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Generallnformation 1-2 Chassis andPaintCodes....................... 1-10 NumberLocations......... ldentification Warning/Caution LabelLocations.......1-11 Under-hoodEmissionsControl . . . . . . . . . . . . . .1 . .-.1. .5. . L a b e l. . . . . . . . . . Lift and SupportPoints 1-19 LiftandSafetyStands....................... FloorJack ....................... 1-20 .........1-21 Towing ServicePrecautions 1-22 PaftsMarkingLocations..,................. for Real-time4WD Precautions (Four-wheel Drivel......... ................. 1-23
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Chassisand PaintCodes U.S. 1997Model VehicleldentificationNumber JHLRD184*VC000001
JHL: HONDAMOTORCO.,LTD HONDA,Multipurpose Passenger Vehicle(MPV) line, Body and Engine Type RDl: CR V/82084 Body Type and TransmissionType 8: 5-door/4-soeed Automatic Vehicle Grade (Series) 4: LX 5: LX (with ABS) CheckDigit Model Year Vt 1997 C: SaitamaFactoryin Japan(Sayama)
B-84P NH-552M NH-592P R-94
Vehicleldentification Number and FederalMotor Vehicle
SupermarineBlue Pearl CypressGreenPearl SebringSilverMetallic FlamencoBlackPearl San MarinoRed
(o
COLORLABEL
INT.COLOR
WPEF
EXT.COLOR
B-84P
KA S2BA1 C
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1-2
U.S.1998Model
JHLRD174*WC000001
B20B4t2.01 DOHCSequentialMultiport Fuel-injected engine
JHL: HONDAMOTORCO.,LTD HONDA.Multipurpose Passenger Vehicle(MPV) Line, Body and EngineType RD1:CR-V/82084 RD2:CR'V/82084 Body Type and TransmissionType 7: 5-door/s-soeed Manual 8; 5-door/4-soeed Automatic
MDLA: 4-speedAutomatic M4TA: 4-speedAutomatic S B X M : s - s p e eM danual MDLA,SBXM:1000001M4TA: 3000001C: SaitamaFactoryin Japan(Sayama)
B-84P G-82P NH-552M NH-592P R-94
VehicleldentificationNumber and CanadianMotor Vehicle
SupermarineBlue Pearl CypressGreen Pearl SebringSilverMetallic FlamencoBlackPearl San MarinoRed
COLORLABEL
INT.COLOR
TYPEF
EXT. COLOR
8.84P
KA S2BA1 C
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1-3
Chassisand PaintCodes U.S. 1999Model Vehicle ldentification Number JHLRDIT4*XC000001
B2OZ2:2.0 | DOHCSequentialMultiport Fuel-injected engine
JHL: HONDAMOTORCO.,LTD HONDA.Multipurpose
RDlt CR-vlB20Z2 RD2t CR-V1B2OZ2 Body Type and TransmissionType 7: 5-door/5-speed Manual 8: 5-door/4-spsed Automatic MDLA: 4-speedAutomatic MDMA:4-speedAutomatic SBXM: s-speedManual
4: LX
6:Ex Chock Digit Model Year X: 1999
MDLA:2000001MDMA:1000001SBXM:2000001-
C: SaitamaFactoryin Japan(Sayama)
B-84P B-92P G.95P NH-578 NH-552M R,81
Vehicle ldentification Number and CanadianMotor Vehicle
SupermarineBlue Pearl NighthawkBlackPearl CloverGreenPearl TaffetaWhite SebringSilverMetallic MilanoRed
COLORLABEL
INT.COLOR
TYPEF
EXT. COLOR
B.84P
KA S2BA1 C
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1-4
Model U.S.2000
J H L R D 1 7 4 *Y C 0 0 0 0 0 1
B20Z2t2.0I DOHCSeouentialMultiDort Fuel-injected engine
JHL: HONDAMOTORCO.,LTD HONDA,Multipurpose Vehicle(MPV) Passenger Line. Body and EngineType RDlt CR-V/82022 RD2iCR-v/BzOz2 Body Type and TransmissionType Manual 7: 5-door/s-speed 8: 5 door/4-soeed Automatic
MDLA; 4-speedAutomatic MDMA:4-speedAutomatic SBXM: s-speedManual
MDLA:3000001MDHA:2000001SBXM:2000001CrSaitamaFactoryin Japan(Sayama)
B-92P B-95P G-95P NH-578 NH-552M R-81
NighthawkBlackPearl ElectronBluePearl CloverGreenPearl Taffeta White SebringSilverMetallic M i l a n oR e d
COLORLABEL
Safety Standard Certification. lrl ..V
INT.COLOR
TYPEF
EXT, COLOR
8.92P
KA S2BA1 C
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1-5
Chassisand PaintCodes Canada1997Model
J H L R D 1 8 5 *V C 8 0 0 0 0 1
B20g4t2.0| DOHCSeouentialMultiDort Fuel-injected engine
HONDAMOTORCO.,LTD HONDA,Multipurpose Passenger Vehicle(MPV) Line, Body and EngineType RDl: CR-V/B2084 Body Typ€ and TransmissionTyp€ 8: s-door/4-soeedAutomatic
MDMA- 1000001
MDMA:4-speedAutomatic SDMA: 4-speedAutomatic C: SaitamaFactoryin Japan(Sayama)
B-84P G-82P NH-552M NH-592P R-94
Vehicle ldentification Number and Canadian Motor Vehicle Safety Standard Certification.
SupermarineBluePearl CypressGreen Pearl SebringSilverMetallic FlamencoBlackPearl San MarinoRed
COLORLABEL
INT.COLOR
TYPEF
EXT.COLOR
B-84P
KCS2BC2 C
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1-6
Canada1998Model
J H LR D 17 4 * W C 8 0 0 0 0 1
JHL:HONDAMOTORCO.,LTD HONDA,Multipurpose Vehicle(MPV) Passenger Lino, Body and EngineType RD1:CR-V/82084 Body Type and TransmissionType Manual 7: 5-door/s-speed Automatic 8: 5-door/4-speed
8208 4:2.0| DOHCSequentialMultiport engine Fuel-injected
M4TA: 4-speedAutomatic SBXM:5-speedManual SBXM:1000001M4TA: 3000001* C: SaitamaFactoryin Japan(Sayama)
B-84P G-82P NH-552M NH-592P R-94
SupermarineBIuePearl CypressGreen Pearl SebringSilverMetallic FlamencoBlackPearl San MarinoRed
COLORLABEL
INT.COLOR
TYPEF
EXT.COLOR
8.84P
KCS2BC2 C
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1-7
Chassisand PaintCodes Canada1999Model Vehicle ldentification Number J H LR D l T 4 * X C 8 0 0 0 0 1
B20Z2i2.0I DOHCSequentialMultiport Fuel-injected engine
JHL:HONDAMOTORCO.,LTD HONDA,Multipurpose Passen0er Vehicle{MPV) Line, Body and Engin6Type RD1:CB-Y/B2OZ2 Eody Typ6 and Transmi$ion Type 7: 5-door/5-speed Manual 8: s-door/4-speedAutomatic 4: LX 5: EX ChockDigit Model Yeal X: 1999
MDMA:4-speedAutomatic SBXM: s-speedManual
C: SaitamaFactoryin Japan{Sayama)
B-84P a-92P G.95P NH.552M R-81
VehicloldentificationNumber and CanadianMotor Vehicle Safety Standard Certification.
SupermarineBluePearl NighthawkBlackPearl CloverGreenPearl SebringSilverMetallic MilanoRed
COLORLABEL
INT.COLOR
TYPEF
EXT. COLOR
B-84P
KCS2BC2 C
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1-8
J H LR D l7 4 * Y C8 0 0 0 0 1 Manulacturer, Make and Type of Vehicle JHL:HONDAMOTORCO.,LTD HONDA,Multipurpose Passenger Vehicle(MPV) Line, Body and EngineType RDlt CR-VlB2oZ2 Body Type and TransmissionType Manual 7: 5-door/s-soeed Automatic 8: 5-door/4-sDeed Vehicle Grade (Seriesl 4: LX 5: EX
8 2022:2.0| DOHCSequentialMultiport engine Fuel-injected
MDMA:4-speedAutomatic SBXM: s-speedManual
Check Digit Model Year Yr 2000 FactoryCode C: SaitamaFactoryin Japan(Sayama) Serial Number B-96P B-92P G-95P NH-552M R-81 YR-524M
Vohicle ldentification Number and Canadian Motor Vohicle
EternalBlue Pearl NighthawkBlackPearl CloverGreenPearl SebringSilverMetallic MilanoRed NaplesGold lVetallic
OOLORLABEL
tNrcoL0R
TYPEF
COLOR EXT.
B-92P
KCS2BC2 C
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1-9
ldentificationNumberLocations
Vehicl€ldentific.tion Number tvtNl
VehicleldentificationNumber lVlNl
-
TransmissionNumb6r lManudl)
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1-10
TransmissionNumbor {Aulomaticl
EngineNumbel
Warning/CautionLabelLocations
A: CABLEREELCAUTION
OF THE SRSCABLEREELIS CRITICAL TNSTALLATION TO THE PBOPEROPERATIONOF THE SRS SYSTEM. REFERTO THE SERVICEMANUAL FOR DETAILED INSTALLATIONINSTRUCTIONS. B: DRIVERMODULEDANGER A DANGER EXPLOSIVE/FLAMMABLE CONTACTWITH ACID, WATEROR HEAVY METALS S U C H A S C O P P E R ,L E A D O R M E R C U R YM A Y PRODUCEHARMFULAND IRRITATINGGASESOR EXPLOSIVECOMPOUNDS.STOMGE TEMPERATURES M U S T N O T E X C E E D2 O O " F{ 1 O O ' C }F. O R P R O P E R HANDUNG,STORAGE,AND DISPOSALPROCEDURES. REFERTO SERVICEMANUAI- SRSSUPPI.EMENT, POTSON C O N T A I N S P O I S O N O U SS O D I U M A Z I D E A N D POTASSIUMNITRATE. FIRSTAID tF CONTENTS ARE SWALLOWED, INDUCE VOMITING.FOR EYE CONTACT,FLUSH EYESWITH WATERFOR 15 MINUTES.IF GASES IFROMACID OR WATER CONTACTIARE INHALED,SEEK FRESH A I R . I N E V E R YC A S E , G E T P R O M P T M E D I C A L ATTENTION. KEEPOUT OF REACHOF CHILDREN
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C: DRIVERMODULEWARNING A WARNING T H E A I R E A GI N F L A T O RI S E X P L O S I V EA N D , I F ACCIDENTALLYDEPLOYED,CAN SERIOUSLYHURT OR KILLYOU. TEST EOUIPMENTOR . DO NOT USE ELECTRICAL PROBINGDEVICES. THEYCAN CAUSEACCIDENTALDEPLOYMENT. . N O S E R V T C E A B LP EA R T S l N S l D E . D O N O T DISASSEMBLE. . PLACEAIRBAGUPRIGHTWHEN REMOVED . F O L L O WS E R V I C EM A N U A L I N S T R U C T I O N S CAREFULLY.
(cont'd)
1-11
Warning/CautionLabelLocations (cont'dl
(U.S.A.modelonlyl {U.S.A.modolonlyl
o: SRSWARNING{HOOD} SUPPLEMENTAL RESTRAINT SYSTEM{SRSI THIS VEHICLEIS EOUIPPEDWITH DRIVERAND FRONT SEATPASSENGER AIRBAGS, ALL SRS ELECTRICAL WIRINGAND CONNECTORS ARE COLOREDYELLOW. T A M P E R I N G W I T H , D I S C O N N E C T I N GO R U S I N G ELECTRICAL TEST EOUIPMENTON THE SRS WIRINGCAN MAKETHESYSTEMINOPERATIVE OR CAUSEACCIDENTAL FIRINGOF THEINFLATOR. A WARNING T H E A I R B A G I N F L A T O R I S E X P L O S I V EA N D . I F ACCIDENTALLYDEPLOYED,CAN SEBIOUSLYHURT YOU. FOLLOWSERVICEMANUAL INSTRUCTIONS CAREFULLY.
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1-12
E: STEERINGCOLUMNNOTTCE tHOODI NOTICE TO PREVENTSRS DAMAGE, REMOVESTEERINGWHEEL BEFOREREMOVINGSTEERING SHAFTCONNECTING BOLT. F: MONITORNOTICE NOTICE . NO SERVICEABLE PARTStNStoE. . REFER TO SERVICEMANUAL FoR DETAILED
rNsrRucTtoNs.
AIRBAGMODULEDANGEN G: FRONTSEATPASSENGER A DANGER EXPLOSIVE/FLAMMABLE CONTACTWITH ACID,WATER.OR I{EAVY METALSSUCH HARMFUL T.EAD. OR MERCURYMAY PRODUCE AS COPPER. AND IRRITATINGGASESOR EXPLOSIVECOMPOUNDS. MUST NOT EXCEED2OO"F STORAGETEMPERATURES I l O O ' C ) . F O R P R O P E RH A N D L I N G ,S T O R A G E ,A N D REFERTO THESERVICEMANUAL, DISPOSALPROCEDURES SRSSUPPLEMENT. POTSON SODIUM AZIDEANO POTASSIUM CONTAINSPOTSONOUS NITRATE. FIRSTAID IF CONTENTSARE SWALLOWED,INDUCEVOMITING.FOR E Y E C O N T A C T ,F L U S H E Y E S W I T H W A T E R F O R 1 5 MINUTES. IF GASES (FROM ACID OR WATEN CONTACT) ARE INHALEO.SEEKFRESHAIR. IN EVERYCASE,GET PROMPTMEDICALATTENTION. KEEPOUTOF REACHOFCHILDREN. A WARNING T H E A I R B A G I N F L A T O R I S E X P L O S I V EA N D , I F CAN SERIOUSLYHURT OR DEPLOYED, ACCIDENTALLY KILLYOU. L E S T E O U I P M E N TO R . D O N O T U S E E L E C T R I C AT PROBINGDEVICES, DEPLOYMENT. THEYCAN CAUSEACCIDENTAL . NO SERVICEABI-E PARTSlNSlDE.DO NOT DISASSEMBII. . PLACEAIRBAGUPRIGHTWHENREMOVEO. . FOLLOWSERVIC€MANUAL INSTRUCTIONSCAREFULLY INFORMATIONlU S.A. modell H: PASSENGER {U.S.A.'97model} AIEBAGSEEOTHERSIDE,
lU.S.A.'98- 00 models) WARNING DEATHOR SERIOUSINJURYCAN OCCUR' . CHILDREN12 ANO UNDERCAN BE KILLEDBY THE AIRBAG. . THE BACKSEATlS THESAFESTPLACEFORCHILDREN. C H I L DS E A T l N T H E . N E V E RP U T A R E A R - F A C I N G FRONT. o SIT AS FARBACKAS POSSIBLEFROMTHEAIRBAG . ALWAYSUSESEATBELTSAND CHll-DRESTRAINTS. TEN YEAnS AFTERlT lS . THE SRSMUST BE TNSPECTED INSTALLED. . T H E O A T EO F I N S T A L L A T I O Nl S S H O W N O N T H E DRIVER'SDOORJAMB. AIRBAGWARNING J: FRONTPASSENGER lU.S.A.'98- 00 models) WARNING C H I L D R E NC A N B E K I L L E D O R I N J U R E D 8 Y T H E AIRBAG. PASSENGER THE BACKSEAT IS THE SAFESTPLACEFORCI{ILDREN12 AND UNDER. MAKE SURE ALL CHILDRENUSE SEAT BELTSOR CHILD SEATS. WARNING K: FRONTSEATBELTTENSIONER WABNING EXPLOSIVEMATERIALINSIDE HURTOR BURNED, YOU CAN BE SERIOUSLY . DO NOT TAMPEROR DISASSEMBLE PARTSINSIDE. NO SERVICEABLE . REFERTO SERVICEMANUAL FORCOMPLETE INSTRUCTIONS.
