u t c hP r e s s u r eC o n t r o lS o l e n o i d Valve Set

Shift Solenoid & Automatic Transaxle C l u t c h P r e s s u r eC o n t r o l S o l e n o i dV a l v e Set

SS & A,/TClutch Pressure C o n t r o lS o l e n o i dV a l v e S e t

1-5

RevisedComponentTerms

'01 Models

'00 and EarlierModels Description

HONDAAbbreviation

S h i f t C o n t r o lS o l e n o i dV a l v eS e t Shift/Lock-upClutch Control Solenoid Valve Assy S h i f t C o n t r o lS o l e n o i dV a l v eA

Description

New Abbreviation SAE Recommendation

S h i f t S o l e n o i d& T o r q u eC o n v e r t o r C l u t c hS o l e n o i dV a l v eS e t S h i f t S o l e n o i d& T o r q u eC o n v e r t o r C l u t c hS o l e n o i dV a l v e

S S & T C CS o l e n o i dV a l v e Set S S & T C C S o l e n o i dV a l v e

S h i f t S o l e n o i dV a l v eA

S S V a l v eA

S h i f t S o l e n o i dV a l v e B

S S V a l v eB

S h i f t C o n t r o lS o l e n o i dV a l v e B T h r o t t l eV a l v eC o n t r o lM o d u l e

Throftle Actuator

Lock-uoClutchControlSolenoidValve Set

T o r o u eC o n v e r t o rC l u t c hS o l e n o i d& A u t o m a t i cT r a n s a x l eC lu t c h P r e s s u r e C o n t r o lS o l e n o i dV a l v e S e t

T C CS o l e n o i d& A v / TC l u t c h P r e s s u r eC o n t r o lS o l e n o i d V a l v eS e t

T o r q u eC o n v e r t o rC l u t c hS o l e n o i dV a l v e

T C CS o l e n o i dV a l v e

T r a n s m i s s i o nR a n g eS w i t c h

T/R Switch V T E CO i l P r e s s u r eS w i t c h

L o c k - u oC l u t c hC o n t r o lS o l e n o i dV a l v e Automatic Transaxle Position Switch V a r i a b l eV a l v eT i m i n g & V a l v e L i f t ElectronicControl PressureSwitch

A,/TGear Position Switch VTECPressureSwitch

VariableValveTiming & Valve Lift ElectronicControlPressure Switch

\

Specifications g-2 Standardsand ServiceLimits .............. DesignSpecifications 3-15 Body Specifications ... 3-18

\

Standardsand ServiceLimits CylinderHead/ValveTrain (B18Bl engine)

Section6 STANDARD(NEW)

MEASUREMENT

I I

Minimum Maximum variation

Compression

250 rpm and wide open throttle k P a ( k g f / c m ' ,p s i )

Cylinderhead

Warpage Height E n dp l a y oil clearance Camshaft-to-holder Totalrunout Cam lobeheight

Camshaft

Valve

lN EX

V a l v e c l e a r a n c e( C o l d ) "

lN EX lN EX lN EX

S t e m - t o - g u i d ec l e a r a n c e

lN EX lN EX

width stem installedheight

Valve spring

Free length (Reference)

IN

NH CH

EX V a l v eg u i d e

t.D. I n s t a l l ehde i g h t

*: Measured between the camshaft and rocker arm. N H : N I H O N H A T S U J O m a n u f a c t u r e dv a l v e s p r i n g CH: CHUO HATSUJO manufacturedvalve spring

SERVICELIMIT

0.05(0.002)

Valve stem O.D.

Valve seat

I

930(9.5,135) 200Q.0,281

lN EX lN EX

t a , | * - 1 3 2 . 0 (55 . 1 9 -5 5 . 1 9 9 ) 0.05- 0.15(0.002- 0.006) - 0.0027) 0.030- 0.069(0.0012 ) ax. 0 . 0 3( 0 . 0 0 1m 4l 33.716 11.327 33.528(1.3200) 0.08- 0.12(0.003- 0.005) 0.16- 0.20(0.006- 0.0081 - 0.2594) 6.580- 6.590(0.2591 - 0.2583) 6.550- 6.560(0.2579 0.02- 0.05(0.001- 0.002) 0.05- 0.08(0.002- 0.003) 1.25- 1.55(0.049- 0.061) 1.25- 1.55(0.049- 0.061) - 1.62341 40.765- 41.235(1.6049 - 1.70221 42J65- 43.235(1.6837 41.27(1.6251 4 1 . 2 8( 1 . 6 2 5 ) 44.32t1-7451 6 . 6 1- 6 . 6 3( 0 . 2 6 -0 0 . 2 6 1 ) 6.61- 6.63(0.260- 0.261) 13.75 - 14.25(0.541- 0.561) 15.75- 16.25(0.620- 0.640)

0 . 5( 0 . 0 2 ) 0 . 1 5( 0 . 0 0 6 ) 0.04(0.002)

ouuto.rutt

6.52rc.2571. 0.08(0.003) 0.11 (0.004) 2.0(0.08) 2.0(0.08) (1.6333) 41.485 43.485(1.71201

6.6s(0.262) 6.65(0.262)

EngineBlock(81881engine) E' -

U n i to f l e n g t hm : m (in)

Section 7 Declror

MEASUREMENT

\

STANDARD(NEW} 0.07(0.003)max. - 3.190) 8 1 . 0 0- 8 1 . 0 2( 3 . 1 8 9

SERVICELIMIT 0 . 1 0( 0 . 0 0 4 ) 81.07(3.192) 0.05(0.002) 0 . 2 5( 0 . 0 1 0 )

80.98- 80.99(3.188 - 3.189) - 0.0016) 0.01- 0.04(0.0004 - 0.0409) 1.030- 1.040(0.0406 - 0.0488) 1.230- 1.240(0.0484 2.805- 2.820(0.1104- 0.1110) - 0.0028) 0.045- 0.070(0.0018 - 0.0026) 0.040- 0.065(0.0016 - 0.0028) 0.045- 0.070(0.0018 0.20- 0.35(0.008- 0.014) 0.20- 0.30(0.008- 0.012) 0.40- 0.55(0.016- 0.022) 0.20- 0.50(0.008- 0.020) 0.20- 0.45(0.008- 0.018) - 0.8268) 20.994- 21.000(0.8265 - 0.0009) 0.010- 0.022(0.0004 - 0.0013) 0.013- 0.032(0.0005 - 0.8260) 20.968- 20.981(0.8255 48.0(1.89) 0 . 1 5- 0 . 3 0( 0 . 0 0 -6 0 . 0 1 2 )

80.97(3.188) 0.05(0.002) 1.06(0.042) 1.26(0.050) 2.84(0.112!. 0 . 1 3( 0 . 0 0 5 1 0 . 1 3( 0 . 0 0 5 ) 0 . 1 3( 0 . 0 0 5 ) 0.60(0.024) 0.60(0.024) 0.70(0.028) 0.70(0.028) 0.70(0.028)

0.40(0.016)

M a i n j o u r n a ld i a m e t e r No. 1,2, 4 and 5 journals No. 3 journal R o d j o u r n a ld i a m e t e r Taper Out-of-round End play Runout

- 2.1654) 54.976- 55.000(2.1644 - 2.16511 54.970- 54-994(2.1642 - 1.77171 44.976-45.000(1.7707 0.005(0.00021 max. 0.005(0.0002) max. - 0.014) 0 . 1 0- 0 . 3 5( 0 . 0 0 4 0.03(0.001)max.