{U.S.A.'98- 00 modelsl AIRBAGWARNING FLIPVISOROVER. l: SRSINFORMATION
model lU.s.A.'97 i '97 lcanada - 00mod€lsI CAUTION TO AVOIDSERIOUSINJURY: lN ALL TYPESOF . FORMAXIMUM SAFEW PROTECTION CRASHES,YOU MUST ALWAYS WEAR YOUR SAFETY 8ELT. CHILOSEATSlN o OO NOT INSTALLREARWARD-FACING SEATPOSITION. ANY FRONTPASSENGER CLOSETO THE . DO NOT SIT OR LEAN UNNECESSARILY AIRBAG. . DO NOT PLACE ANY OBJECTSOVERTHE AIRBAGOR BETWEENTHEAIRBAGAND YOURSELF. . SEE THE OWNER'S MANUAL FOR FURTHER INFORMATIONAND EXPLANATIONS TEN YEARSAFTERlT lS . THE SRS MUST BE INSPECTED INSTALLED. . T H E D A T E O F I N S T A L L A T I O Nl S S H O W N O N T H E DRIVER'SDOORJAMB.
(cont'd)
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1-13
Warning/CautionLabelLocations (cont'd)
VACUUM HOSEROUTING DIAGRAMlUndor-hood EmissionsControl Lrb6ll ENGINECOOLANT INFORMATION
SERVICE INFORMANON {Under-hood Emission3 Control l.rbell STEERING COLUMNNOTICE (s€epage 1-12)
(Canadamodel)
RAOIATORCAP CAUTION
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1-14
AIR CONDITIONING INFORMATION
Under-hoodEmissionsControlLabel EmissionGroupldentification (1997modell Example: VACUUMHOSEROUTINGDIAGRAM
INFORIMATION VEHICLE Ii/PORTANT VHN2 OIJCrcK ENGINE FAMILY OLITER DISPIACEMENT'2 VNNl0778YMBP VEf AM]LY EVAPORAT
CATALYST
NFORMATON. REfERTOSEBVICEMANUALfORAODITIONAL I-]P TUNT CONDITIONS TEMPERATURE, ATNORI\,!AL OPERATNG ENGINE FANOIF OFFCOOLING ESTL]RNED ALLACCESSOR NNEUTRAL TRANSM1SSION ADJUSTMENIS NEEDED NOOTHEB
ap'
| \6( Zror '.
ND\. 61FL r
TO U.S EPAREGUI.ATIONS TNISVENICLE CONFORMS TO I99] MODET YEARN€WL GNI DUTYTRACKS APPICASLE
E n g i n eF a m i l y :
Year Model v:1s97
l JGKE vHN2.o
T_fT
I I | L
Manufaqturer H N :H o n d a Displacement Class 1: Light DutyVehicle Fuol Systom ,nd Numb€r of valves J: ElectronicSequentialMultiport Injection(threeor more valvesper cylinder) Fuel Type G: Gasoline Standard F: 49 or 50 StatesTier 1 K: 49 or 50 StatesTier 1 1: CaliforniaTier 1 2: CaliforniaTLEV 3: CaliforniaLEV 4: CaliforniaULEV Catalyst E, F, G, H: ThreeWay Catalyst
i I
OBD
@
K - T: OBDEquipped
ONCONTROL'EOLJIPPED OSVEORTRACT fOUBWHEEL OFPERMANENT LOADED IM TEST]NG ZED ON A IOUR WHEELDRVE SPEEOSYNCHRON VEHTCLES MUST BE CONDUCTED ANONLOADEDTESTPBO(EOUBEMUSIBEPERFORMEO
50ST (50 Statesl: TO U.S.EPAAND STATEOF CONFOBMS THISVEHICLE C A L I F O R N IR A E G U L A T I O NASP P L I C A B LTEO 1 9 9 7 MODELYEARNEWLIGHTDUTYTRUCKS. 49ST{49 Statos/Federall: TO U.S.EPA REGULATIONS CONFORMS THISVEHICLE YEARNEW LIGHTDUTY TO 1997IVIODEL APPLICABLE TRUCKS. CAL (Calitornial: TO U.S.EPAAND STATEOF CONFORMS THISVEHICLE TO '1997 APPLICABLE I A R E G U L A T I ONS CALIFORN M O D E LY E A R N E W T L E V L I G H T D U T Y T R U C K S THAT THISVEHICLEIS ONLY INTRODUCED PROVIDED I N T O C O M M E R C EF O R S A L E I N T H E S T A T E O F CALIFORNIA.
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Families Engineand Evaporative
Evaporative Family: "r0",
V HNlOTTBYMBP T|
"*,
V: 1997 Manufacturer HN: Honda Storago System 1: Canister CanistorWorking Capacity (gramsl CanisterConfigulation A: PlasticHousing(ClosedBottom) B: PlasticHousing(OPenBottom) Fusl System Y: FuelInjection FuelTank M: Metal Standard A: CurrentEvap B: EnhancedEvap Wild C.rd
1 - 15
Under-hoodEmissionsControlLabel EmissionGroupldentification (1998modell
Engineand EvaporativeFamilies EngineFamily:
Example: DwlF\AIo|NG oBcha\GtftcI + cootr\r -s€msoru1or or FoNoA-IEaoTTxD-ibl a\D wATfB. M w r or_ut-ir coolqNt,oR-l;ir,FEaFEf1'v!Lrff EzEcoo-aN' ENGINE MAY BESEflIOUSLYSIONTENEO. DSEPLACI CoOTANT AnEs85 itNlgsloF@ MILIS l@0 rnl, wHrcHEvEs coMEs
Mod€l Year W: 1998 ManufacturerSubcods HNX:HONDA
TNEREAFT€R, REPLACE EvEny fmAFSlm m M[Esi@ kml,wHcHrvEB coMEs DCHEC(ONADOCOOLqNTATTHE RSSEFVETANX. NOTTHE iAD]ATOR. DFOR FUFTNEfr INFO8MATION ONIN€COOT]NC SYSIEM NEAD THE OWNEN'S MANUAL, . CHECK W|TH YOUR NONDA OEALEF.
FamilyTypo V: LDV T: LDT
IMPORTANT VEHICLE INFORMATION THISVEHICLE CONFOEMS TOI], S.EPA FEGIJLAIIONSAPPLICASLE TO1993MOOEL Y€AFNEWLIGHTDUIYTNUCXS.
CATALYST
rwqHozst2l/sFt/osD l cERI|FtEO vAlvttAsH lrr0.l010.02nm icolo) EX:01310.02mm SPAS( PIUGGAP I.O IINM 686,13G96 lDLlSPTED 750I 50rym PROCEOURESI 2.0L TlNt UPCoND/ToNS: ENGINE ATNOiM IEMPETAIURT,ALLACCESSORIESTUNNI fANOFf.TRAI1SMISSON INNEUTMI NOOIIIERAOJUSTI\TFIIS IIEEOED.
GD
@
50ST {50 States}: THISVEHICLE CONFORMS TO U.S.EPAAND STATEOF C A L I F O R N I AR E G U L A T I O N S APPLICABLE TO 1998 MODELYEARNEWLIGHTDUTYTRUCKS, /$ST (itg Statos/Fodsrsll: THISVEHICLE CONFORMS TO U.S.EPA REGULATIONS APPLICABLE TO 1998MODELYEARNEW LIGHTDUTY TRUCKS. CAL {California}: THISVEHICLE CONFORMS TO U.S.EPAAND STATEOF C A L I F O R N I AR E G U L A T T O NASP P L I C A B L E TO 1998 M O D E LY E A R N E W T L E V L I G H T D U T Y T R U C K S PROVIDED THATTHIS VEHICLEIS ONLY INTRODUCED I N T O C O M M E R C EF O R S A L E I N T H E S T A T E O F CALIFORNIA.
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1-16
W HNX T O2.OUF1
Displacomsnt Soqu€ncoCharaciors
Evaporative Fami Family: Model Yeat W:1998 Manufastu16rSubcode HNX:HONDA Family Type E: EVAP R; EVAP/ORVR CanisterWork Capacity SgquoncoCharaqtsrs
W HNXEOOSOAAB
EmissionGroupldentification (1999model) Example: U-ECo-q.NOEDI USE THE COOLANT. NGORCNANGINC @SOLU I ONOfFONOA '.WNEN AOO 0FTNE LIFE THE CooLANT,0RTHE oILLJTE mcrtniuvcoourr mo wlttt NEVEF
coMEs lmo rhl,wNrcHEVEn "Eifil:$o""niii?i,THffiffi'"R@ MLEs os@
i'lrt^torrrr,^,r*a, rurr"*
coMEs MLEs 1@ kmrwNICHEVER
TAN(NOTIHENADIATOS ATTHERESER!'E }CNECK ORADDCOOLANT MANUAL' READ THEOWNER'S NCSYSTEM ONTHECOOL DFOfifWTHEFNFORMATION ' CHECK HONOA OEALER. WIIHYOUS
INFORMATION VEHICLE IMPORTANT S EPANLEV CONFOAMSTOU. THISVEHICLE TO1999MOD€L APPLICCBLI FEGULANONS YEA8NEWTIEVLIGHTDUTY]nUCKSAND IO 19S9 APPLICASLE REGULATIONS CALIFORNIA YEARNEWTLEVLIGHTDUTYIFIJCKS, MOOEL
CATALYST mm IASN lN:010r0.02 VALVE E X0 1 3 1 0 0m 2m lCoLDj PLUG GAP 10- l l nm SPA8K rPm 130 t 5{ IDLE SPEED
NOB I]PCONDIIIONS INGINEAT TUNE ESTLJRN ATLACCESSOS TEI\'PERATUR€ NNEL]TML FANOFf IRANSMSSION NEEOEO. ADJUSTMTNTS NOOINER
EngineFamily:
,| F
--'-
Ll:.-.-,1 I rFrll \=#_H* JL
SPEED MUsT BE coMoufitooNArounwNEElDslvE Iooro nr tist rc orn svtncrE MU sT8EPfRrouRE DrEsrPRoCE iitriunor mo ovuvo uenn orr EnwsEaNoN.loaDE
X HNXT02,OUA2
Model Year X:1999 Manutao{urerSubcode HNX:HONDA
FamilyType V: LDV T: LDT Displacoment SaquenceCharactors
EvaporativeFamily:
OBDIICERT]ATD 201
Engineand EvaporativeFamilies
X HNXEOO8OAAB
Model Yoal X:1999 ManutacturarSubcode
HNX:HONDA Family Typo E: EVAP R: EVAP/ORVR Canbter Work Capacity S€quonceChartsters
GD 50 state TLEV + NLEV {Unrestricted} T H I S V E H I C L EC O N F O R M ST O U . S . E P A N L E V E O 1 9 9 9 M O D E LY E A R R E G U L A T I O NA SP P L I C A B L T T R U C K SA N O C A L I F O R N I A N E W T L E V L I G H TD U T Y T O 1 9 9 9 M O D E LY E A R A P P L I C A B L E REGULATIONS NEWLIGHTDUTYTRUCKS.
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1-17
Under-hoodEmissionsControlLabel EmissionGroupldentification (2000model)
EngineFamily:
Example: DWFEN aDDr,tc0RChA\CtN! rlt cooraN.ust MsoLU- oNor fioNpAq-af6MrNp-ol
\rvEn u u'r+-E coo|-d',r os-Fiiiiifi-' lfi ;!,."5:P!$t:1t9ffilf 1
DREpf cEcoolaNrAFTEBt3tlomistoR@MtLEs r@km),wH ctlEvrscoMEs T|E8EAFTER, BEprAcE EVEny ErdFstoB@ MttEs lmr,t, ffitcHEVER coMEs DCIIICXOF ADDCOOLA\I I'-FE
":3lliJ#fl
AISIRVI TAI{I\.NOI THEMDIAIOR
s,5TEM 8r!D TrE owrEp sMA\u.r. "lj,9lx6L;T&Iji(0or|]\G IMPORTANT VEHICLE INFORMATION
IHIS\/IHICLECONFONMS TOU.S.EPANLEV SEGULATIONS APPIJCq3LE TO2OOO IVOOEL YEAFNEWT!!V LIGHTDUTYTBUCKS AND CALIFONNIA SEGULATIONS APPLICASLE TO2OOO MOO€LYIAA NEWTLEVLIGHT.OUTY TFIJCKS.
vALvtLA5h tN:0,10r0.02 mm {C0t0l E l : 0 . 1 3 ! 0 0m2h S P A n ( P L U G G A1P. 0 - 1 1 m m O8OCENTFIED l D l ES P E E o 734150lpm ?.0t TUNIUPCoNDIToNS: ENGINE ATNORM TTMPERAIURE ATLACCESSORIES fu BNI TANOFFTiANSMISS ONINN€UTRAL NOOTHER AD.ILJSTMENIS NEEDEO.