0.010(0.0004) 0.010(0.0004) 0 . 4 5( 0 . 0 1 8 ) 0.05(0.002)

M a i n b e a r i n g - t o - j o u r n a lo i l c r e a r a n c e No. 1,2, 4 and 5 journals No. 3 journal R o d b e a r i n g - t o - j o u r n a lo i l c r e a r a n c e

- 0.0017) 0.024- 0.042(0.0009 - 0.0019) 0.030- 0.048(0.0012 - 0.0015) 0.020- 0.038(0.0008

0.050(0.0020) 0.060(0.0024) 0.0s0(0.0020)

Cylinder block

Warpage of deck surface Bore diameter Bore taper R e b o r i n gl i m i t

Piston

Skirt O.D. at 15 mm (0.6in) from bottom of skirt C l e a r a n c ei n c y l i n d e r Groove width (For ring) Top Second oil

Piston ring

R i n g - t o - g r o o v ec l e a r a n c e

Ringend gap

Top Second Top Second oil

Piston Pin

o.D.

Connectingrod

P i n - t o - r o di n t e r f e r e n c e Small end bore diameter Large end bore diameter E n d p l a y i n s t a l l e do n c r a n k s h a f t

P i n - t o - p i s t o nc l e a r a n c e

Crankshaft

Yl

B e ar i n g

Nominal

R T H T

R T

R : R I K E Nm a n u f a c t u r e d p i s t o n r i n g T : T E I K O K U P I S T O NR I N G m a n u f a c t u r e d p i s t o n r i n g

3-3 rlllllllllrltruE

Standardsand ServiceLimits 8C1.818C5engines) Gylinder Head/Valve Train (B'lEC'1,

Section 6 STANDARD(NEW}

MEASUREMENT Minimum Maximum variation

Compression

250 rpm and wide open throttle k P a ( k g f / c m ' ,p s i )

C y l i n d e rh e a d

Warpage Height

Camshaft

End play C a m s h a f t - t o - h o l d e ro i I c l e a r a n c e Total runout Cam lobe height lN engine PrimarY 818C1/818C5 engine 818C1/818C5 Mid S e c o n d a r Y8 1 8 C 1 / B 1 8 C 5e n g i n e EX 5ngine Primarv 818C1/818Ce B 1 8 C 1 / 8 1 8 C e5 n g i n e Mid S e c o n d a r vB 18 C 1 / 8 1 8 C 5e n g i n e

Valve

0.05(0.002)

lN EX lN EX lN EX

V a l v e c l e a r a n c e( C o l d ) *

S t e m - t o - g u i d ec l e a r a n c e

8 1 8 C 1e n g i n e B 1 8 C 5e n g i n e E X B 1 8 C 1e n g i n e 8 1 8 C 5e n g i n e lN EX lN

Width

S t e m i n s t a l l e dh e i g h t

Valvespring

F r e e l e n g t h ( R e f e r e n c e lB 1 8 C 1e n g i n e : lN

Outer lnner

EX 8 1 8 C 5e n g i n e : lN EX Valve guide

t.D. Installedheight

R o c k e ra r m

- 142.05(5.589- 5.593) 0.05- 0.15(0.002- 0.006) - 0.0035) 0.050- 0.089(0.0020 0.03(0.001)max. r**

Valve stem O.D.

Valve seal

LIMIT SERVICE

930 (9.5,135) 200 t2-0,281

Arm-to-shaftclearance

*: Measured between the camshaft and rockerarm N H : N I H O N H A T S U J O m a n u f a c t u r e dv a l v e s p r i n g C H : C H U O H A T S U J O m a n u f a c t u r e dv a l v e s p r i n g

NH CH NH CH

Outer lnner Outer lnner

lN EX lN EX lN EX

0.s (0.02) 0.15(0.006) 0.04(0.002)

3 3 . 4 1 ( 1 . 3 1 5 4 ) / 3 3 . 0( 18.83 0 2 7 ) (1.4138) 36.377(.43221/36.865 4l 11-367 34.547(1.3601) 134.132 85 (1.29071 33.111 (1.3036) 132.7 (1.4304) 35.720(1.4063)/36.333 (1.3658) 34.381(1.3536)/34.691 0 . 1 5- 0 . 1 9( 0 . 0 0 -6 0 . 0 0 7 ) 0.17- 0.2't(0.007- 0.008) 5 . 4 7 5- 5 . 4 8 5( 0 . 2 1 5-60 . 2 1 5 9 - 0.2150 5.450- 5.460(0.2146 - 0.0022 0.025- 0.055(0.0010 - 0.0031 0.050- 0.080(0.0020 ( 0 . 0 4 9 0 . 061) 1 . 5 5 1.25 0.85- 1.15(0.033- 0.045) 1 . 2 5- 1 . 5 5( 0 . 0 4 -9 0 . 0 6 1 ) 0.85- 1.15(0.033- 0.045) - 1.4935) 37.465- 37.935(1.4750 ( 1 . 4 6 3-2 1 . 4 8 1 7 1 3 7 . 1 6 -5 3 7 . 6 3 5

in* to.r',ool 5.420(0.2134) 0.08(0.003) 0 . 11 ( 0 . 0 0 4 )

2.0(0.08) 2.0(0.08) 2.0(0.08) 2.0(0.08) (1.5033) 38.185 (1.4915) 37.885

(1.616) 41.05 3 6 . 1 6( 1 . 4 2 4 ) 3 6 . 1 9( 1 . 4 2 5 ) 4 1. 9 6( 1 . 6 5 2 ) 4 1 . 9 4( 1 . 6 5 1 ) 4 3 . 1 9( 1 . 7 0 0 ) 36.84(1.450) 4 1 . 0 5( 1 . 6 1 6 ) 3 6 . 1 6( 1 . 4 2 4 ) -0.2181 5"51- 5.53 {'0.217 - 0.2181 5 . 5 1- 5 . 5 3r c . 2 1 7 - 1 3 . 0 5( 0 . 4 9 -4 0 . 5 1 4 1 12.55 1 2 . 5 5- 1 3 . 0 5( 0 . 4 9 -4 0 . 5 1 4 ) - 0.0020) 0.025- 0.052(0.0010 - 0.0020) 0.025- 0.052(0.0010

5 . 5 5( 0 . 2 1 9 ) 5 . 5 5( 0 . 2 1 9 )

0.08(0.003) 0.08(0.003)

U n i to f l e n g t hm : m (in}

EngineBlock(818C1,818C5engines) Section 7 STANDARD(NEW} 0.05(0.002)max. 8 1 . 0 0- 8 1 . 0 2( 3 . 1 8 -9 3 . 1 9 0 )

MEASUREMENT Cylinder block

Warpageof decksurface Borediameter Boretaper Reboringlimit

Piston

Skirt O.D.at 15 mm (0.6in) from bottom of skirt C l e a r a n c ei n c y l i n d e r Groove width (For ring) Top Second oil

Pistonring

R i n g - t o - p i s t o ng r o o v e c l e a r a n c e

Top Second

Ring end gap

Top Second oil

Piston Pin

o.D. P i n - t o - p i s t o nc l e a r a n c e

Connectingrod

Crankshaft

Bearing

J

Pin-to-rod interference Small end bore diameter Large end bore diameter E n d p l a y i n s t a l l e do n c r a n k s h a f t

Nominal

80.98- 80.99(3.188- 3.1891 - 0.0016) 0.01- 0.04(0.0004 - 0.0409) 1.030- 1.040(0.0406 - 0.0488) 1.230- 1.240(0.0484 2.805- 2.820(0.1104- 0.1110) - 0.0028) 0.045- 0.070(0.0018 - 0.0026) 0.040- 0.065(0.0016 0.20* 0.35(0.008- 0.014) 0.40- 0.55(0.016- 0.022) 0.20- 0.50(0.008- 0.020) - 0.8268) 20.994- 21.000(0.8265 - 0.0009) 0.010- 0.022(0.0004 - 0.0014) 0.017- 0.036(0.0007 - 0.8267) 20.964- 20.997(0.8254 48.0(1.89) 0.15- 0.30(0.006- 0.012)

I

SERVICELIMIT 0.08(0.003) 8 1 . 0 7( 3 . 1 9 2 ) 0.05(0.002) 0 . 2 5( 0 . 0 1 0 ) 80.97(3.188) 0.05(0.002) 1.060(0.04171 1.260(0.0496) 2 . 8 4 0( 0 . 1 1 1 8 1 0.13(0.005) 0 . 1 3( 0 . 0 0 5 )

0.60(0.024) 0.70(0.028) 0.70(0.028)

0 . 4 0( 0 . 0 1 6 )

Mainjournaldiameter No. 1, 2, 4 and 5 journals No. 3 journal Rodjournaldiameter Taper Out-ofround Endplay Runout

- 2.1654) 54.976- 55.000(2.1644 - 2.1653) 4 - 54.998(2.1643 54.97 44.976-45.000(1.7707-1.7717l. max. 0.005(0.0002) 0.005(0.0002) max. 0 . 1 0- 0 . 3 5( 0 . 0 0 -4 0 . 0 1 4 ) 0.03(0.001)max.

orro to.ooool

Main bearing-to-journal oil clearance N o . 1 ,2 , 4 a n d 5 j o u r n a l s N o .3 j o u r n a l Rodbearing-to-journal oil clearance

- 0.042(0.0009 - 0.0017) 0.024 - 0.048(0.0012 - 0.0019) 0.030 - 0.050(0.0013 - 0.0020) 0.032

0.050(0.0020) 0.060(0.0024) 0.060(0.0024)

EngineLubrication

0.010(0.0004) 0.45(0.018) 0.05(0.002)

Section 8

STANDARD(NEW} SERVICELIMIT (4.9, 81881engine 4.6 4.0)for engineoverhaul 3.8(4.0,3.3)for oil change,includingfilter 3 . 5( 3 . 7 , 3 . 1 ) f oori l c h a n g ew, i t h o u tf i l t e r 8 1 8 C 1B, 1 8 C 5 e n g i n e s 4.8(5.1,4.2)for engineoverhaul 4.O(4.2,3.5)for oil change.includingfilter 3.7(3.9,3.3)for oil change,withoutfilter lnner-to-outer rotorclearance 0.04- 0.16(0.002- 0.006) 0.20(0.008) Pumphousing-to-outer rotorclearance 0.10- 0.19(0.004- 0.007) 0.20(0.008) Pumphousing-to-rotor axialclearance 0.02- 0.07(0.001- 0.003) 0.1s(0.006) Pressure settingat engineoil temp. 176'F(80"C) , 0 1m i n . kPa(kgf/cm,.psi) 7 0( 0 . 71 At idle At 3,000rpm 340(3.5,50)min. MEASUREMENT

E n g i n eo i l

O i lp u m p

R e l i e fv a l v e

Capacity / (USqt, lmp qt)

3-5

Standardsand ServiceLimits Gooling- Sectlon 0 Radiator

MEASUREMENT 81881engine Coolantcapacity / (USqt, lmp qt) h e a t e r , e n g i n e , I n c l u d i n g I I I c o o l i n gl i n ea n d r e s e r v o iI r capacity: Reservoir 818C1engine 0.6f (0.63US qt, 0.53lmp qt) 8 1 8 C 5e n g i n e

R a d i a t o rc a p Thermostat

C o o l i n gf a n

, Openingpressure kPa(kgf/cm'Psi) Start to open 'F ("C) F u l l yo p e n " F ( " C ) Valve lift at fully open

"ON" temperature "F ('C) Thermoswitch "OFF"temperature "F ("C) Thermoswitch

STANDARD(NEW} M / T : 6 . 4 ( 6 . 8 ,5 . 6 ) f o r o v e r h a u l 4 . 4 1 4 . 6 , 3 . 9f)o r c o o l a n tc h a n g e * A , / T : 6 . 7 ( 7 . 1 ,5 . 9 ) f o r o v e r h a u l 4 . 7 $ . 0 , 4 . 1 ) f o r c o o l a n tc h a n g e * M / T : 6 . 7 ( 7 . 1 , 5 . 9 )f o r o v e r h a u l 4 . 7 ( 5 . 0 ,4 . 1 )f o r c o o l a n t c h a n g e * M / T : 6 . 5 ( 6 . 9 ,5 . 7 )f o r o v e r h a u l 4 . 5 ( 4 . 8 ,4 . 0 ) f o r c o o l a n t c h a n g e *

9 3 - 1 2 3( 0 . 9 5- 1 . 2 5 1, 3 . 5- 1 7 . 8 ) 1 6 9- 1 7 6( 7 6- 8 0 ) 1 9 4( 9 0 ) 8 . 0( 0 . 3 1 ) m i n . 1 9 6- 2 0 3( 9 1- 9 5 ) "ON" temperature Subtract5 - 14 (3 - 8) from actual

* : I n c l u d i n g t h e c o o l a n t i n t h e r e s e r v o i ra n d t h a t r e m a i n i n g i n t h e e n g i n e

Fuel and Emissions-

Section11 STANDARD(NEW}

MEASUREMENT

SERVICE LIMIT

with regulatorvacuumhosedisconnected Pressureregulator Pressure 81881engine 270- 320(2.8- 3.3,40 - 47]. , kPa(kgf/cm' psi) 8 1 8 C 1e n g i n e 329- 378 (3.35- 3.85,48 - 55) 8 1 8 C 5e n g i n e 320- 370(3.3- 3.8,47 -541 5 0 ( 1 3 . 21, 1 . 0 ) Fuel tank Capacity / (US gal, lmp gal) 818818 , 1 8 C 1e n g i n e s7 5 0t 5 0 ( M / T :n e u t r a l ) ldle speed with headlight and cooling fan off rpm Engine 750I 50 (A/T:N or E Position) 818C5engine800t 50 (M/T:neutral) B 1 8 8 18, 1 8 C 1e n g i n e s1 , 6 0 0t 2 0 0( M / T :n e u t r a l ) Fastidle rpm 1,600t 200(A/T:E or E Position) 818C5engine1,500t 200(M/T:neutral) ldleCO

Clutch -

Section

0.1 max.

%

'lZ MEASUREMENT

Clutchpedal

Pedal height Stroke Pedalplay D i s e n g a g e m e n th e i g h t

Flywheel

Clutchsurfacerunoul

Clutch disc

Rivet head depth Thickness

Pressure plate

Warpage s p r i n gf i n g e ra l i g n m e n l Diaphragm * I n c l u d i ntgh e p e d a lp l a y1 - 1 0m m ( 0 . 0 4- 0 . 3 9i n ) .