.l-L
gt couolorooN,{raua.wxEtt |oAoEDr/MTESTNG oFTHsvtHrctE uLrst onuspreo syNoiRoN zEoDvNAMoMETER. olrEiwsE.ANoN.LoAoEo rEsrpBocEounr uust sr pair
m
1
50 State TLEV + NLEV (Unrestricied, T H I S V E H I C L EC O N F O R M ST O U . S . E P A N L E V R E G U L A T I O NA SP P L I C A B L T EO 2 O O O M O D E LY E A R N E W T L E V L I G H TD U T Y T R U C K SA N D C A L I F O R N I A REGULATIONA S P P L I C A B LT EO 2 O O O M O D E LY E A R NEWLIGHTDUTYTRUCKS.
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Y HNX TO2.OUA2
Model Y€ar Y: 2000 ManufaqturerSubcodo HNX:HONDA
FamilyType V: LDV T: LDT Displacement SaquencoCharasters
Evaporative Family:
CATALYST
1-18
Engineand EvaporativeFamilies
Modol Yea. Y: 2000 ManufacturerSubcode HNX:HONDA Family Type E: EVAP R: EVAP/ORVR CanisterWork Capacity SoquencaCharactet3
Y HNXEOOSOAAB
Lift and SupportPoints Lift and SafetyStands place ffi When heaw rear components such as suspension,Iuel tank, spare tire and tailgate are to b€ lemoved, vehicle, the !iiii-'rn"t r""igtrt in the trunk before hoisting. When substantial weight is removed flom the lear ot the center of gravity may change and can causethe vehicle to tip fotward on the hoist' NOTE:Sinceeachtire/wheelassemblyweighsapproximately30 lbs (14 kg),placingthe front wheelsin the cargoareacan assistwith weight distribution. 1. Placethe lift blocksas shown. and rockthe vehicleto be sure it is firmly supported. 2. Raisethe hoista few inches(centimeters), 3. Raisethe hoistto full height,and inspectthe lift pointsfor solidsupport' NOTE:Usethe samesuppon pointsto supportthe vehicleon safetystands'
FRONTSUPPORTPOINT
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LIFTBLOCKS
REARSUPPORTPOIMT
1-19
Lift and SupportPoints FloorJack 1 . Blockthe rear wheelswhen raisingthe front of the vehicle;blockthe front wheelswhen raisingthe rear of the vehicle. Placethe blocksbehindand aheadof the wheels, Raisethe vehicle high enough to insert the safety stanos.
Always usg safety standg when working on or under any vehicle that is supported by only a iack. Nevor attempt to use a bumper jack for tifting or supporting ths vehicl€.
Adjust and place the safety stands so the vehicle will be approximatelylevel,then lower the vehicle onto them.
Front:
Center the jack
bracketin the middle of the jack lift platform.
JACK LIFTPLATFORM
Rsar:
Centerthe iack bracketin the middle of the iack lift platform. www.emanualpro.com
1-20
JACK LIFT PLATFORM
Towing
l f t h e v e h i c l en e e d st o b e t o w e d , c a l l a p r o f e s s i o n a l towing service.Never tow the vehicle behind another vehjclewith just a rope or chain.lt is very dangerous. EmergencyTowing Thereare three popularmethodsof towing a vehicle. Flat-bedEquipment- The operator loads the vehicle on the the backof a truck.Thisis the bestway of transporting vehicle. Wheel Lift Equipment- The tow truck usestlvo pivoting armsthat go underthe tires lfront or rear)and liftsthem o f f t h e g r o u n d .T h e o t h e r t w o t i r e s r e m a i no n t h e g r o u n d . T h e v e h i c l e ' ss u s p e n s i o na n d b o d y c a n b e seriouslydamagedif this methodof towing is attempted. Sling-typeEquipment- The tow truck usesmetalcables with hookson the ends.Thesehooksgo aroundpartsof the frame or suspensionand the cableslift that end of the vehicleoff the ground.The vehicle'ssuspensionand body can be seriouslydamagedif thjs methodof towing i s a t t e m p t e d .T h i s m e t h e d o f t o w i n g t h e C R - Vi s unaccePtable. The onlv recommendedway of towing the CR-Vis on a f l a t - b e dt r u c k . T w o w h e e l d r i v e C R - V ' sm a y a l s o b e towed with all four wheelson the ground.
Front:
lOwlNG HOOKS.nd TIE DOWN BRACKETS
Rear:
Towing the four-wheel dlive CR-v with only two wheels on the ground will damage parts of the 4wD system. It this vehicle is damaged, it should be towed on a flat-bed truck ol trailel. It the 2 wheel drive CR-v is towed wiih all tour wheels on the ground, do the following: Manual Transmission . Release the parkingbrake. . Shiftthe transmissionin Neutral Automatic Transmission . Releasethe parkingbrake. . Start the engine. . Shiftto lD.lposition.then E position. . Turn off the engine. TIEDOWNBRACKET lmproper towing preparation will damage the transmission.Follow the above procedure exactly. lf you cannot shift the transmission or start the engine, the vehicle must be transported on a flat-bed truck. lf the vchicle is towed with four wheels on the ground, il is best to tow the vehicle no larther than 50 miles (80 km), and keep the speed below 35 mph {55 km/h). Trying to lift or tow the vehicle by ihe bumpers will cause serious damage. The bumpers ale not dosigned to support the vehicle's weight.
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1-21
ServicePrecautions PartsMarkingLocations To deter vehicletheft, cenain major componentsare markedwith the vehicleidentificationnumber {VlN).Originalparts will have self-adhesivelabelsor labelsattachedwith a break-offbolt. Replacementbody parts will have self-adhesive labels,and replacement engineand transmissionpartswill be stampedwith a codetor spareparts. NOTE: . Be carefulnottodamagethe partsmarkinglabelsduringbody repairs.Maskthe labelsbeforerepainting. ' Labellocationletterswithout parenthesisindicateoriginalparts.Letterswith parenthesisindicate replacement pans. A, (A): Engine B, (B): Transmission C, (C): FrontBumoer D, (D); Hood E, (E): Tailgate F, (F): RearBumper G, (G):FrontFenders(Lefrand Right) H, {H): FrontDoors(Leftand Right} l, (l): RearDoors(Leftand Right) J, (J): OuterSide Panel(Leftand Right)
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1-22
for Real-time4WD(Four-wheelDrivel Precautions U n d e r n o r m a l c o n d i t i o n s t, h e v e h i c l ei s i n 2 W D ( f r o n t - w h e edl r i v e ) .H o w e v e r ,t h e s y s t e m w i l l i n s t a n t l yt r a n s m i t appropriatedrivingforceto the rearwheels{dependingon the drivingforceof the front wheelsand the road conditons) The Real-time4WD-DualPump Systemdoes not have a manual switch to disablethe 4WD system.Wheneverservice work requiresspinningthe front or rearwheelswith the engine,alwayslift up and supportthe vehicleso all lour wheels are off the ground (seepage1-19).
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1-23
Specifications 2-2 Standardsand ServiceLimits............... .......... 2-12 DesignSpecifications .................. ..........2-14 BodySpecifications
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Standardsand ServiceLimits EngineElectrical- Section4 MEASUREMENT lgnitioncoil
R a t e dv o l t a g e V P r i m a r y w i n d i n g r e s i s t a n c e0 a t 6 8 ' F ( 2 0 ' C )
lgnition wire
Besistance at 68"F(20 C) ktl Firingorder
Sparkplug
STANDAFDINEWI
1 3
l g n i t i o nt i m i n g
Type Gap At idle
Alternator belt*r
D e f l e c t i o nw i t h 9 8 N { 1 0 k g f , 2 2 l b f )
Alternator
Belttension N {kgf,lbt) Measuredwith bek tensiongauge OutputA (at 13.5V, hot and 6,000alternatorrpm
4-2
See Section 4 1 . 0 - 1 . 1 ( 0 . 0 3 9- 0 . 0 4 3 )
BTDC
AII M/I
Brushlength Staningmotor
SERVICELIMIT
12 0.63 0.77 25 max.
A/f Mfi
Output kW Micadepth Commutatorrunout CommutatorO.D. Brushlength Brushspringtension N (kgf,lbf)
1 6 12 { R e d ) 8 . 5 1 1 . 5 1 0 . 3 30 . 4 5 ) w i t h u s e db e l t 5.5- 8.0 (0.22- 0.31)with new belt 340- 490{35- 50,77 110)with usedbelt 690 880(70 90, 150- 200iwith new belt 95 90 1 0 . 5( 0 . 4 1 ) 1.5(0.06i 1.1 1.0 0.5- 0.8{0.02- 0.03) 0,0.02 (0 0.0008) 2 7 . 9 2 8 . 0( 1 . 0 9 8 41 . 1 0 2 4 ) 14.0 14.5(0.55 0.57) - 3.97) 13.7- 17.7(1.40- 1.80,3.09
0.2 (0.008) 0.0s(0.002) 2 7 . 0( 1 . 0 6 ) 9.0 (0.35)
' 1 W h e n u s i n g a n e w b e l t , d d i u s t d e f l e c t i o nt o n e w v a l u e . R u n t h e e n g i n e f o r 5 m i n u t e s t h e n t u r n i t o f { . B e a d i u s t d e f l e c t i o nt o u s e d b e l t v a l u e .
CylinderHead/ValveTrain - Section6 MEASUREMENT Compression
250rpm and wide openthrottle , kPa(kgflcm' psi)
Cylinderhead
Warpage Height E n dp l a y
Camshaft
STANDARD{NEW}
Camshaft to hoider oil clearance
Totalrunout Cam lobe height
'97,'98models '99,'00models
(Cold)* Valveclearance ValvestemO.D. Stem'to-guide clearance width Steminstalledheight
lN EX lN EX lN EX lN EX lN EX tN EX lN EX
Valve spring
Freelength
lN EX
Valve guide
I,D,
IN EX tN EX
Installedheight *: Measuredbetweenthe camshaftand rockerarm,
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2-2
SERVICELIMIT
Nominal 1,230i'12.5, 11Al Minimum 930(9.s,135) Maximumvariation 20012.0,2al 1 3 1 . 9-5 1 3 2 . 0{55 . 1 9 -5 5 . 1 9 9 ) 0.05 0.1s(0.002 0.006) - 0.0027) 0.030- 0.069(0.0012 0 . 0 3{ 0 . 0 0 1 ) m a x . 33.204\1.30721 33.528{1.3200) 33.116 \1.3214) 33.528{'1.3200) 0.08- 0.12(0.003 0.005) 0.16 0.20(0.006- 0.008) 6.580- 6.590(0.2591 0.2594) 6.550- 6.560(0.2579 0.2s83) 0.02- 0.05{0.00t 0.002) 0.05- 0.08(0.002 0.003) 1.25- 1.55(0.049- 0.061) 1 . 2 5 1 . 5 5( 0 . 0 4 -9 0 . 0 6 1 ) 40.765- 41.235{1.6049 1.6234) - 1.70221 42.765- 43.235i'1.6837 42.36(1.668i 44.32t1.1451 - 0.261) 6.61 6.6310.260 6.61 6.63{0.260- 0.261i 1 3 . 7 -5 1 4 . 2 5 1 0 . 5 4 10 . 5 6 1 i 15.75- 16.25{0.620 0.640i
0.05{0.002) 0.5(0.02) 0.15(0.006) 0.04(0.002)
u* to.rutt 6.52lO.257l 0.08{0.003i 0.'1t(0.004) 2.0 (0.08) 2.0 (0.08) 41.485{1.6333} 43.485{1.7120i
6.6510.2621 6.65(0.262i
o
STANDARD(NEWI
MEASUREMENT Cylinder block
Piston
Pistonring
Warpageof deck surface Borediameter Boretaper bottomof skart SkirtO.D.*1trom in cylinder Clearance Groovewidth {Forringi
clearance Ring-to'groove Ringend gap
PistonPin
0.07(0.003)max. 84.00- 84.02(3.307 3.308)
Top Second oil ToP Second ToP Second oil
o.D.
Pin-to-piston clearance Pin-to-rodinterference Smallend borediameter Nominal Largeend borediameter Endplayinstalledon crankshaft Mainjournaldiameter Crankshaft N o .1 , 2 , 4 a n d5 i o u r n a l s No.3 journal Rodiournaldiameter Taper Out ol round Endplay Bunout Main bearing-to-iournal oil clearance Bearing N o .1 ,2 , 4 a n d 5 i o u r n a l s No.3 journal oil clearance Rodbearing-to-,ournal *1: '97,'98models15 mm (0.6in) '99,'00models20 mm (0.8ini rod Connecting
o
Unit of length: mm (in)
EngineBlock- Section7
83.98- 83.99(3.306- 3.307) - 0.00161 0.01- 0.04(0.0004 - 0.0492) 1.240- 1.250{0.0488 - 0.0484) 1.220 1.230{0.0480 2 . 8 0 5 2 . 8 2 51 0 . 1 1 0- 40 . 1 1 1 2 ) 0.055- 0.080(0.0022 0.0031) - 0.0024) 0.035 0.060(0.0014 0.20 0.30(0.008- 0.012) 0.40- 0.55(0.016 0.022) 0.20- 0.50(0.008- 0.020) - 0.8268i 20.996- 21.000(0.8266 - 0.0007) 0.010- 0.017(0.0004 - 0.0013) 0.015- 0.032(0.0006 -0.8260) 20.968-20.98110.8255 48.0(1.89) 0.15- 0.30{0.006- 0.012i
SERVICELIMIT 0.10(0.004) 84.07(3.310) 0.05(0.002) 83.97(3.306) 0.05{0.002) 1.26(0.0s0) 1.25(0.049) 2.44lo.112l 0.13(0.005) 0.13(0.005) 0.60(0.024) 0.70(0.028) 0.70(0.028)
oroto.oroi
- 2.1654) 54.976- 55.000(2.' l644 - 2.1651) 54.970 54.994(2.1642 - 1.71111 44.976- 45.000/.1.1707 0.005(0.0002)max. max. 0.005(0.0002) 0.10- 0.35(0.004- 0.0r 4) 0.03(0.001)max.
0.010(0.00041 0.010(0.0004) 0.45(0.0r8) 0.04(0.002)
- 0.042 0.024 10.00090.0017) - 0.048(0.0012 - 0.0019) 0.030 0.020- 0.038(0.0008 0.0015)
0.06(0.002) 0.06(0.002) 0.05(0.002)
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2-3
StandardsandServiceLimits EngineLubrication
Section8 MEASUREMENT
Engineoil
Capacity f (US qt, lmp qt)
Oilpump
Inner-to-outer rotorclearance Pumphousing-to-outer rotorclearance Pumphousing-torotoraxialclearance Pressure settingat engineoil temp. 176'F(80'C) kPa(kgt/cm,,psi) At ldle At 3,000rpm
R e l i e fv a l v e
Cooling
Radiatorcap Thermostat
Coolingfan
70 (0.7,10)min. 3 4 0{ 3 . 5 , 5 0m ) in.