3-6

to floor

to floor

STANDARD(NEW} (6 164 7/16) 1 3 0- 1 4 0( 5 . 1 2- 5 . 5 1 ) 12 -21 (12 - 13/16)* ) in. 8 3 ( 3 . 2 7m (0.002) max, 0.05 ( 0 . 1 . 2 1 . 7 0 5- 0 . 0 7 ) 8.3- 9.0(0.33- 0.35) 0.03(0.001)max. max. 0.6(0.021

SERVICELIMIT

0 . 1 5( 0 . 0 0 6 ) 0 . 2( 0 . 0 1 ) 6.0(0.24) 0 . 1 5( 0 . 0 0 6 ) 0.8(0.03)

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

ManualTransmission Section 13 _/

MEASUREMENT T r a n s m i s s i ooni l

Capacity / (US qt, lmp qt)

Mainshaft

End play Diameterof ball bearing contact area ( c l u t c hh o u s i n g s i d e ) Diameterof 3rd gear contact area Diameterof ball bearing contact area ( t r a n s m i s s i o nh o u s i n g s i d e ) Runout

Mainshaft 3rd and 4th gears

Mainshaft sth gear

Countershaft

Countershaft 1st gear Countershaft 2 n dg e a r

\r/

S p a c e rc o l l a r (Countershafl 2nd gear) Spacercollar (Mainshaft 4th and 5th gears)

STANDARD(NEW}

0 . 11 - 0 . 1 8( 0 . 0 0 -4 0 . 0 0 7 ) 27.977- 27.990(1.101- 1.102]|

Adiust 2 7. 9 3( 1 . 1 0 1

37.984- 38.000(1.495- 1.496) - 1.1024l. 27.987- 28.000(1.1018

37.93(1.493) 27.94 11.101

0.02(0.0008) max. 43.009- 43.025(1.6933- 1.(i939) - 0.0083) 0.06- 0.21(0.0024 3rd 81881engine 34.42- 34.47(1.355- 1.357) 8 1 8 C 1B, 1 8 C 5 e n g i n e s 34.92- 34.97(1.37 5 -' t.377) 4th 8 1 8 8 1e n g i n e 30.92- 30.97(1.2't7-' t.219) 8 1 8 C 18, 1 8 C 5e n g i n e s 31.42- 31.47n.237 - 1.239) - 1.6939) t.D. 43.009- 43.025(1.6933 - 0.0083) E n dp l a y 0.06- 0.21(0.0024 Thickness 31.42- 31.4711.237- 1.2391 Diameterof needle bearing contact area 33.000- 33.015(1.299- 1.300) Diameterof ball bearing contact area 24.980- 24.993(0.9835- 0.9840) - 1.45671 Diameterof 1st gear contact area 36.984- 37.000(1.4561 Runout 0.02(0.0008) max. - 1.6545) t.D. 42.009- 42.025(1.6539 - 0.0081) E n dp l a y 0.045- 0.205(0.0018 Thickness 3 1 . 4 5- 3 1. 5 0( 1 . 2 3 -8 1 . 2 4 0 ) - 1.8514) t.D. 47.009- 47.025(1.8507 End play 0.07- 0.14(0.003- 0.006) Thickness 81881engine 34.62- 34.67(1.3630- 1.3650) - 1.1405) 8 1 8 C 1 ,8 1 8 C 5e n g i n e s 28.92- 28.97(1.1386 - 1.4366) (1.4362 t.D. 36.48 36.49 - 1.6535) o.D. 41.989- 42.000(1.6531 - .14531 Length 2 9 . 0 7- 2 9 . 0 9( 1 . 1 4 4 5 1 t.D. 31.002- 31.01211.2205- 't.2209' - 1.4961 o.D. 37.989- 38.000( 1.4956 ) Length A 56.45- 56.55(2.2224- 2.2264' ) - 1.0268) B 26.03 26.08(1.0248 LD. E n dp l a y Thickness

SEBVICELIMIT

2 . 2 1 2 . 3 ,1 . 9 )f o r o i l c h a n g e 2 . 3 1 2 . 4 , 2 . 0f)o r o v e r h a u l

0.05(0.002) 43.0t ( 1 . 6 9 6 ) 0 . 3( ( .0121 34.3 1 . 3 5 0 ) 34.8 1 . 3 7 0 ) 30.8 1.2131 3 1. 3 1.2321 43.08(1.696) 0 . 3( 0 . 0 1 2 ) 31.3 11.2321 32.95(1.2971 24.94(0.982) 36.93(1.454) 0.05(0.002) 42.08(1.657)

47.08(1.8s41 0.20(0.008) 3 4 . 5( 1 . 3 5 8 ) 2 8 . 8( 1 . 1 3 4 1 36.5(1.437) 4 1 . 9 4( 1 . 6 5 1 ) 3 1 . 0 6( 1. 2 2 3 ) 37.94(1.494)

(cont'd)

Standardsand ServiceLimits 13 . ct, ateulrl Section ManualTransmission(cont'd) MEASUREMENT

Reverseidler gear

Synchroring

8 1 8 8 1e n g i n e B18C1 engine 8 1 8 C 5e n g i n e gearshaftclearance 81881engine Gear-to-reverse 8 1 8 C 1e n g i n e 8 1 8 C 5e n g i n e (ring pushed againstgear) clearance Ring-to-gear l.D.

Double cone synchro ring *

C l e a r a n c e( r i n g p u s h e d a g a i n s t g e a r ) O u t e r s y n c hr o r i n g - t o - g e a r Inner synchro ring-to-gear Outer synchro ring-to-synch ro cone

Shift fork

Shiftfork fingerthickness sleeveclearance Fork-to-synchro

Reverseshift fork

Shift fork pawl groove width F o r k - t o - r e v e r s ei d l e r g e a r c l e a r a n c e "L" groove width at Sth gear side . . a t r e v e r s eg e a r s t d e Fork-to-5th/reverse shift piece pin clearance at 5th gear side at reverse gear side

Shiftarm

Groove width of change piececontact area C h a n g e p i e c e - t o - s h i f ta r m c l e a r a n c e

Shift piece

Groovewidth of shift arm contactarea arm clearance Shiftpiece-to-shift t.D. clearance Shift piece-to-shaft Diameterof shift fork contactarea fork shaftclearance Shift oiece-to-shift Diameterof changepiececontactarea piececlearance Arm-to-change Groovewidth of interlockcontactarea clearance Arm-to-interlock

Selector arm

* : 8 1 8 C 18, 1 8 C 5e n g i n e s

STANDARD{NEW} - 0.7891) 20.016- 20.043(0.7880 20.028- 20.049(0.7885- 0.7893) - 0.7917) 20.030- 20.110(0.7886 - 0.0033) 0.036- 0.084(0.0014 - 0.0020) 0.028- 0.053(0.0011 - 0.0046) 0.030- 0.117 (0.0012 0.85- 1.t0 (0.033- 0.043)

LIMIT SERVICE 20.09(0.7909) 20.09(0.7909) 20.09(0.7909) 0.16(0.006) 0.16(0.006) 0.16(0.006)

0.95- 1.68(0.037- 0.066) 0.5- 1.0(0.02- 0.04) 0.5- 1.0(0.02- 0.04) -0.299) 7 . 4 - 7 . 6( 0 . 2 9 1 0.35- 0.65(0.014- 0.026) 1 3 . 0- 1 3 . 3( 0 . 5 1 -2 0 . 5 2 4 ) 0 . 5 - 1 . 1( 0 . 0 2 0 - 0 . 0 4 3 ) 7.40- 7.70(0.291- 0.303) 7.05-7.25 (0.278- 0.285)

0.6(0.024) 0 . 3( 0 . 0 1 ) 0 . 3( 0 . 0 1 )

0.4- 0.9(0.016- 0.035) - 0.018) 0.05- 0.45(0.0020 11 . 8- 1 2 . 0( 0 . 4 6- 0 . 4 7 ) 0.0s- 0.35(0.002- 0.014) 8.1- 8.2(0.319- 0.323) 0.10- 0.30(0.004- 0.012) 14.000- 14.068(0.551- 0.554) - 0.0036) 0.011- 0.092(0.0004 11.90- 12.00(0.469- 0.472) 0.20- 0.50(0.008- 0.020) 11 . 8- 1 2 . 0( 0 . 4 6- 0 . 4 7 ) 0.05- 0.35(0.002- 0.014) - 0.3996) 10.05- 10.15(0.3957 0.05- 0.25(0.002- 0.010)

0 . 4( 0 . 0 1 6 )

1.0(0.039) 1 . 8( 0 . 0 7 )

oto to.ottt 0.60(0.024) 0.150(0.0059)

oroto.or'D 0.50(0.0201 0.50(0.020)

t

L

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

Automatic Transmission- Section r;rEGl,l(tll 14 I+ MEASUREMENT

\.,

STANDARD{NEW}

SERVICELIMIT

Transmission fluid

Capacity f (US qt, lmp qt)

5 . 9 ( 6 . 2 ,5 . 2 ) f o r o v e r h a u l 2 . 7 ( 2 . 9 , 2 . 4 )f o r f l u i d c h a n g e

Hydraulic pressu re

Linepressureat 2,000rpm in I or @ position 1stclutchpressureat 2,000rpm in [Of position 1st-holdclutchpressureat 2,000rpm in I position 2nd clutchpressureat 2,000rpm in p position

830- 880(8.5- 9.0,120- 130)

, 10) 7 8 0( 8 . 0 1

800- 850 (8.2- 8.7, 120- 1241

76017.7,1101

kPa (kgf/cm' , psi)

3rd clutchpressureat 2,000rpm in fOrlposition 4th clutchpressureat 2,000rpm in iOl position S t a l l s p e e d r p m ( C h e c kw i t h v e h i c l e o n l e v e l g r o u n d )

Clutch

Clutch initial clearance

C l u t c hr e t u r n s p r i n g f r e e l e n g t h Clutch disc thickness Clutch platethickness

1st 2nd, 3rd, 4th 1s t - h o ld 1st,2nd,3rd,4th lsf hold 2nd, 3rd, 4th 1st,1st-hold

Clutchend platethickness (1st)

Mark 1 M a r k2 M a r k3 M a r k4 M a r k5 M a r k6 M a r k7 M a r k8 M a r k9 M a r k1 0

Clutch end plate thickness (2nd, 4th)

Mark 6 Mark 7 Mark8 Mark9 Mark 10 Mark11 Mark 12 Mark 13 Mark 14 Mark 15 Mark 16 Mark 17

Clutch end platethickness (3rd)

Mark g Mark 9 Mark10 Mark11 Mark 12 Mark 13 Mark 14 Mark 15 Mark 16 Mark 17

Clutch end plate thickness (lst-hold)

Mark 1 Mark2 Mark3 Mark4 No mark Mark6 Mark7

\r'

2,550 0.65- 0.85(0.026- 0.033) 0.40- 0.60(0.016- 0.024) 0.5- 0.8(0.020- 0.031) 31.1(1.221 3 4 . 6( 1 . 3 6 ) 1.88- 2.00(0.074- 0.079) 1.95- 2.05(0.077- 0.081l - 0.065) 1 . 5 5- 1 . 6 5( 0 . 0 6 1 2.05- 2.'t0(0.081- 0.083) 2.15- 2.20(0.085- 0.087) 2.25- 2.30(0.089- 0.091) 2.35- 2.40(0.093- 0.094) 2.45- 2.50(0.096- 0.098) 2 . 5 5- 2 . 6 0( 0 . 1 0 -0 0 . 1 0 2 ) 2 . 6 5- 2 - 7 0( 0 . 1 0 -4 0 . 1 0 6 ) - 0.110) 2 . 7 5- 2 . 8 0( 0 . 1 0 8 2 . 4 5- 2 . 9 0( 0 . 11 2- 0 . 11 4 ) 2 . 9 5- 3 . 0 0( 0 . 11 6- 0 . 11 8 ) - 0.102) 2 . 5 5- 2 . 6 0 ( 0 . 1 0 0 2 . 6 5- 2 . 70 ( 0 . 1 0 -4 0 .10 6 ) 2 . 7 5- 2 . 8 0( 0 . 1 0 -8 0 . 1 1 0 ) 2 . 8 5- 2 . 9 0( 0 .11 2- 0 . 114 ) 2 . 9 5- 3 . 0 0( 0 . 11 6- 0 . 11 8 ) 3.05- 3.10(0.120- 0.1221 - 0.1261 3.15- 3.2010.124 3.25- 3.30(0.128 - 0.130) 3 . 3 5* 3 . 4 0( 0 . 1 3 -2 0 . 1 3 4 ) 3 . 4 5- 3 . 5 0( 0 . 1 3 -6 0 . 1 3 8 ) 3 . 5 5- 3 . 6 0( 0 . 1 4 -0 0 . 1 4 2 ) - 0.146) 3 . 6 5- 3 . 7 0( 0 . 1 4 4 2 . 7 5 2 . 8 0( 0 . 1 0 8 0 . 1 1 0 ) 2 . 8 5- 2 . 9 0( 0 . 11 2- 0 . 11 4 ) 2 . 9 5- 3 . 0 0( 0 . 1 1-6 0 . 1 1 8 ) 3.05- 3.10(0.120- 0.1221 3.15- 3.20@j24 - 0.1261 3 . 2 5- 3 . 3 0( 0 . 1 2 -8 0 . 1 3 0 ) 3 . 3 5- 3 . 4 0( 0 .1 3 2- 0 . 1 3 4 ) 3 . 4 5- 3 . 5 0( 0 . 1 3 -6 0 . 1 3 8 ) 3 . 5 5- 3 . 6 0( 0 . 1 4 -0 0 . 1 4 2 ) 3 . 6 5- 3 . 7 0( 0 . 1 4 -4 0 . 1 4 6 ) 2.05- 2.10(0.081- 0.083) 2.15- 2.20(0.085- 0.087) 2.25- 2.30(0.089- 0.0911 2.35- 2.40(0.093- 0.094) 2.45- 2.50(0.096- 0.098) 2.55- 2.60(0.100- 0.102) 2 . 6 5- 2 . 7 0( 0 . 1 0 -4 0 . 1 0 6 )

2,400- 2,700

,r, tr.'tur 32.6 i'1.281 Until grooves worn oul Discoloration Discoloration Discoloration

Discoloration Discoloration

Discoloration Discoloration

Discoloration Discoloration

t

I

i

Discoloration

(cont'd)

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

Diameter of needle bearing contact area On mainshaft stator shaft bearing On mainshaft 2nd gear On mainshaft 4th gear collar On mainshaft 1st gear collar O n c o u n t e r s h a f t( t o r q u e c o n v e r t e r h o u s i n g s i d e ) O n c o u n t e r s h a f t3 r d g e a r O n c o u n t e r s h a f t4 t h g e a r O n c o u n t e r s h a f t r e v e r s eg e a r c o l l a r On countershaft1st gear collar O n s u b - s h a f t ( t r a n s m i s s i o nh o u s i n g s i d e ) O n s u b - s h a f t4 t h g e a r c o l l a r On reverseidler gear shaft Insidediameter of needle bearing contact area On mainshaft 1st gear On mainshaft 2nd gear On mainshaft 4th gear On countershaft1st gear O n c o u n t e r s h a f t3 r d g e a r O n c o u n t e r s h a f t4 t h g e a r On countershaft reverse gear O n s u b - s h a f t4 t h g e a r O n r e v e r s ei d l e r g e a r R e v e r s ei d l e r g e a r s h a f t h o l d e r L D . End play Mainshaft 1st gear Mainshaft 2nd gear Mainshaft 4th gear C o u n t e r s h a f t1 s t g e a r C o u n t e r s h a f t3 r d g e a r C o u n t e r s h a f t4 t h g e a r S u b - s h a f t4 t h g e a r R e v e r s ei d l e r g e a r C o u n t e r s h a f tr e v e r s e g e a r Selectorhub O.D. Mainshaft 4th gear collar length Mainshaft 4th gear collar flange thickness Mainshaft 1st gear collar length C o u n t e r s h a f td i s t a n c e c o l l a r l e n g t h