Section 10 MEASUREMENT
Radiator
STANDARO{NEWI SERVICELIMIT 4.6(4.9,4.0)Iorengineoverhaul 3 . 8{ 4 . 0 , 3 . 3 ) f oori l c h a n g ei n , c l u d i nfgi l t e r 3.5 (3.7,3.1)for oil change,withoutIilter 0.04- 0.16(0.002- 0.006) 0.20(0.008) 0 . 1 0- 0 . 1 9 ( 0 . 0 0-4 0 . 0 0 7 ) 0.20(0.008) 0.02-0.07 (0.001- 0.003i 0.15(0.006)
Coolantcapacity , (USq1,lmp qt) llncludingengine,heater,I lineand reservoirl Lcooling Reservoir capacity: 0 . 6 1 ( 0 . 6 3U S q t , 0 . 5 3 l m pq t ) psi) Openingpressure kPa(kgf/cm?, Startsto open 'F 1"C) Fullyopen 'F ("C) Valvelift at tully open "ON" temperature "F Thermoswitch {'C) "OFF"temperature 'F ('C) Thermoswitch
Fueland Emissions
M/T
STANDAROINEW} 5.9{6.2,5.2}toroverhaul 3.9(4.1,3.4ifor coolantchange 6.0(6.3,5.3ifor overhaul 4.0(4.2,3.5)for coolantchange 9 3 - 1 2 3( 0 . 9 5- 1 . 2 5 1, 4 1 8 ) 169- 176(76- 80) 194(90) 8 . 0( 0 . 3 1 i m i n . 196- 203 (91- 95) Subtract5 - 14 (3 - 8) trom actual"ON" temperature
Section 11 MEASUREMENT
STANDARDINEW}
Pressureregulator Pressurewith regulatorvacuum hose disconnected '97,'98models , kPa(kgflcm' psi) '99, '00 rnodels Fueltank (US gal, Capacity / lmp gal) En g i n e ldle speedwith headlights and coolingfan off rpm '97 model '98 model '99,'00 models Fastidle rpm
ldle CO %
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2-4
'97 model '98 model '99,'00 models
260- 31012.7 3.2,38- 46) 270-32012.8 3.3,40- 471 5 8 ( 1 5 . 31, 2 . 8 ) MT
750r 50 7301 50 1,5001200 1,600r 200 0.1max.
AT {E or E position)
750t 50 750r 50 7 3 0 15 0 1 , 5 0 0 12 0 0 1 , 5 0 0 12 0 0 1,600r 200
Clutch
Unitof length:mm lin)
Section 12 MEASUREMENT
Clutchpedal
Pedalheight Stroke Freeplay Pedalplay Disengagement height Clutchsurfacerunout
to floor
to floor
Clutchdisc
Rivet head depth Thickness
plate Pressure
Warpage Diaphragmspringfingeralignment
SERVICELIMIT
STANDARDINEWI 183(7.20) 1 3 5 - 1 4 5 1 5 . 3- 15 . 7 1 ) 7 - 2210.24- 0.41J 1-9 (0.04-0.35) 7 2 1 2 . 8 3m) i n .
max. 0.05(0.002)
0.r5(0.006)
1 . 2- 1 . 7 1 0 . 0 50-. 0 7 ) 8 . 4 9 . 1( 0 . 3 3 , 0 . 3 6 ) 0 . 0 3( 0 . 0 0 1 ) m a x . 0.6 (0.02)max.
0.2(0.01) 6.0i0.24) 0.15(0.006) 0.8 (0.03)
ManualTransmission Section 13 Transmission fluid Mainshaft
STANDARDINEW}
MEASUREM€NT Capacity f (USqt, lmp qti
I
SERVICEI-IMIT
1 . 71 1 . 8 1 , . 4 ) f o ro i l c h a n g e 2 . 1 ( 2 . 2 ,1 . 8 ) { o r o v e r h a u l
0.'11- 0.18(0.004- 0.007) - 1.1020) 27.977- 27.990(1.1015 37.984- 38.000(1.4954-1.4961)
Endplay Diameterof ball bearingcontactarea(clutchside) Diameterof needlebearingcontactarea Diameterof ball bearingcontactarea (transmission housingside) Runout
Adjust 2 7 . 9 4( 1 . 1 0 0 ) 37.93(1.493)
- 1.1024) 27.987- 28.000(1.1018 0.02(0.0011max. 43.009- 43.02511.6933- 1.6939) 0.06- 0.21 (0.002- 0.008) - 1.377) 34.92 34.9711.375 31.42- 31.4'711.237, 1.2391
Mainshaftsth gear
LD. Endplay Thickness
Countershaft
Diameterol needlebearingcontactarea DiameteroI ball bearingand needlebearingcontact
27.94(1.100) 0.05{0.002) 43.08011.6961) 0.3 (0.01) 34.811.37) 31.311.23) - 43.02511.6933 1.6939) 43.08011.6961) 43.009 - 0.008) 0 . 3( 0 . 0 1 ) 0.06- 0.21(0.002 - 1.219) - 30.97 3 0 . 8( 1 . 2 1 ) 30.92 {1.217 36.000 36.015{1.4173 1.4179) 3s.95(1.415) (0.982) 24.94 24.987- 25.000(0.9837- 0.9843)
Diametero{ 1st gear contactarea Runout
-1.4567) 36.984- 37.00011.4561 0.02(0.001)max.
(1.4s4) 36.93 0.0s(0.002)
LD. Endplay Thickness t.D. Endplay Thickness
- 43.025 (1.69331.6939) 43.009 - 0.007i 0.06- 0.18(0.002 - 1.063) (1.061 26.9s,27.00 - 47.025 - 1.8514) (1.8507 47.009 ,0.006) 0.07- 0.1410.003 2As2- 2a.97l 1.139-1.1411
43.08(1.696) 0.2310.009)
3 1 . 0 6( 1 . 2 2 3 ) 37.94(1.494)
Mainshatt3rd and 4th gears
countershatt1st gear Countershaft2nd gear
LD. Endplay Thickness
3rd gear 4th gear
47.08{1.854) 0.18(0.007)
Spacercollar (Mainshaft 4th and 5th gears)
t.D. o.D.
Reverseidlergear
t.D. gearshaftclearance Gear-to-reverse
31.002- 31.O1211.2205, 1.2205) 37.989- 38.000(1.4956 1.4961) 56.45- 56.55Q.222- 2.2261 26.03,26.08(1.025- 1.027) 20.01 6 - 20.043(0.7880,0.7891) - 0.0033) 0.036- 0.084(0.0014
R i n g - t o - g e a rc l e a r a n c e ( r i n g p u s h e d a g a i n s l g e a r )
0.85- r.10(0.0330.043)
0.4 (0.02)
(ringpushedagainstgear) Clearance Outersynchroring to synchrocone Synchrocone-to-gear Outersynchroring-to-gear Fingerthickness 3rdl4thshiftlork Exceptabove Fork-to-synchrosleeveclearance
0.5 1.0(0.02 0.04) - 0.04) 0.5- 1.0(0.02 - 0.066) 0.95- 1.68(0.037 - 0.30) 7.4- 7.6(0.29 6.2- 6.4(0.24-0.2s) - 0.026) 0.35- 0.65(0.0't4
0.3(0.01) 0 . 3( 0 . 0 1 ) 0.6(0.02)
Synchroring Dualcone
Shift fork
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Length
A
l' les
I
26.01t1.0241
20.09(0.7909) 0.16010.0063)
't, torag)
Standardsand ServiceLimits ManualTransmission{cont'd}- Section 13 MEASUREMENT Raverseshift Iork
Pawl groove width Fork-to-reverseidler gear clearance Groovewidth*l
STANDAROINEW) '13.0 - 13.3(0.5' -j 0.52) 0.5- 1.1(0.02- 0.04) 7.O5- 7.25 i.0.21 4 - 0.2451 7.4-7.7 t0.29 0.301
at A atB
Fork-to-5th/reverse shift shaft clearance*'
PinionshaftcontactareaLD. Carrier-to-pinion shaftclearance Driveshaft,intermediateshatt contact area LD, Carrier-to-driveshaft clearance Carrierto-interrnediateshaft clearance
Backlash t.D. Piniongearto-pinion shaftclearance
- 0.006) 0.05-0.r5{0.002 - 18.066 - 0.7113) (0.7103 18.042 - 0.0037) 0.059- 0.09510.0023
oru ro.ooor
1.4 2.5i'14 26,12-231
Adjust
33.984- 34.000(1.337- 1.339) 21.977- 27.99011.1011.1021 - 1.576) 40.002- 40.01811.575 - 1.379) 35.002- 35.01811.378 26.975,26.988(1.062 1.063) 0.06- 0.16{0.002 0.006) 2.64 3.41 \21.3,35.4,23.1 30.t|
33.93(1.336) 27.92 (1.O99) 39.95(1.573) 34.95(1.376) 26.92(1.060) Adjust Adjust
Shift arm A
Shift fork diameter at contact area Shift arm A-to-shitt tork shaft clearance
Shiftarm C
Shiftarm C'to-shiftarm B clearance Diameterof shift arm B contactarea Selectarm'to-shift arm A clearance Diameterof shiftarm A contactarea
Selectlever
o.D. Transmission housingclearance
Shift lever
o.D. Shift arm cover clearance
Differential carner
Differential piniongear
Ditferential taperedroll€rbesringpreloac Staningtorque N.m (kgf.cm,lbl.ini Transter
11:fuleasuring points
Diameterof rollerbearingcontactarea Translershaft {driven gear side} Translorshaft {middle of shaft) Transterdrive gear Translordrivengearshaft{drivengearside) Transterdrivengearshaft(splinedside) Trans{ergear backlash TotalstartingtorqueN.m (kgicm,lbiin)
A
A 'Ay"
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2-6
18 (0.07)
0.05- 0.35(0.002- 0.014) 0.4,0.8 (0.02 0.03) 12.9- 13.0(0.508- 0.512) 0.2- 0.5 (0.008-0.020) 0.05 0.25(0.002 0.01) r2.9- 13.0(0.508- 0.512) 0.05- 0.25(0.002 0.01) 7 . 9- 8 . 0( 0 . 3 1-1 0 . 3 1 s ) - 0.6287) 15.94r- 15.968(0.6276 - 0.0034) 0.032- 0.086(0.0013 - 0.6287) r5.941- 15.968(0.6276 - 0.0050) 0.032- 0.127(0.0013 - 0.7098) 18.010 18.028(0.7091 - 0.0022) 0.027- 0.057(0.0011 28.005- 28.025(1.1026,1.1033) 0.025- 0.066(0.0010,0.0026) - 0.0036) 0.055- 0.09110.0022
at B'
Selectarm
SERVICELIMIT
*2: Measuringpoints
0.5{0.02) 1.0(0.04) 0.6{0.024i
0.1 (0.004) 0 . 1 2{ 0 . 0 0 5 i 0 . 1 5( 0 . 0 0 6 i
A'
-l-...
_{-P)
U n i t o f l e n g t h :m m ( i n )
Automatic Transmission Section 14 STANDAROINEW}
MEASUREMENT Transmission fluid
Capacity I {US qt, lmp q0
4WD 2WD
Hydraulic pressure kPa (kgflcm', psi)
Linepressureat 2,000rpm in LII or El position 1slclutchpressureat 2,000rpm in Da position 1st-holdclutchpressureat 2,000rpm In l position
2nd clutchpressureat 2,000rpm in El position 3rd clutchpressureat 2,000rpm in E position('97, '98 models),or positionwith O/DOFFindicator E light ON ('99,'00models) 4th clutchpressureat 2,000rpm in gl position('97, '98 models),or E positionwith O/DOFFindicator lightoFF ('99,'00models) Stallspeedrpm (Checkwith vehicleon levelground) 1st Clutchinitialclearance 2nd,3rd,4th 'lst-hold Clutchreturnspringfree length Clutchdiscthickness Clutchplatethickness Clutchend platethickness (lsti
1st,2nd,3rd,4th '1st-hold 2nd,3rd, 4th 1st,1st-hold Mark1 Mark2 Mark3 Mark4 Mark5 Mark6 Mark7 Mark8 MarkI Mark 10
Clutchend platethickness {2nd,4th)
Mark6 Mark7 Mark8 Mark9 M a r k1 0 M a r k1 1 lvlark12 M a r k1 3 M a r k1 4 M a r k1 5 M a r k1 6 Mark17
Clutchend platethickness {3rdi
Mark8 MarkI M a r k1 0 M a r k1 1 M a r k1 2 M a r k1 3 M a r k1 4 M a r k1 5 M a r k1 6 M a r k1 7 Mark1 M a r k2 Mark3
Clutchend platethickness ( 1 s th o l d )
No mark Mark6 Mark7
SERVICELIMIT
6.8(7.2,6.0)for overhaul 2.9(3.1,2.6)for fluid change 5.9{6.2,5.2)foroverhaul 2.7{2.9,2.4}forfluid change 830- 880(8.5- 9.0,120 130)
780(8.0,1' t0)
800- 850(8.2 4.7,120 1241
760t7.7,1101
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 11.22) 3 4 . 6( 1 . 3 6 ) 1.88- 2.00(0.074- 0.079) 'r.95- 2.05 {0.077 0.081) '1.55-1.65(0.061- 0.065) 2.05- 2.r0 (0.081- 0.083) 2.15 2.20(0.085- 0.0871 2.25 2.30(0.089,0.091) 2.35 2.40{0.093- 0.094} 2.45- 2.50{0.096-0.098} 2.55- 2.60(0.100- 0.102) 2.65- 2.70(0.104- 0.106) 2.75 2.80i0.108- 0.110) 2 . 8 5- 2 . 9 0 1 0 1. r2 0 . 1 1 4 ) 2 . 9 5- 3 . 0 0 1 0 . 1 1 6 0.118) - 0.102) 2.55 2.6010.100 2.65 2.70(0.104,0.106) 2.75- 2.80(0.108 0.110) 2 . 8 5- 2 . 9 0( 0 . 1 1-20 . r r 4 ) 2 . 9 5 3 . 0 0( 0 . 1 1 6 - 0 . 1 1 8 ) 3 . 0 5- 3 . 1 0( 0 . 1 2-0 0 . 1 2 2 ) 3 . 1 5 3 . 2 0( 0 . 1 2 4 - 0 . 1 2 6 ) 3.25- 3.30(0.128 0.130) 3.35- 3.40(0.r32- 0.134) 3.45- 3.50(0.136- 0.138) 3 . 5 5 3 . 6 0( 0 . 1 4 -0 0 . 1 4 2 ) 3.65- 3.70(0.144- 0.146) 2 . 7 5- 2 . 8 0( 0 . 1 0 8 0 . 1 1 0 ) 2 . 8 5 -2 . 9 0( 0 . 1 1-2 0 . 1 1 4 ) 2 . 9 5- 3 . 0 0( 0 . 1 1 -6 0 . 1 ' j 8 ) 3.05 3.10(0.120- 0.122) 3 . 1 5 - 3 . 2 0{ 0 . 1 2 4 0 . 1 2 6 ) 3.25- 3.30(0.128- 0.r30) 3.35- 3.40(0.132- 0.r34i 3.45- 3.50(0.136- 0.138) 3.55- 3.60{0.140- 0.142) 3.65- 3.70{0.144- 0.r46) 2.05 2.10(0.081- 0.0831 2.r5 2.20(0.085- 0.087) 2.25- 2.30{0.089- 0.091} - 0.094i 2.35- 2.4010.093 2.45- 2.50(0.096-0.098i 2.55- 2.60(0.r00- 0.102) 2.65- 2.70(0.r04- 0.106)
2,400,2,700
2 9 . 1( 1 . 1 5 ) 32.6(r.28) Untilgroovesworn out Discoloration Discoloration Discoloration
Discoloration Discoloration
Discoloration
Discoloration
Discoloration
(cont'd)
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2-7
Standardsand ServiceLimits Automatic Transmission (cont'd)- Section 14 MEASUBEMENT Transmission
Diameterof needlebearingcontactarea On mainshaftstatorshaftbearing On mainshaft2nd gear On mainshaft4th gearcollar On mainshaft1stgearcollar (torqueconverterhousingside) On countershatt On countershaft 3rd gear 4th gear On countershaft On countershaft reversegearcollar 1stgearcollar On countershaft housingsidei On sub-shaft{transmission On sub shaft4th gearcollar On reverseidlergearshaft Insidediameterof needlebearingcontactarea On mainshaft1stgear On mainshaft2nd gear On mainshaft4th gear 1stgear On countershaft 3rd gear On countershaft 4th gear On countershaft reversegear On countershaft On sub-shaft4th gear On reverseidlergear fleverseidlergearshaftholderl.D. Endplay Mainshaft1stgear Mainshaft2nd gear Mainshaft4th gear Countershaft 1stgear Countershaft 3rd gear Countershaft4th gear Sub-shaft4th gear Reverseidlergear Countershaftreversegear Selectorhub O.D. Mainshaft4th gearcollarlength Mainshaft4th gearcollarflangethickness Mainshaft1stgearcollarlength Countershaft distancecollarlength
Countershaft 3rd gearcollarlength reversegearcollarlength Countershaft Countershaft reversegearcollarflange thickness 1stgearcollarlength Countershaft lst gearcollarflangethickness Countershaft Sub-shaft4th gearcollarlength Sub shatt4th gearcollarflangethickness
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2-8
STANDARD{NEW}
SERVICELIMIT
- 0.9446) Wearor damage 23.980-23.993(0.9441 35.975 35.99'!(1.4163 1.4169) ( 1 . 2 5 8 91 . 2 5 9 5 i 3 1 . 9 7 53 1 . 9 9 1 - 1.2201l' 30.975- 30.99111.2195 - 1.4180) 36.004- 36.017(1.4175 35.980 35.996(1.4165 1.4172) ( 1 . 1 0 1-61 . 1 0 2 1 i 2 7 . 9 8-0 2 7 . 9 9 3 ( 1 . 2 5 8-9' j . 2 5 9 5 i 3 1 . 9 7 5 -3 1 . 9 9 1 ( 1 . 2 5 8-91 . 2 5 9 5 ) 3 1 . 9 7 53 - 1.991 - 1.0236) 25.991- 26.000(1.0233 - 23.006s(0.9053 0.9058) 22.9935 - 0.5512) Wearor damage 13.990- r4.000(0.5508 35.000 35.016(1.3780 1.3786) 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 - 1.4967) 38.000- 38.016(1.496'1 4 1 . 0 0 0 4 1 . 0 1 (61 . 6 1 4 21 . 6 1 4 8 ) 33.000- 33.016(1.2992 1.2998) - 1.4967) 38.000- 38.016(1.4961 - 1.2605) 32.000- 32.016(1.2598 - 0.7094) 18.007- 18.020(0.7089 14.416 14.434(0.5676 0.5683) 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) 0.10 0.18(0.004 0.007) 0.0s 0.17(0.002- 0.007) 0.05- 0.18(0.002- 0.007) 0 . 1 0 , 0 . 2 5 ( 0 . 0 0 40 . 0 1 0 ) 51.87- 51.90(2.042- 2.043) - |.9508) 49.50- 49.55(1.9488 4 . 4 3 5 4 . 5 2 5( 0 . 1 7 4 6 - 0 . 1 7 8 1 ) 2 7 . 0 0 , 2 7 . 0{51 . 0 6 3 ' 1 . 0 6 5 i 38.97- 39.00(1.534- 1.535) 39.02 39.05(1.536, 1.537) 39.07 39.10(1.538 1.539) 3 9 . 1 2- 3 9 . 1 5( 1 . 5 4-0 1 . 5 4 1 ) 39.17- 39.20(1.542* 1.543) - 1.545) 39.22- 39.2511.544 - 1.547i 39.27 39.301'1.546 38.87 38.90{1.530 1.531) 38.92 38.95(1.s32 1.533) 21.15- 21.20rc.4327- 0.4346) 14.5, 14.6(0.57't, 0.575) 2.4- 2.6(0.094- 0.102) 14.5- 14.6(0.571- 0.575) 2.4- 2.6(0.094- 0.102) 24.0 24.1(0.945 0.949) 2 . 9 5- 3 . 1 0( 0 . 1 1 -6 0 . 1 2 2 )
Wearor damage
Wearor damage
il*=lo'.d"'.n"n" Wearor damage
Wearor damage Wearor damage Wearor damage
Unit of length:mm (in)
Automatic Transmission - Section 14 (NEWI STANDARD
MEASUREMENT Transmission
Mainshaft 2nd gear thrust washer thickness
Thrustwasherthickness l'rainshaftballbearingleftside Mainshaft1stgear Countershaft 3rd gearsplinedwasher Sub-shaft4th gear thrust washer
o
ATFpump
One-wayclutchcontactareaLD. 1stgear Countershaft Parkinggear Mainshaftfeed pipeA, O.D.(at 15 mm trom end) Mainshaftfeed pipe B, O.D.(at 30 mm from end) teed pipeO.D.lat 15 mm from end) Countershaft Sub-shaft feed pipeO.D.(at 15 mm from end) Mainshattsealingring thickness (29mm and 35 mm) MainshaftbushingI.D. Mainshaftbushingl.D. Countershaft bushingl.D. Sub shattbushingLD. Mainshaftsealingring groovewidth ATFpump gearsideclearance ATFpump gear'tobody clearance Drive Driven ATFpump drivengearLD. ATFpump drivengearshaftO.D.
Regulator valve body
Sealing ring contact area l.D,
Stator shaft
Insideof diameteroI bearingcontactarea On torqueconvenerside On ATFpump side Reverseshittfork fingerthickness Parkingbrakepawl Parkinggear Shiftfork shattborel.D. Shiftfork shattvalvebore l.D.
Shiftingdeviceand parkingbrakecon' trol Servo body Differential carrier
Differential prnrongear
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- 0.157) 4.0010.156 4.05{0.158- 0.159) 4.1010.160 .161) 4 . 1 5( 0 . 1 6-2 0 . 1 6 3 ) 4.20(0.164 0.165) - 0.167) 4.2510.166 4.30(0.168- 0.169) 4 . 3 5( 0 . 1 7 0 - 0 . 1 7 1 ) 4.40(0.172 0.173) 4.45(0.174- 0.r75)
2.95 2.434.9s2 . 9 3-
3 . 0 5( 0 . 1 1 6 0 . 1 2 0 ) 2.50(0.096- 0.098) 5.00(0.195- 0.197) 3 . 0 0( 0 . 1 1 -5 0 . 1 1 8 1
Wearor damage
83.339 83.365(3.2810 3.2821) - 2.6259) 66.685- 66.698(2.6254 8.97- 8.98 (0.353- 0.354) 5.97 5.98{0.2350- 0.2354) - 0.3142) 7.97- 7.98(0.3138 - 0.3142) 7.97,7.98 (0.3138 1.87- 1.97(0.074-0.078)
Wearor damage Wearor damage 8.95(0.352) 5.95(0.234) 7.95(0.313) 7.95{0.313) 1.42$.O72)
- 0.2374) 6.018- 6.030(0.2369 - 0.3549) 9.000- 9.015(0.3543 8.000- 8.022(0.3150-0.3158) 8.000- 8.022(0.3150 0.3158) 2.025- 2.075(0.0797 0.0811) 0.03- 0.05(0.001- 0.002) 0.1050 0.1325(0.004,0.005) - 0.002) 0.0350- 0.062510.001 14.016*14.034(0.5518 0.5525) 13.980- 13.990{0.5504 0.5508) - 1.3782) 35.000 35.025{1.3780
5.045(0.2380) 9.03(0.356) 8.03(0.316) 8.03(0.316) 2.095(0.082)
2't.o00 27.021I '1.063, 1.064) 2 9 . 0 0-0 2 9 . 0 1 3 1 1 . r 4 117. 1 4 2 2 )
Wearor damage Wearor damage 5.40(0.213)
5.90- 6.00{0.232,0.236)
I I
I
Wearor damage
t
I Wearor damage
0.0710.003) Wearor damage Wearor damage 35.050(1.3799)
lWear
or otherdefect
Carrierto driveshaltclearance Carrier-to-intermediate shaftclearance
- 0.5516) 14.000- 14.010(0.55' l2 - 1.4582) 37.000- 37.039(1.4567 '18.010 - 18.02810.709 - 0.710) 0.023- 0.057{0.001- 0.002} - 1.0254) 26.025- 26.045(1.0246 28.025- 28.045(1.103- 1.104) 0.045- 0.08610.0020.003) 0.075- 0.11110.003-0.004)
Backlash t.D. Piniongear'to-pinion shaftclearance
- 0.006) 0.05- 0.15(0.002 - 18.066 - 0.7113) (0.7103 18.062 - 0.0037) otu to.oout 0.055- 0.09510.0022
PinionshaftcontactareaLD. Carrierto-pinion shaftclearance Driveshafvintermediate shaftcontactare l.D.
S e t r i n g - t o - b e a r i n go u t e r r a c e c l e a r a n c e
Transfer
SERVICELIMIT
3.974.024 . 0 74 . 1 24.17 4.224.274.32 4.374.42-
Diameterof rollerbearingcontactarea Transfershaft(transfergearside) Transfershaft(middleof shaft) Transferdrive gear Transferdrivengearshaft{drivengearside) Transferdrivengearshaft{splinedside) Transfergearbacklash TotalstartingtorqueN.m (kgf.cm,lbf.in)
2WD 4WD
37.045(1.4585) 0.r {0.004) 0.12(0.005) 0.15(0.006)
0 0.15(0- 0.006)
Adjust
38.485 38.500(1.515- 1.516) - 1.102) 27.917- 21.990 |.1.101 40.002- 40.018(1.575- 1.576) 35.002 35.018(1.378- 1.379) 26.975 26.988(1.062-' l.063) 0.060 0.160(0.002- 0.006) 2.64- 3.41 - 35.4,23.1 30.71 127.3
3 8 . 4 3( 1 . 5 1 3 ) 27.92(1.099) 39.95(1.573) 34.95(1.376) 26.92(1.060) Adiust Adiust
(cont'd)
2-9
Standardsand ServiceLimits Automatic Transmission(cont'dl - Section 14 STANDAROINEWI MEASUREMENT Wire Dia. Springs
Regulator valvespringA Regulator valvespringB Statorreactionspring Modulatorvalvespring Torqueconvenercheckvalvespring '97 model '98 - 00 models Coolerreliefvalvespring Reliefvalvespring 2nd orilicecontrolvalvespring 1-2shittvalvespring 2 3 shiftvalvespring 3-4shiftvalvespring 1staccumulator spring 4th accumulator springB 4th accumulator springA 2nd accumulator springA 3rd accumulator springA 2nd accumulator springB 3rd accumulator springI 3rd sub accumulator spring 2nd accumulator springC Lock-upshiftvalvespring Lock-uptiming valvespring Lock'upcontrolvalvespring 3'4 orificecontrolvalvespring Servocontrolvalvespring CPBvalvespring 4th exhaustvalvespring
o.D.