C o u n t e r s h a f t3 r d g e a r c o l l a r l e n g t h C o u n t e r s h a f tr e v e r s e g e a r c o l l a r l e n g t h C o u n t e r s h a f t r e v e r s eg e a r c o l l a r f l a n g e thickness C o u n t e r s h a f t1 s t g e a r c o l l a r l e n g t h C o u n t e r s h a f t1 s t g e a r c o l l a r f l a n g e t h i c k n e s s S u b - s h a f t4 t h g e a r c o l l a r l e n g t h S u b - s h a f t4 t h g e a r c o l l a r f l a n g e t h i c k n e s s

STANDARD(NEW}

LIMIT SERVICE

- 0.9446) W e a r o r d a m a g e 23.980- 23.993(0.9441 ( 1 . 4 1 6-3 1 . 4 1 6 9 ) 3 5 . 9 7 -5 3 5 . 9 9 1 ( 1 . 2 5 8-9 1 . 2 5 9 5 ) 3 1 . 9 7 -5 3 1 . 9 9 1 ( 1 . 2 1 9-5 1 . 2 2 0 1 ) 3 0 . 9 7 -5 3 0 . 9 9 1 3 6 . 0 0 -4 3 6 . 0 1 7( 1 . 4 1 7-5 1 . 4 1 8 0 ) 35.980- 35.996{1.4165- 1.41721 2 7 . 9 8-0 2 7 . 9 9 (31 . 1 0 1- 61 . 1 0 2 1 ) 3 1 . 9 7 -5 3 1 . 9 9 1 { 1 . 2 5 8-9 1 . 2 5 9 5 ) ( 1 . 2 5 8-9 1 . 2 5 9 5 ) 3 1 . 9 7 -5 3 1 . 9 9 1 - 1.0236) 25.991- 26.000(1.0233 22.9935- 23.0065(0.9053- 0.9058) - 0.5512) W e a r o r d a m a g e - 14.000(0.5s08 13.990 ( 1 . 3 7 8-0 1 . 3 7 8 6 ) W e a r o r d a m a g e 3 5 . 0 0 -0 3 5 . 0 1 6 4 1 . 0 0-0 4 1 . 0 1 (61 . 6 1 4- 21 . 6 1 4 8 ) - 1.4967) 38.000- 38.016(1.4961 ( 1 . 4 9 6-1 1 . 4 9 6 7 ) I 3 8 . 0 0 -0 3 8 . 0 1 6 ( 1 . 6 1 4-2 1 . 6 1 4 8 ) 4 1 . 0 0 -0 4 1 . 0 1 6 ( 1 . 2 9 9-2 1 . 2 9 9 8 ) 3 3 . 0 0 -0 3 3 . 0 1 6 ( 1 . 4 9 6-1 1 . 4 9 6 7 ) 3 8 . 0 0 -0 3 8 . 0 1 6 ( 1 . 2 5 9-8 1 . 2 6 0 5 ) 3 2 . 0 0 -0 3 2 . 0 1 6 - 0.7094) 18.007- 18.020(0.7089 - 0.5683) Wearor damage - 14.434(0.5676 14.416

1

II

I

0.05- 0.16(0.002- 0.006) 0.05- 0.13(0.002- 0.005) 0.05- 0.16(0.002- 0.006) 0.1- 0.5(0.004- 0.020) 0.05- 0.17(0.002- 0.007) 0 . 1 0- 0 . 1 8( 0 . 0 0 -4 0 . 0 0 7 ) 0.05- 0.17(0.002- 0.007) 0.05- 0.18(0.002- 0.007) 0 . 1 0- 0 . 2 5( 0 . 0 0 -4 0 . 0 1 0 ) - 2.0431 51.87- 51.9012.042 49.50- 49.55(1.9488- 1.9508) 4 . 4 3 5- 4 . 5 2 5( 0 . 1 7 4-60 . 1 7 8 1 ) 27.00- 27.05(1.063- 1.065) 38.97- 39.00(1.534- 1.535) 39.02- 39.05(1.536- 1.537) 3 9 . 0 7- 3 9 . 1 0( 1 . 5 3 -8 1 . 5 3 9 ) - 3 9 . 1 5( 1 . 5 4-0 1 . 5 4 1 ) 39.12 3 9 . 1 7- 3 9 . 2 0( 1 . 5 4 -2 1 . 5 4 3 ) 39.22-39.25(1.544- 1.545) 39.27- 39.30(1.546- 1.547) 3 8 . 8 7- 3 8 . 9 0( 1 . 5 3 -0 1 . 5 3 1 ) 38.92- 38.95(1.532- 1.533) - 0.8346) 21.15- 21.20(0.8327 1 4 . 5- 1 4 . 6( 0 . 5 7 -1 0 . 5 7 5 ) 2 . 4- 2 . 6( 0 . 0 9 -4 0 . 1 0 2 ) 1 4 . 5- 1 4 . 6( 0 . 5 7 -1 0 . 5 7 5 ) 2 . 4- 2 . 6( 0 . 0 9 -4 0 . 1 0 2 ) 24.0- 24.1(0.945- 0.949) 2 . 9 s- 3 . 1 0( 0 . 11 6- 0 . 1 2 2 )

Wear or damage

)--

Wear or damage

Wear or damage Wear or damage **,

damage

:-

U n i to f l e n g t hm : m (in)

Automatic Transmission Section 14

J

MEASUREMENT Transmission

ATF pump

o

Mainshaft 2nd gear thrust washer thickness

Thrustwasherthickness Mainshaftball bearingleftside Mainshaft1stgear Countershaft 3rd gearsplinedwasher Sub-shaft4th gearthrustwasher One-wayclutchcontactareal.D. Countershaft lst gear Parkinggear Mainshaftfeed pipeA, O.D.(at 15 mm from end) Mainshaftfeed pipeB, O.D.(at 30 mm from end) Countershaft feed pipeO.D.(at 15 mm from end) Sub-shaftfeed pipeO.D.(at 15 mm from end) Mainshaftsealingring thickness ( 2 9m m a n d3 5 m m ) Mainshaftbushingl.D. MainshaftbushingLD. Countershaft bushingLD. Sub-shaftbushingl.D. Mainshaftsealingring groovewidth ATFpump gearsideclearance ATFpump gear-to-body clearance Drive Driven ATF pump drivengearl.D. ATFpump drivengearshaftO.D.

Regulator valve body

Sealing ring contact area l.D.

Stator shaft

Insideof diameter of bearing contact area On torque converter side On ATF pump side

Shifting device and parking brake control

Reverseshiftfork fingerthickness Parkingbrakepawl Parkinggear

Servo body

Shift fork shaft bore LD. Shift fork shaft valve bore l.D.

3.974.O24 . 0 74 . 1 24 . 1 74 . 2 24.274 . 3 24.374 . 4 2-

STANDARD(NEW} 4.00(0.156 - 0.157) 4.05(0.158- 0.159) 4 . 1 0( 0 . 1 6 -0 0 . 1 6 )1 4 . 1 5( 0 .16 2- 0 . 1 6 3 ) 4 . 2 0( 0 .1 6 4- 0 .16 5 ) 4 . 2 5( 0 . 1 6 -6 0 . 1 6 7 ) 4.30(0.168- 0.169) 4 . 3 5( 0 .1 7 0- 0 . 1 7 )1 4.40rc.172- 0.1731 - 0 .1 7 5 ) 4 . 4 5( 0 . 1 7 4

2 . 9 52.434.452 . 9 3-

- 0.120) 3 . 0 5( 0 . 1 1 6 2.50(0.096- 0.098) 4.50(0.175- 0.1771 3 . 0 0( 0 . 11 5- 0 . 11 8 )

Wearor damage

83.339- 83.3658.2810- 3.28211 - 2.6259) 66.685- 66.698(2.6254 8.97- 8.98(0.353- 0.3541 - 0.2354) 5.97- 5.98(0.2350 7 . 9 7- 7 . 9 8( 0 . 3 1 3-80 . 3 1 4 2 ) 7 . 9 7- 7 . 9 8( 0 . 3 1 3-80 . 3 1 4 2 ) 1.87- 1.97(0.074- 0.078)