Fiee Length
1 . 81 0 . 0 7 1 ) 1 . 8i 0 . 0 7 1 ) 4 . 5( 0 . 1 7 7 ) 1.4{0.055)
14.7(0.579) 9.6 (0.378) 35.4{1.394} 9.4 (0.370)
87.8(3.457) 44.011.1321 30.31r.193) 35.0{1.378)
1.1(0.043) 1.2(0.047) 1.0(0.039) 1 . 1( 0 . 0 4 3 ) 0.7 (0.028) 0.9 (0.035) 0.9 (0.035) 0.9 (0.03s1 2.1 (0.083) 2.3 (0.091) 2.6 (0.102) 2.410.094) 2 . 8( 0 . 1 1 0 ) 1.6(0.063) 2.1(0.083) 2.7{0.r06) 2.2lO.OA7) 0.9 (0.035) 0.9 (0.035) 0.7 (0.028) 0.6 (0.024) 1.0(0.039) 0.9 (0.035) 0.9 (0.035)
8.4 (0.331) 8.4 (0.331) 8.4 (0.331) 8.6(0.3391 6.6(0.260i 7.6{0.299} 7.6{0.299) 7.6{0.299) 16.0(0.630) 10.2to.402l 17.0(0.669) 29.0\1.1421 'r7.510.689) 9.0 (0.354) 3 1 . 0( 1 . 2 2 0 ) 17.0(0.669) 14.510.571) 7.610.299i 8 . 1{ 0 . 3 1 9 } 6.6(0.260) 6.6(0.260i 8.1(0.319) 8.1{0.319) 6.t (0.240)
36.4{1.433) 32.4tl.216J 3 3 . 8{ r . 3 3 1 ) 3 7 . 1( 1 . 4 6 1 ) 34.8(1.370) 41.3(1.626) 57.0 (2.2441 57.0 12.2441 89.1(3.508) 5 1 . 6( 2 . 0 3 1 ) 88.4(3.480) 39.011.s35) 94.313.713) 20.710.8r5) 38.2(1.504) 39.0(1.535) 68.0(2.677) 73.7 12.902) 8 r . 4( 3 . 2 0 5 ) 38.0fl.496) 37.9(1.492) 5 2 . 1( 2 . 0 5 1 ) 41.2 t\ .A5Al 36.4(1.4331
Differential (4WDl * Section 15 MEASUREMENT
STANOABD{NEW' 1 . 2( 1 . 3 1, . 1 )a t o v e r h a u l 1 . 0( 1 . 10, . 9 1a t f l u i dc h a n g e
Capacity f (US qt, lmp ql)
Steering
Section 17 STANDARD INEWI
MEASUREMENT Steeringwheel
Gearbox
Pump
playat steeringwheelcircumference Rotational Staningloadat steeringwheelcircumference N {kgf,lbl) Enginerunning Angleof rack$uide-screw loosenedlrom lockedposition '97, '98 models '99, '00 models Pumppressurewith shut off valveclosed kPa (kgvcm,,psi)
Powersteering fluid
Recommended tluid Fluidcapacity I {USqt, lmp q0
Powersteering belt*
Deflection with 98 N {1Okgl,22lht) betweenpulleys Belttension N {kgt,lbf} Measuredwith belttensiongauge
0 - 1 0( 0- 0 . 3 9 ) 29 (3.0,6.6) 10"1 5" 20" MAX. 6,900- 7,800(70 80,995 1,138)
Hondapowersteeringfluid. For overhaul 0.85(0.90,0.75) For reservoir 0.4{0.42,0.35) 11.0 14.5(0.43 0.57)withusedbelt 7.5- 10.0(0.30 0.40)with new belt 390- 540(40- 55,88 - 121)with usedbelt 740-880 (75 90, 165 198)withnew belt
* When usinga new belt,adjustdeflectionor tensionto new values.Runthe enginefor 5 minutesthen turn it off. Readjustdellectionor tensionto usedbeltvalues.
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2-10
No. of Coils
r 1.0 1.9 10.9 12.O 12.7 8.2 13.4 22.0 26.4 26.8 13.8 14.2 2.9 15.9 2.6 6.3 32.0 47.A 20.8 '18.3 '19.5
Unit of length:mm {in)
Suspension Section18
STANDARD{NEW)
MEASUREMENT Wheelalignment
Front Rear Front Front near Inwardwheel Outwardwheel
Camber Caster Totaltoe Frontwheelturningangle
Wheelbearing
E n dp l a y
Rim runout
Front Rear Aluminumwheel
Axial Badial Axial Radial
Steelwheel
0"00'1 1' - 1"00'1 1' 2"10'! 1" 0J3(011/8) r N2 r i ( 1 / 1 6 11 / r 6 ) 37"00'! 2 31'30'(Referencei 0 - 0.05{0- 0.002} 0 - 0.05(0 0.002i STANOARD(NEW) 0 - 0.7 (0 0 , 0 . 7 ( 00 1.0(0 0 - 1.0{0 -
0.03) 0.03) 0.04) 0.04)
SERVICELIMIT 2.0(0.08) 'r.5 {0.06) 2.0{0.08) 1.s(0.06)
Brakes Sec'tion 19 STANDARDINEWI
MEASUREMENT Parkingbrake lever Footbrakepedal
To be lockedwhen Dulled:2 - 6 notches
Playin strokeat 196N (20kgf,44lbf) leverforce Pedalheight(withtloor mat removed) NT Freeplay
Mastercylinder Discbrake
tl o
Piston-to-pushrod clearance Front
Discthickness
Front Front Front
Discrunout Discparallelism Padthickness Rearbrakedrum
'97,'98 models '99,'00 models
LD. Liningthickness
Air Conditioning
155(6 1/8) 1 6 1( 6 5 / 1 6 ) 1 5 (1/16- 3/16) 0 - 0.4(0- 0.02) STANDARD{NEW' 22.9- 23.1(0.902- 0.909) 23.6 23.8(0.929- 0.937) 10.5- 11.5(0.4' t 0.45) 2r9.9 220.0(8.657- 8.661) 3 . 9- 4 . 5( 0 . 1 5- 0 . 1 8 )
Compressor (KEIHIN)
Compressor belt*
221.O8.7011 2.0(0.08)
Section 22 STANDARD {NEWI
MEASUREMENT Air conditioning
SERVICE LIMIT
21.0(0.83) 21.0(0.83) 0.10{0.004) 0.015(0.0006) 1.6(0.06)
Lubricanttype: KEIHINSP 10 (P/N38897- Pl3 - A01AHor 38899P l 3- A 0 1 ) Condenser Lubricantcapacity Evaporator mf {floz, lmp oz) Lineor hose Receiver
25 (5/6,0.9) 40 {1 1/3,1.4) 1 0{ 1 / 3 , 0 . 4 ) 10(.]/3,0.4)
Lubricant type:SP 10 Lubricantcapacity ml ({l 02,lmp oz} Stator coil resistanceat 68'F (20"C)O plate clearance Pulley-to-pressuae Deflection with 98 N (10kgl,22lbli betweenpulleys Belttension N (kgf,lbf) Measuredwith belttensiongauge
130'3'{41fi'3o,4.6;"} 3.05- 3.35 0.51 0.15(0.021 0.006) 7.5- 10.5{0.30- 0.41)with usedbelt 5.0- 7.0(0.20- 0.28)with new belt 3 9 0- 5 4 0( 4 0 5 5 , 8 8 - 1 2 0 ) w i t h u s e d b e l t 740- 880 {75 90, 170- 200)with new belt
* When usinga new belt,adjustdeflectionor tensionto new values.Runthe enginefor 5 minutesthen turn it off. Readjustdeflectionor tensionto usedbeltvalues.
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2-11
DesignSpecifications ITEM DIMENSIONS
WEIGHT(USA) WEIGHT(CANADA) ENGINE
METRIC
Overalllength Overallwidth Overallheight Wheelbase Track
Front Rear
Seatingcapacity Grossvehicleweightrating(GVWR) Grossvehicleweightrating(GVWR) Type Cylinderarrangement Bore and stroke Displacement Compression ratio
'97,'98mooers '99,'00 models
Lubricationsystem Oil pump displacement at 6,000enginerpm Waterpump displacement at 7,600enginerpm Fuelrequired Type Normaloutput Nominalvohage Hourrating Directionof rotation Weight CLUTCH
Clutchtype
MIT
Clutchlacingarea Transmission type
MIT
TRANSMISSION
MIT
PrimaryredLrction Type 1st 2nd 3rd 4th 5th Reverse
Finalreduction
Geartype Gearratao
Transfer Type
Transfer
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2-12
3.500 1.956 1.344 1.071 0.812 3.000*,.3.461*' Single helicalgear 4.562
0.434
Reardifferential
Finalreduction
4 , 1 6 5t b s | 1,900kg Water-cooled,4-strokeDOHC gasolineengine Inline4-cylinder, transverse 84.0x 89.0mm 3.31x 3.50in .1,973 cm3(m{) 1 2 0c u - i n 9.2 9.6 Beltdriven,DOHC 4 valvesper cylinder Forcedandwet sump,trochoidpump 501 (53 US qt,44 lmp qt)/minute 1401(148US qt, 123lmp qt)/minute gasoljnewith 86 UNLEADED PumpOctaneNumberor Higher gearreduction Planetary A/T:1.1kW M/T: 1.0kW 12V 30 seconds Clockwiseas viewedfrom gearend 3.7kg 8.2 lbs Singleplatedry, diaphragmspring Torqueconverter 203cm, 31.5sq-in Synchronizeds-speedtorward, 1 reverse Electronically controlled 4-speedautomatic,1 reverse Direct I : 1
Approx.
Manualtransmission
Gearratio
Gearratio
NOTES
1 7 7 . 6i n 68.9in 63.3in 1 0 3 . 2i n 60.4in 60.4in 5lf
Valvetrain
STARTER
ENGLISH
4 , 5 1 0m m 1,750mm 1,608mm 2,622mrn 1,533mm 1,534mm
1st 2nd 3rd 4th Reverse Geartype Gearratio
2.533 Automatictransmission 2.722 1.079 0.711 1.955 Singlehelicalgear 4.357
0.393
*1: '97- 99 models *2: '00 model
ITEM AIR CONDITIONING
Compressor
-Condenser Evaporator Blower
-
METRIC
Cooling capacity
Type/manutacturer No. of cylinder CaPacity Max.speed Lubricantcapacity Lubricanttype Type Type Type Motor input Speedcontrol Max.capacity
ENGLISH
NOTES
j 14,000BTU/h 3,520Kcal/h Scroll/KElHlN 85.7mf/rev
| 5.23cu'in/rev 10,000rpm algIloz 130mf 1 sP-10 fin Corrugated Corrugated fin Siroccofan
200w 112v 4-Speeo 15,500 cu fvh
440 m3/h
Temperature control Compressor clutch Befrigerant
Type Powerconsumption Type Ouantity
STEERING SYSTEM Type Overallratio Turns, lock to lock Steeringwheeldiameter SUSPENSION
Type
Front Bear
Shockabsorber WHEEL ALIGNMENT Camber
Tvpe
Front hear Front Front Rear Front
Pad surface area Lining surfacearea P a r k i n gb r a k e
Rear Front Rear Tvpe
Caster Totaltoe
BRAKESYSTEM
TIRE ELECTRICAL
Frontand Rear
Sizeand pressure Baftery Starter Alternator In under-dash fuse/relaybox In under hood fuse/relaybox In underhoodABSfuse/relay box Headlights Frontturn signallights Frontparkinglights Frontsidemarkerlights Rearsidemarkerlights Rearturn signallights Erake/parkinglights Back-uplights Ceilinglights{fronvrear) Licenseplatelight Spotlights Highmountbrakelight lgnitionkey light Ashtraylight Gaugelights Indicatorlights lllLrmination and pilotIights Heaterilluminationlights
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Dry,singleplate,poly-V-belt drive 40 W max./12V HFC-134a 1R-134a) 24j anoz zoo o' g Powerassisted,rackand pinion
At 68'F (20 C)
Independent doublewishbone,coil spring with stabilizer Independent doublewishbone,coil spring with stabilizer hydraulicnitrogengas tilled Telescopic,
0' - r"00' 2.10' 0mm 0in l n 1 / 1 6i n ln2mm Power-assisted selt-ad,usting ventilateddisc Power assistedself-adiustingdrum 49 cm, x 2 7.6sq-inx 2 7 3 c m ,x 2 1 1 . 3s q - i nx 2 reartwo wheelbrakes Mechanical actuating, Seetire inlormationlabel.
Drum brake
12V, 36 AH/sHR 1 2 V 1 . 0 ,1 . 1k W 12V 100A 7.5A, 10A, 15A, 20 A 7.5A, 10A, 15A, 20 A, 30 A, 40 A '100A 7 . 54 , 2 0 A . 4 0A 12V 60/55W 12V- 21 W ('97model), 1 2V - 2 7W ( ' 9 8 - 0 0m o d e l s ) 12V 5 W {'97model),3CP('98- 00 models) 12V-8W 1 2V , 3 C P 12V-21W 12V 2115W 1 2 V 2 1C P( 1 8W ) 12V-8W 12V-8W 12V-5W 1 2 V- 2 1 W 1 2V - 1 . 4W 1 2 V 1 . 4W 1 2V 1 . 4W , 3 W , 3 . 4W 1 2 V - 0 . 8 4 W ,1 . 1 2W , 1 . 4W , 3 W , L E D 12V - 0.84W, 1.4W, LED 1 2V , 1 . 4W
2-13
Body Specifications U n i t :m m ( i n )
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2-14
Maintenance ............3-2 Points Lubrication MaintenanceSchedulefor 1997Model (NormalConditions) ...".3-4 Schedulefor 1997Model Maintenance (SevereConditions) ."...3-6 Schedulefor 1998- 2000Models Maintenance (NormalConditionsl ..'."3-8 Schedulefor 1998- 2000Models Maintenance (severeConditionsl '....'3-10
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LubricationPoints
Forthe detailsof lubricationpointsand type of lubricantsto be applied.referto the illustratedindexand variouswork procedures(suchas Assembly/Reassembly, Replacement, Overhaul,Installation, etc.)containedin eachsection. NO.
LUBRICATION POINTS Engine
Transmission
Manual
2
3
Automatic Reardifferential Brakeline(includesABS line) ClutchLine
6
Shift lever pivots (Manual transmission)
1
Release fork (Manualtransmission)
10 l1 12 14 16 17 18 19 20 21 22 23 24
GenuineHondaMTF*1 GenuineHondaPremiumFormulaAutomaticTransmission Fluid (ATF)*' GenuineHondaCVTFluid
4 5
I
LUBRICANT gradeoil.The oil APIServiceGrade:UseSJ "EnergyConserving" containermay alsodisplaythe APICertitication sealshown "For below.Makesure it says GasolineEngines."SAEvjscosity: Seechartbelow.
Power steeringgearbox
GenuineHondaDOT3 BrakeFluid*3 Brakefluid DOT3 or DOT4*3 Greasewith molybdenumdisultide - PYs- 305 LJrea GreaseUM264P/N4'1211 SteeringgreaseP/N 08733- B070E
T h r o t t l e c a b l e e n d { D a s h b o a r dl o w e r p a n e l h o l e l
Siliconegrease
Throttlecableend (Throttlelink) Brakemastercylinderpushrod Pedallinkage Batteryterminals F u e l f i l ll i d Clutchmastercylinderpushrod Hoodhingesand hood lock Tailgatehinges Hatchglasshinges Doorhinges,upperand lower Dooropeningdetent Caliper Pistonseal,Dustseal, Caliperpin, Piston Shiltcableand selectcable{Manualtransmission) Brakeline ioints(Frontand rearwheelhouse) Powersteeringsystem Air conditioningcompressor
25
API SERVICELABEL
/,.*-G\
/.'z-\e\ t / 6 A
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w
SEAL API CERTIFICATION
ffi
Multi purposegrease
HondaWhiteLithiumGrease
Silicone grease
Rustpreventives GenuineHondaPowerSteeringFluid-. Compressor oil: SP 10 lP/N38897- P13- A0lAH or 38899-P13-A01) For Refrigerant: HFC134a(R,134a)
Recomm6ndedEngine Oil Engine oilviscosity for ambient temperature ranges
-20
0
20
-30 -20 .10
100'F
10 20 30 40'c 0 r1: Always use GenuineHonda Manual TransmissionFluid {MTF).Using motor oil can causestiffer shifting becauseit does not containthe orooeradditives. *2: Always use GenuineHondaPremiumFormulaAutomaticTransmissionFluid(ATF).Usinga non-HondaATF can affect shift qualitv. +3rAlways use GenuineHondaDOT3 BrakeFluid.Using a non-Hondabrakefluid can causecorrosionand decreasethe life of the system. *4: Always use GenuineHondaPowerSteeringFluid.Usingany other type of power steeringfluid or automatictransmission fluid can causedincreasedwear and poor steeringin cold weather.
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3-2
NOTE:Lubricateall hinges,latches,and locksoncea year. In corrosiveareas,more frequentlubricationis necessary. We recommendHondaWhite LithiumGrease.
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3-11
EngineElectrical 4-2 ChargingSystem ............. SpeciafTools 4-22 ComponentLocationIndex ............ Starting System 4-23 ....................,........... Diagram 4-3 Circuit ComponentLocationIndex ............ 4-24 Troubleshooting.............................. 4-4 CircuitDiagram................................ 4-30 ..........,....... AlternatorReplacement ........... 4-5 StarterTest 4-31 AlternatorOverhaul.......,,................ 4'5 StarterSolenoidTest ...................... .........4-32 RectifierTest 4-7 StarterReplacement....................... ........... 4-32 Inspection Alternator Brush 4-7 FieldWindingTest ........................... 4-33 4-8 RotorSlip RingTest ........................ StarterOverhaul............................,. 4-33 ............. Stator Test 4-9 BrushInspection...........................,., Alternator Belt Inspectionand OverrunningGlutchInspection ......4-9 ........4-34 Adiustment Armaturelnspectionand Test ........4-10 GruiseControl 4-12 BrushHolderTest ............................ 4-36 ComponentLocationIndex .,,,........ 4-12 StarterReassemb|y......................... 4-37 CircuitDiagram................................ 4-13 PerformanceTest ............................. 4-38 ControlUnit InputTest ................... lgnition System Main Switch Test/Replacement.....4-40 4-14 ComponentLocationIndex ............ Set/ResumeSwitch Test/ 4-15 CircuitDiagram................................ 4'40 Replacement.......................,........ lgnition Timing Inspectionand ....,,., 4-41 Actuator Test 4-16 Setting .......................................... 4-42 Actuator Replacement...............,.... 4-17 ........,........ DistributorReplacement 4-43 Actuator CableAdiustment ............ 4-18 DistributorOverhaul.............,,......... 4-43 ClutchSwitchTest .......................... lgnition Control Module (lCM)Input 4-44 .......... SwitchTest .................. T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , .4.-. 1 . .9. . . . . . . . .Brake .. ...,. 4-44 Test .............. Actuator Solenoid 4-2O fgnitionCoilTest .............................. 4-45 ActuatorDisassembly..................... lgnition Wire Inspectionand 4-20 Test ............................................... 4-21 SparkPlugInspection.....................
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+
ENGINE
SpecialTools
Ref. No.
Tool Number
o -o o
A973X- 041 XXXXX 0 7 J G G- 0 0 1 0 1 0 A 07PAZ- 0010100
Description
Oty
VacuumPump/Gauge, 0 30 in.Hg. BeltTensionGauge SCSServiceConnector * Includedin the BeltTensionGaugeSet,T/N 07JGG- 0010004
o
I
PageReference 4-41 434 4-16
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4-2
StartingSystem ComponentLocationIndex
CLUTCHINTERLOCK
swtTcH{M/T) BATTERY Test,section23
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Test,page 4-43 Switchpositionadiustment, section12
A/T GEARPOSITIONSWITCH{A/T} Test,section14 Reolacement. section14
Test,page4 5 SolenoidTest,page4-6 Replacement,page 4-7 Overhaul,page4 8 page4-12 Reassembly, PerformanceTest,Page4-13
4-3
StartingSystem CircuitDiagram IGNTION SWITCH
UNDER.HOOD FUSE/RELAY 8OX N0.41(100A)
N0.42(40A)
-+o
/ BAI
\i7
\
cf-.|
I
BLKMHT
II I
t
l
ELKMHT
BLK'WHT
t
IGNITIONCONTROL MOoULE ( CM)
l
STARTEF CUl RELAY
-.1
GRY
BLKRED
GRN
I
I PosrroN! I A/TGEAR (A/T) | i swrTcH ll \/ o N E o r N \ | !--
p . s i t o n/ : -_ --___J
f';--"-l I TNTERLooK I
fYl""yl, I
8LK
STARTEB (Fieldwndnglype)
Gl0l
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4-4
StartingSystem Starter Test NOTE: The air temperaturemust be between 59 and '100'F(15and 38"C)beforetesting. RecommendedProcedure: . . .
Usea stanersystemtester. Conneca t n d o p e r a t et h e e q u i p m e n ti n a c c o r d a n c e instructions. with the manufacturer's Testand troubleshootas described.
.
4. Unplug the connector(BLK /VHTwire and solenoid terminal)from the starter. 5 . Connecta jumper wire from the bafterypositive(+) terminalto the solenoidterminal. The startershouldcrankthe engine.
Alte.nate Procedure: .
Checkthe battery, battery positivecable, ground. stanercut relay,and the wire connectionsfor loosenessand corrosion.Testagain. lf the staner still does not crank the engine,go to step 4.
Usethe followingequipment: - Ammeter,0 - 400A - Voltmeter,0 - 20 V (accurate within 0.1volt) T a c h o m e t e r ,-01 , 2 0 0r p m Hookup a voltmeterand ammeteras shown.
NEGATIVETERMINAL
NOTE: After this test, or any subsequentrepair. reset the ECM/PCM to clearany codes(seesection11).
. .
l f t h e s t a r t e rs t i l l d o e s n o t c r a n k t h e e n g i n e , removeit, and diagnoseits internalproblem. lf the startercranksthe engine,go to step6.
Checkthe Starter Engagement: '1. Removethe No. 44 (15A) fuse from the under-hood fuse/relaybox. 2.
Turn the ignitionswitchto START(lll)with the shift lever in E or E position (A/T) or with the clutch pedaldepressed{M/T).The startershouldcrankthe e n gi n e . . .
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lf the starter does not crank the engine, go to step3. lf it cranksthe engineerraticallyor too slowly,go t o " C h e c kf o r W e a r a n d D a m a g e "o n t h e n e x t page.
6 . Checkthe ignitionswitch(seesection23). 7 . Checkthe startercut relay{seesection23}. 8. Checkthe IVT gear position switch (A/T)or the clutch interlockswitch (M[). Checkfor an open in the wire betweenthe ignition switchand starter.
(cont'd)
4-5
StartingSystem StarterTest (cont'dl
Starter Solenoid Test
Checklor Wear and D8mage T h e s t a r t e rs h o u l dc r a n kt h e e n g i n es m o o t h l ya n d s t e a d i l y l.f t h e s t a n e re n g a g e s b, u t c r a n k st h e e n g i n e erratically,removeit, and inspectthe starterdrive gear and torque converterring gear or flywheelring gear for oamage.
1.
Checkthe drive gear overrunningclutchfor binding or s l i p p i n gw h e n t h e a r m a t u r ei s r o t a t e dw i t h t h e d r i v e gear held.lf damaged,replacethe gears.
Checkthe hold-incoil for continuitybetweenthe S t e r m i n a la n d l h e a r m a t u r eh o u s i n g( g r o u n d )T. h e coil is OK if thereis continuity. STARTER
B TERMINAL MOUNTINGNUT 9 N.m 10.9kgtm, 7 tbtftl
CheckCrankingVoltage and Current Draw Crankingvoltageshouldbe no lessthan 8.7 volts on Ay'T models,and 8.0volts on M/T moders. Currentdraw should be no more than 230 ampereson A,/Tmodels,and 200ampereson M/T models. lf crankingvoltageis too low, or currentdraw too high, checkfor: . deador low battery. a o p e n c i r c u i t i n s t a r t e ra r m a t u r ec o m m u t a t o rs e g , ments. . starterarmaturedragging. . shortedarmaturewinding. . excessivedrag in engine. CheckCrankingrpm Enginespeedduringcrankingshouldbe above 100rpm. lf speedis too low, checkfor: a loosebafteryor starterterminals. . excesslvely worn stanerbrushes . opencircuitin commutatorsegments. . dirty or damagedhelicalsplinesor drivegear. a defectivedrive gearoverrunningclutch. CheckStarter Disengagement With the shift lever in @ or @ position(A,iT)or with the clutchpedaldepressed{M/T).turn the ignitionswitchto START(lll).and releaseto ON (ll). The starterdrive gear shoulddisengagefrom the torque c o n v e r t e rr i n g g e a r o r f l y w h e e l r i n g g e a r w h e n y o u releasethe key. lf the drive gear hangs up on the torque converterring gearor flywheelring gear,checkfor . solenoidplungerand switchmalfunction. . dirty drive gear assemblyor damaged overrunning clutch.
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4-6
TERMINAL
ARMATURE HOUSING (GROUND}
BLK/WHT WIRE 2.
Checkthe pull in coil for continuitybetweenthe S and M terminals.The coil is OK if thereis continuity.
StarterReplacement
Field Winding Test
1 . Disconnectthe battery negativecable.
t.
Disconnectthe startercablefrom the B terminalon the solenoid. then disconnectthe BLK/WHTwire from the S terminal. B TERMINAL MOUNNNG NUT I N.m (0.9kgl.m,
Checkfor continuitybetweenthe brushes.lf there's no continuity,replacethe armaturehousing, Checkfor continuity between each brush and the a r m a t u r eh o u s i n g{ g r o u n d ) l. f t h e r e i s c o n t i n u i t y . replacethe armaturehousing.
STARTER ERUSHES
7 rbtftl
RE
l0 x 1.25mm 4,1N.m {4.5 kgf.m, 33 tbt.ftl 5.
R e m o v et h e t w o b o l t s h o l d i n g t h e s t a r t e r .t h e n remove the starter.
4.
I n s t a l l i n t h e r e v e r s eo r d e r o f r e m o v a l . W h e n i n s t a l l i n gt h e s t a r t e r c a b l e , m a k e s u r e t h a t t h e crimpedside ofthe ring terminal is facing out, Crimpedside of ring terminal
TERMINAL
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Connectthe batterypositivecableand negativecable to the batterv.
4-7
Starting System Starter Overhaul STARTERSOLENOID
STARTER SOLENOID Test,page4 6 OVEBRUNNING CLUTCH
w ARUSH
-6^l MOLYBDENUM DISULFIDE
SPRINGCLIP Replace. BBUSHHOLDER Test,page4-12 GEARHOUSING ARMATURE HOUSING
ARMATURE Inspection and Test.page4-10 ENDCOVER
BAUSH InsPeclon,page4-9
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4-A
..'...:|@{ MOLYBDENUM DISULFIDE
BrushInspection
ClutchInspection Overrunning
Measurethe brush length.lf it is not within the service limit, replacethe brush(or brushholderassembly).
1.
2. Brush Lsngth Standard{Newl:14.0- I'1.5mm (0.55- 0.57inl ServicoLimit: 9.0 mm (0.35in)
Slidethe overrunningclutchalongthe shaft.Doesit move freely?lf not, replaceit. Rotatethe overrunningclutch both ways. Does it l o c k i n o n e d i r e c t i o na n d r o t a t e s m o o t h l y i n reverse?lf it does not lock in either directionor it locksin both directions,reDlaceit.
BRUSH
NOTE:To seat new brushesafterinstallingthem in their holders.slip a strip of #500or #600sandpaper,with the grit side up, over the commutatorand smoothly rotate the armature.The contactsurfaceof the brusheswill be sandedto the samecontouras the commutator.
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3.
lf the starterdrive gear is worn or damaged,replace t h e o v e r r u n n i n gc l u t c ha s s e m b l yt;h e g e a r i s n o t availableseparately. Checkthe conditionof the torqueconverterring gear or the flywheel ring gear if the starter drive gear teethare damaged.
4-9
StartingSystem ArmatureInspectionand Test 1.
I n s p e c t h e a r m a t u r ef o r w e a r o r d a m a g ed u e t o contact with the field winding. lf there is wear or damage.replacethe armature.
3.
C h e c kt h e c o m m u t a t o rd i a m e t e r .l f c o m m u t a t o r d i a m e t e r i s b e l o w t h e s e r v i c el i m i t , r e o l a c et h e armalure. Commutator Diameter Standard(Newl:27.9- 28.0mm (1.09- 1.10in) ServiceLimilr 27.0mm (1.06inl
lnspectfor damage.
Checkthe commutatorsurface.lf the surfaceis dirty or burnt,resurfacewith emery cloth or a lathewithor reconditionwith in the tollowing specifications, #500or #600sandDaoer.
4.
Measurethe commutatorrunout. l f t h e c o m m u t a t o r u n o u ti s w i t h i n t h e s e r v i c e limit, checkthe commutatorfor carbon dust or brasschipsbetweenthe segments. lf the commutator runout is not within the service limit, replacethe armature. CommutatorRunout Standard(Newl:0 - 0.02mm (0 - 0.0008in) ServiceLimit: 0.05mm {0,002inl
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4-10
I
5.
Checkthe mica depth. lf necessary,undercutthe mica with a hacksawbladeto achieveproperdepth. l f t h e s e r v i c el i m i t c a n n o tb e m a i n t a i n e dr,e D l a c e the armature.
7.
Placethe armature on an armaturetester. Hold a hacksawbladeon the armaturecore.
NOT GOOD
MICA DEPTI{
Commutator Mica Depth Standard (Nsw): 0.5 - 0.8 mm 10.02- 0.03 inl ServicoLimit: 0.2 mm (0.008in) 6.