Wearor damage Wearor damage 8.95(0.352) 5.95(0.234) 7 . 9 5( 0 . 3 1 3 ) 7 . 9 5( 0 . 3 1 3 ) 1.82(0.0721

- 0.2374l 6.018- 6.030(0.2369 - 0.3549) 9.000- 9.015(0.3543 - 0.3158) 8.000- 8.022(0.3150 - 0.3158) 8.000- 8.022(0.3150 - 0.0811) 2.025- 2.075(0.0797 (0.001 0.03 0.05 0.0021 0.1050- 0.1325(0.004- 0.005) 0.0350- 0.0625(0.001- 0.002) 1 4 . 0 1-6 1 4 . 0 3 (40 . 5 5 1-80 . 5 5 2 5 ) - 0.5508) 13.980- 13.990(0.5504 35.000- 35.025(1.3780- 1.37821

6.045(0.2380) 9.03(0.356) 8.03(0.316) 8.03(0.316) 2.095(0.082)

SERVICELIMIT Wear or damage

I

II

Wear or damage

*""1, damase

0.07 (0.003)

Wear or damage Wear or damage

35.050(1.3799)

27.000- 27.021(1.063- 1.064) - 1,14221 29.000- 29.013(1.1417 5.90 6.00(0.232 0.2361

Wear or damage Wear or damage

5 . 4 0( 0 . 2 1 3 ) f

1 4 . 0 0-0 1 4 . 0 1 (00 . s 5 1-2 0 . 5 5 1 6 ) - 1.4582) 37.000- 37.039(1.4567

w"r, o, other defect 37.045(1.4585)

(cont'd)

c 3-11

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

STANDARD(NEW}

MFASIIREMENT

Wire Dia. Springs

R e g u l a t o rv a l v e s p r i n g A R e g u l a t o rv a l v e s p r i n g B S t a t o r r e a c t i o ns P r i n g Modulator valve spring T o r q u e c o n v e r t e rc h e c kv a l v e s p r i n g Cooler reliefvalve spring R e l i e fv a l v e s p r i n g 2nd orifice control valve spring 1-2shift valve spring 2-3 shift valve spring 3-4 shift valve spring 1st accumulator spring 4th accumulator spring B 4th accumulator spring A 2nd accumulator spring A 3rd accumulator spring A 2nd accumulator spring B 3rd accumulator spring B 3rd sub accumulator spring 2 n d a c c u m u l a t o rs p r i n g C L o c k - u ps h i f t v a l v e s p r i n g L o c k - u pt i m i n g v a l v e s p r i n g L o c k - u pc o n t r o l v a l v e s p r i n g 3-4 orifice control valve spring Servo control valve spring C P Bv a l v e s p r i n g 4th exhaust valve spring

1 . 8( 0 . 0 7 1 ) 1 . 8( 0 . 0 7 1 ) 4.5 rc.177]. 1 . 4( 0 . 0 5 s ) 1.2 10.047l. 1 . 0( 0 . 0 3 9 ) 1 . 1( 0 . 0 4 3 ) 0.7(0.0281 0.9 (0.035) 0.9(0.035) 0.9(0.035) 2 . 1( 0 . 0 8 3 ) 2 . 3( 0 . 0 9 1 ) 2 . 6( 0 . 1 0 2 ) 2.4(0.094) 2 . 8( 0 . 1 1 0 ) 1.6(0.063) 2.1(0.083) 2 . 7( 0 . 1 0 6 ) 2.2 l0.o87l 0.9(0.035) 0.9(0.035) 0.7(0.028) 0.6 (0.024) 1 . 0( 0 . 0 3 9 ) 0.9(0.0351 0.9(0.035)

o.D. 14.7(0.5791 9.6(0.378) 35.4(1.394) 9.4(0.370) 8 . 4( 0 . 3 3 1 ) 8 . 4( 0 . 3 3 1 ) 8.6(0.339) 6.6(0.260) 7.6(0.299) 7.6(0.299) 7.6 (0.299) 16.0(0.630) 10.2rc.4021 17.0(0.669) 29.011.1421 17.5(0.689) 9.0(0.354) 3 1 . 0( 1. 2 2 0 ) 17.0(0.669) 1 4 . 5( 0 . 5 7 1 ) 7.6(0.299) 8 . 1( 0 . 3 1 9 ) 6.6(0.260) 6.6(0.260) 8 . 1( 0 . 3 1 9 ) 8 . 1( 0 . 3 1 9 ) 6.1(0.240)

No. of Goils

Free Length

87.8(3.457) 44.0(1.732\ 3 0 . 3( 1 . 1 9 3 ) 3 5 . 0( 1 . 3 7 8 ) 32.4(1.2761. 3 3 . 8( 1 . 3 3 1 ) 3 7 . 1( 1 . 4 6 1 ) 3 4 . 8( 1 . 3 7 0 ) 4 1 . 3( 1 . 6 2 6 ) 57.0 12.2441 57.012.244]. 89.1(3.508) s 1 . 6( 2 . 0 3 1 1 88.4(3.480) 39.0(1.53s) 9 4 . 3( 3 . 7 1 3 ) 2 0 . 7( 0 . 8 1 5 ) 38.2(1.504) 3 9 . 0( 1 . 5 3 5 ) 68.0(2.677) 73.7(2.9021 8 1 . 4( 3 . 2 0 5 ) 38.0(1.496) 3 7 . 9( 1 . 4 9 2 ) 52.1(2.0511 47.2(1.858) 3 6 . 4( 1 . 4 3 3 )

co(J

@

b

- ! @ @

Y ;

o(I)m

a

()

.E

b

N N

a

o

E

d . U a

h

r

r

o ; .

v L O . . 1

E 6

u o

O o aan

P

F +

A

-

;

I

iZx V;;

z0 zo

h

!

t

'

-

oI

c ob 9 -oi1 dl(J+l

o o o r r n d)Cnr

t

!

3

* E 3 : 30

c ' 6 .9 .9 @ , =

9 6

;;;iss o a ; i

U 6

zo

O O

O

c

E

9

: i

ts

=

E

oo i",>.E

,^^. ..; J63 3E * * -

c . 9< r :

A ; .9;

,,3+{l Fi y , E : : : :

o

a

o . ! a

F i 6 o o o ! l o > < oo o

o r

= 3

o o

N

r

E

o

N

= = =

i

o u

=

N @

a a

a

^ O

c

= :

a

,v 9 E; EN ^ -

a

o E (J

|

;j a.; -t ,; U ,Nj F 6-

c o ; o ^ !ooi ooiY

g N F r E ; .,,i o o,i 3

>

c

o c

.;

-

r

r :

E

st

ai o

sl

L

B

=

o

O

P

O

P

P

O

=

^

O

S E 8 b * 9

EE

P

o o o t r a

39

L

a a o a

N : ,

-

o N

R F 9

o

o

E o o u

a

ci a

E

F

=

a

5 t

6 z

e

C

a

u

F

a

o

/;

E E

o

o

E

)

=e>a r! - E \* .

X

E E

c

) rEn o

-o

o

CD f

6

F G

f

.5

'!

! o

> ; aC ;

L

d E 3

o o

o o a

€E -^o? o 3l a c : i

i

E

!

o

o o a li

L

9 o - = o P

A

r f

o

C

Q

F

F o

E c '6

a 5 @

=

6 r

a o

q

= c

o @

o

o

q 0) o

o c

o

q)

f

o

=

d]

o

E

q

@

q

o o

=o O

x

LU

o)

S? !- U

I g ()

o r o r 6 9 o ( ) o 4

E E E ;

3 = o

l!

o o !t 0

o o ( , o AU) qT.

o

l

'6

-

o c

E

(u

o

c c.lg ( o( o - < E E E c

!

o

J

U) o

P

.F 6

o o c G o o

-

-O- ) N ; i :

'i5 o c o c

_

oo

C c

c

c q)

.9

-

a

G

I

L

bHi 5 !rz+ E = 8 -E 5

q

c c o c

o

h O E E

\

o

e c

(J 0) o q) @

o

o o

a

@

o)

o C 6 P t c o )

- t : o t r : 0 )

o ,i

c o (o s

6 6

a

or

a



l L

N

9 : i i ;

o

=

; E !

:,;F

,@

z

oJ:

c c o o

r

ro)

c o o 'o

c

n

a

0)

d \

=

; o

^ :

U F

E;t -

o) q o O o . = J o u'o ol ol -9

N

a

q l Y ' e

c

@ (n'i A^i.s

N

i

.g o c

o (o

o o o o

.s

N

;

(o

O _ u J

a o

E I

o f

9e;ci r b b.=.E.€

dd FS€

fr{gE

c

|E !

o E

()G o ll

4-5

MaintenanceSchedule(SevereConditionsl \ e o

$L

z

O _ u

oat-

o

c

H FT

N

N

o

19dl(J _ ! @ €

q)

o d l m G

o

o o

E E E E

E E E E

o

J

O e r N

::

6,i

: u

c a

6 u c

q l , l i

@

o

c

o

m

6

m

@

d

i

l

- =

P6--cct?

. . 1 v o u)(o

e

c

F

C

F

- n F - O F j j

[6z.!.;:-E

c

4

a :

o : :

I

v

$ e ,

9



:t gE€T

0) o) t/,

.tsXo-

;bP?

' -

9 -

L

F o

6 ; i ; ' F- t

,; -

o1. o-(9 X : ( Y ) ;

fYE

*a

J J

eEbtgz

^O)(,)(u;.

F= r: Z o Q E

.i t o. : > ' t r - ^i

=

=

a

s r q R i " . () E6;3f g )t r > : . : E

.E:P;i; E EF P 1 ! : + : . = . = h r

s:*E 5ftE==:

6 q

c o o

( u

(JF=o

c

o

> ' !

EgbE

" ' " . ( E O

o c

g E

P

EE g i EEE

F

?

- v ' ;

o

3 =

' or =

.--

::-o

C

=

ii o

=

=Fgg U5.E

0) o

o

o o c ,6

o c 'F o o c c

F

i

@ *) -: ( o

I

o

E

@ E e

o o c c

-

oo_ o o 9-o : i o F . . ; O o = o F- i9'< l-EC a'e 92 e ) i ( ,

a

c

F

EE

o [J

,

L

( J a

o

rOr

o

a

F

I-o

O

b

o a o

ci

' -

- L

O

o o

c)

.= (E

q

o

:

(o

== 3E

o

o

F--

a

;o-

li o

6i

ooo

o

- o

o

E

o 9 o(/)

o c

ts

:

(o

. Y n o E

c f

o

! l O F

o

@

a

o

6 > ; o@ 0 o ) - ot/ ott o L F o o

. Y O

c 'F

e

> ; ! o

E

ooo

oo

N

a

@ c c

O

o oo

o a

N

E'r

o . y = 6 r 7

O

O

E

o o

Y o

x

;.Y

> E

t c I

oo o

(0 o

c

c G a

o o o o ! c O

'o

o

!rc

: F : o

s x =

e

- V c o q )

c o 0)

:

3 ;= o t !

6

o 0 ) v x

3 i,,

N

: c 6

t L

c

-e:6 c o

9>

6 B

- ;

' = o 6 o o F v ur6

.

O

e : P

a

^

a

c 'F o : >

;r != ;e

0) c

i

w

Y

o

a q 3

E

@

J

N

o

o

G c c o c o c a o

6 q-a c o,! o 3 t -

:Etr

g

o o o o U,Q o o)l9

-

= o r

o o T o

E c

q) a

= '^

3

o

.9

(9 -

c

:

;

-

o

-S !- :>

L

a

c o

C

r O

c

o

r

r o

o > f

o

: : ?

o

: P

P

o q

.a

r

N

9 A 6

o,

E

x ; !

o)

N N

=t \t o

F c = o0)

= o

,E o

6 6 6 6 aa 6i

o j y . = y o o .5 gr g,'A f g,

::c.=a ##E E=

orooijFo

(J

e e E n . o' ' ^t r =' t r:! ;g 'E- *= ;

d dn E € 8 . . . . . F i l Xg E S

ro !r+

z a

4-7

Cooling Radiator EngineCoolantRefillingand Bfeeding

....10-2

NOTE: Referto the '98 INTEGRAServiceManual,PiN 61ST705,for the i t e m sn o t s h o w ni n t h i s s e c t i o n .

\t

,f

Outlineof ModelChange E n g i n ec o o l a n t h a s b e e n c h a n g e d .

rfltmlfr

Radiator EngineGoolantRefillingand Bleeding CAUTION:When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electricalparts or the paint. lf any coolant spills, rinse it off immediately. 1.

Slide the heatertemperaturecontrol leverto maximum heat. M a k es u r e t h e e n g i n ea n d r a d i a t o ra r e c o o l t o t h e touch.

2.

Removethe radiatorcaD.

3.

Loosenthe drain plug,and drainthe coolant.

5.

A p p l y l i q u i d g a s k e t o t h e d r a i n b o l t t h r e a d s t, h e n reinstallthe bolt with a new washer and tighten it securely.

6.

Tightenthe radiatordrain plug securely.

7.

R e m o v e ,d r a i n a n d r e i n s t a l tl h e r e s e r v o i r F . illthe t a n k h a l f w a yt o t h e M A X m a r k w i t h H o n d a A l l SeasonAntifreeze/Coolant Type 2.

\

COOLANT RESERVOIR

I \.-\_-l

-

I

tW.

DRAINPIUG

4.

Removethe drain bolt from the cylinderblock.

ENGINEDRAINBOLT 78 N.m (8.0kgf.m,58 lbf.ftl Apply liquidgasketto boltthreadwhen installing. WASHER Reolace.

\-

tt.

Pour Honda All SeasonAntifreeze/Coolant Type 2 into the radiatorup to the baseof the filler neck.

9 . Installthe radiatorcap loosely. 1 0 . Installthe battery.

NOTE: o Always use HondaAll SeasonAntifreeze/Coolant Type 2. Using a non-Hondacoolantcan resultin c o r r o s i o n ,c a u s i n gt h e c o o l i n g s y s t e mt o m a l f u n c t i o no r f a i l . o HondaAll SeasonAntifreeze/Coolant Type 2 is a m i x t u r e o f 5 0 % a n t i f r e e z ea n d 5 0 % w a t e r . Premixingis not required. Engine Coolant Refill Gapacity[including reservoir (0.6f {0.6US qt, 0.5 lmp qtlll: 8 1 8 8 1e n g i n e : M/T: 4.4 / {4.6 US qt, 3.9 lmp qtl B18B1,Bl8Cl engines: AIT:4.7/ (5.0US qt,4.1 lmp qtl 818C1,B18C5engines: MIT:4.7 / (5.0US qt,4.1 lmp qtl

FILLER NECK

F i l lu p t o h e r e

1 1 . Startthe engineand let it run until it warms up (the radiatorfan comeson at leasttwice). 1 2 . Turn off the engine.Checkthe level in the radiator, and add HondaAll SeasonAntifreeze/Coolant Type 2 if needed.

1 3 . P u tt h e r a d i a t o rc a p o n t i g h t l y ,t h e n r u n t h e e n g i n e againand checkfor leaks.