Checkfor continuitybetweenthe segmentsof the commutator.lf an open circuit exists betweenany segments.replacethe armature.
lf the bladeis attractedto the core or vibrateswhile the core is turned.the armatureis shorted.Replace the armature. 8.
COMMUTATOR
With an ohmmeter,checkthat no continuityexists betweenthe commutator and armature coil core, and betweenthe commutatorand armatureshaft.lf there is continuity.replacethe armature,
cotLcoRE
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4-11
StartingSystem Starter Reassembly
Brush Holder Test 1.
Checkthat there is no continuitybetweenthe O and O brush holders.lf there is continuitv,replacethe brushholderassembly.
O BRUSHHOLDER
NOTE:Use the illustrationon page 4I as referencefor reassemDty. 1.
Pry backeachbrushspringwith a screwdriver, then positionthe brush about halfwayout ol its holder, and releasethe springto hold it there.
2.
Installthe armaturein the housing.Next, pry back each brush spring again,and push the brush down until it seatsagainstthe commutator,then release the springagainstthe end of the brush.
@ BRUSHHOLDER
Insertthe brushinto the brushholder,and bring the brush into contactwith the commutator,then attach a springscaleto the spring.Measurethe springtension at the momentthe spring liftsoff the brush.
-
E ^
F*4#-@ 6t ta
al
la
tl l l ft
SPRINGSCALE
3.
SpringTension:13.7- 17.7N (1.40- 1.80kgf, 3.09- 4.00lbf)
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4-12
I n s t a ltlh e e n dcovero n t h e b r u s hh o l d e r .
,r
?
Test Performance 1.
Disconnect the wire from terminalN4.
5.
Disconnectthe battery also from the body. lf the pinion retractsimmediately,it is working properly, To avoiddamagingthe starter,do not leavethe batterv connectedfor more than 10 seconds.
6.
Clampthe starterfirmly in a vise.
7.
Connectthe starter to the battery as describedin t h e d i a g r a m b e l o w ,a n d c o n f i r mt h a t t h e m o t o r starts and keepsrotating.
8,
lf the electric current and motor soeed meet the when the batteryvoltageis at 11.5V, specifications the starteris workingproperly.
M a k e a c o n n e c t i o na s d e s c r i b e db e l o w u s i n g a s heavy a wire as possible(preferablyequivalentto the wire usedfor the vehicle). 3.
Connectthe batteryas shown. lf the starterpinion pops out. it is working properly.To avoid damaging the starter,do not leavethe batteryconnectedfor more than 10 seconds.
@
o
12V BATTERY
ie
Disconnectthe batteryfrom the M terminal. lf the pinion does not retract,the hold-in coil is working p r o p e r l y .T o a v o i d d a m a g i n gt h e s t a r t e r ,d o n o t leavethe batteryconnectedfor more than 10 sec onds.
Specifications: Maker DENSO
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Electriccurrent 90 A or less
Motor speed 3,000rpm or more
4-13
lgnition System ComponentLocationIndex IGNITIONTIMINGCONTROLSYSTEM . ldle speedInspection/Adjustment, section11 . Inspectionand Sening.page4-16
SERVICECHECKCONNECTOR(2P) lwi.c colo6: BRNrnd BLKI
TESTTACHOMETER
SPARKPLUGS page4-21 Inspection, DISTRIBUTOR page4-17 Replacement, Overhaul,page4-18 lgnitionCoilTest,page4,20 lgnitionControlModule CM) InputTest,page4,19
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4-14
WIRES Inspection and Test,page4-20
CircuitDiagram IGNITON SWTCH
UNDEF.HOOD FUSE/RELAY 8OX
UNDEF,DASH FUSEiRELAYBOX
6\ l;;l i{Hr6-(-\9-'-'*'.--EII
Eci,.pcM
' i Vl
BLK/YEL
l^
IGNITION cotL
IGN]TION CONTROL MODULE (CM) / Hasbuil-if\ I no|se l
TDCTopdeadcenler poslion CKP Cran[shan C Y PC y l n d epro s r l o n TDC/CKP/CYP SENSOR
l-- r
f
IGNTION W]BES
i l ' i - - ,l l i f r BLU
I
IJltfi --cMFcr,r
SPARK PLUGS
I
BLU BLU
l l / ' i |
| I
I I
resr
TACHOMETER
tott"to*
LTTCHoMEIEB '97-'98 models
j
I I l: www.emanualpro.com
'99- 00models
Gt01
4-15
lgnition System lgnition Timing Inspectionand Setting 1.
Checkthe idle speed,and adjustit if necessary(see section11).
2.
Pull out the servicecheckconnector2P (BRN and BLKwires)from the connectorholderlocatedunder the dash on the front passengerside,then connect to the scs serviceconnector(P/N07PAz- 0010100) it.
6.
lf necessary,adjust the ignition timing as follows. Loosenthe distributormountingbolts,and turn the to distributorignition(Dl)housingcounterclockwise advancethe timing or clockwiseto retardthe timtn o , To RETARD
Startthe engine.Holdthe engineat 3,000rpm with no load (A/T in N or E, Mff in neutral)until the radiatorfan comeson, then let it idle. Connectthe timing light to the No. I ignitionwire, then point the light towardthe pointeron the timing belt cover. 5.
C h e c kt h e i g n i t i o nt i m i n g i n n o l o a d c o n d i t i o n s : headlights,blower fan, rear window defogger,and air conditionerare not operating. lgnitionTiming: M/T: 16"12" BTDC(RED)idling in neutral AlTt'16"!2" BTDC(RED)idling in E or E
MOUNTING BOLTS 24 N.m{2.4kgfm, 17lbtft} 7 . Tightenthe distributormountingbolts,and recheck t h e i g n i t i o nt i m i n g . 8.
CRANKSHAFT PULLEY
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4-16
Disconnectthe SCSserviceconnectorfrom the servicecheckconnector.
DistributorReplacement Removal: e o
5.
1.
Disconnect the connectorfrom the distributor.
2.
Disconnectthe ignition wires from the distributor i g n i t i o n( D l )c a p .
3.
R e m o v et h e m o u n t i n gb o l t s f r o m t h e d i s t r i b u t o r , then removethe distributorfrom the cylinderhead.
Connectthe ignitionwires to the distributorignition (Dl)cap as shown,
I'
CAMSHAFT END
No. 1 CYLINDER MARK
6.
Connectthe connectorto the distributor.
7.
Setthe ignitiontiming (seepreviouspage).
8.
After settingthe ignitiontiming, tightenthe mounting bolts.
BOLTS MOUNTING 8 x 1.25mm 17lbfftl 2,1N.m{2.,1kgrf.m,
lnstallation: 1.
Bringthe No. 1 pistonto compressionstrokeTDC.
2.
Coata new O-ringwith engineoil, then installit.
3.
Align the lug on the end of the distributorand its mating grooves in the camshaftend, then slip the distributorinto position. NOTE:The lug on the end of the distributorand its mating groovesin the camshaftend are both offset to eliminatethe possibilityof installingthe distributor 180oout of time.
4.
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Installthemountingbolts,and tightenthem lightly.
4-17
lgnition System Distributor Overhaul LEAK COVEN
CAPSEAL Checkfor damage.
DISTRIBUTOR IGNITIONIDII ROTOR IGNITION{DII CAP OISTRIBUTOR Checkfor cracks,wear, damage,and to!ling. Cleanor replace.
IGI{ITIONIDOHOUSING OISTBIBUTOR forcracks anddamage. Check
O.RING Replace.
b
IGNITIONCOIL Test, page 4 20
@_ IGNITIONCONTROL MODULE{ICMI InputTest,page4-19
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4-18.
lgnitionControlModule(lCMlInputTest NOTE: . See section11 when the malfunctionindicatorlamp ( M l L )c o m e so n . . Performan input test for the ignitioncontrol module ( l C M )a f t e r f i n i s h i n gt h e f u n d a m e n t atl e s t sf o r t h e ignitionsystemand the fuel and emissionssystems. . '97 -'98 models:The tachometershouldoperatenorm a l l yi f t h e I C Mi s O K .
Turn the ignition switch ON {ll). Checkfor voltage betweenthe BLK,^/EL wire and body ground.There shouldbe batteryvoltage. . .
lf there is no batteryvoltage,checkthe BLK/rEL wire betlveenthe ignitionswitchand the lclvl. lf there is bafteryvoltage, go to step 4.
L
Removethe distributorignition(Dl)cap,the distributor ignition(Dl)rotor,and the leakcover.
T u r n t h e i g n i t i o ns w i t c hO N ( l l ) .C h e c kf o r v o l t a g e betweenthe WHT/BLUwire and body ground.There shouldbe batteryvoltage.
2.
Disconnect the wiresfrom the lCM.
.
8LU WIRE '98 models} {'97 -
lf thereis no batteryvoltage,check: - ignitioncoil. - WHT/BLUwire betweenthe ICM and ignition corl. . lf thereis batteryvoltage,go to step5, '97 model: Disconnectthe ECM/PCM connectorA (32P)C . h e c kf o r c o n t i n u i t yo n t h e Y E L / G R Nw i r e betweenthe ICM and ECM/PCM.There should be continuity. '98 - 00 models: Disconnectthe ECM,PCM connector B (25P).Checkfor continuityon the YEUGRNwire betweenthe ICM and ECM/PCM.There should be continuity. Checkfor continuityon the YEUGRNwire to body ground.Thereshouldbe no continuity. 7 . Reconnect the ECM/PClvl connector. '97 -'98 models: Checkfor continuityon the BLU wire betweenthe test tachometerconnectorand the lCM.Thereshouldbe continuity. 9 . ' 9 7 - ' 9 8 m o d e l s :C h e c kf o r c o n t i n u i t yo n t h e B L U wire to body ground.Thereshouldbe no continuity. '10. lf all the
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testsare normal,replacethe lCM.
4-19
lgnition System lgnitionCoilTest
lgnition Wire Inspectionand Test
Using an ohmmeter, measureresistancebetweenthe terminals.lf the resistanceis not within sDecifications, replacethe ignitioncoil.
1 . C a r e f u l l yr e m o v et h e i g n i t i o nw i r e s b y p u l l i n go n the rubber boots.Do not bendthe wires;you might breakthem inside.
NOTE: Resistancewill vary with the coil temperature; specifications are at 68"F(20'C).
Checkthe conditionof the ignitionwire terminals.lf any terminalis corroded,cleanit, and if it is broken or distorted,replacethe ignitionwire.
Plimary Winding Resistance {Betweenthe A and B terminals): 0.6it- 0.77 0 SecondaryWinding Resistance {Betweenthe A and secondarywinding terminals): 12.8- 19.2kO
IGNITIONWIRE
e
Connectthe ohmmeter probesand measureresistance.
o
lgnition Wire Resistance: 25 kO max. at 68'F 120'Cl
TERMINALA {+l
IGNITIONWIRE 4.
4-20
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lf the resistance exceeds 25 kO, replace the ignition wire.
SparkPlugInspection Inspectthe electrodesand ceramicinsulatorfor:
2.
Checkthe electrodegaP. .
Adjustthe gap with a suitablegappingtool.
ElectrodeGap
I
. . . .
lmpropergap Oil-fouling Carbondeposits Crackedcenter electrodeinsulator
in) 1.1 3 ' mm (0.043Loo.
Standard
the plug if the centerelectrodeis rounded Replace as shownbelow: ROUNDEO ELECTRODE
,--, (--/ Burned or worn electrodesmay be causedby: . Advancedignitiontiming . Loosesparkplug . Plugheat rangetoo hot . Insufficientcooling Fouledplug may be causedby: . Retardedignitiontiming . O i l i n c o m b u s t i o cnh a m b e r . Incorrectsparkplug gap . Plug heatrangetoo cold . Excessive idling/lowspeedrunnang . C l o g g e da i r c l e a n eer l e m e n t . Deteriorated ignitionwires
| |
/ r--'--'--r
-.-l-:=---:1 : Spark Plugs '97 - '98 modsls:
Z F R 5 F - 1(1N G K ) (D KJ16CR-11 1E N S O ) '99 - 00 models; NGK) Z F R 6 F - 1( 1 (DENSO) KJ2OCR-111 Apply a small quantity of anti-seizecompound to the plug threads,and screwthe plugs into the cylinder head finger-tight.Then torque them to 18 N'm (1.8kgf.m.13lbf.ft).
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4-21
ChargingSystem ComponentLocationIndex CHARGINGSYSTEMLIGHT (ln the gaugeassembly) Test, page 4-24
BATTERY
Test,
ALTERNATOR Troubleshooting, page4-24 Replacement, page4-30 Overhaul,page4-31 RectifjerTest,page 4,32
4-22
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ALTERNATOR BELT Inspection and Adjustment,page4 34
CircuitDiagram BOX FUSUF€tAY UNDES.HOOD BATTERY
(1Cr0A) N0.41
,-a\
(40A) N0.42 WHT/8tK
l.
( tot,o, )
Y
IGNITON SWITCH
8LI(YEL
GRN/RED
ECM/PCM
V I
WHT/RED
ALTERNATOR
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4-23
GhargingSystem Troubleshooting lf the chargingsystemlight does not come on or does not go off, or the batteryis dead or low, test the followingitems in the order listedbelow: 1. Battery(seesection23) 2. Chargingsystemlight 3. Voltage 4. Alternatorcontrolsystem(U.S.A.model) 5. Alternator/regulator ChargingSystem Light Test ChsrgingSystomLight Check: Turn the ignition switch ON {ll), and makesure the chargingsys tem lightcomeson.
Doesthe chargingsystem lightcome on?
Check for a blown No. 15 17.5Al fuse and a blown charging system light bulb. lf the tusa .nd bulb are OK, repair th€ open in th€ WHT/BLUwire.
I
I
Charging System Light Check {com'd}: Startthe engine.
I
Doesthe chargingsystem light go offf
Perform the Alte.nator/Regulator Test lsee page +281.
ALTERNATOR 4P CONNECTOR {U.S,A.modell
2
Voltage Check: Measurethe voltageat the No. I lNo.2iterminalof the 4P [3Plconnectorwith the ignitionswitch ON
(BLK/YEL)
3
Wiresadeof femaleterminals
{ ).
ls there battery voltage?
Ropair the open in the BLK/YEL wiae betwoen the altemator and under-da3hluso/relay box.
ALTERNATOR 3P CONNECTOR lCanedamodel'
Iemale terminals
(To next page)
[ ] : C a n a d am o d e l
4-24
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(Frompreviouspage)
in
Ch6ckthe L circuil: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 4P [3P] connectorfrom the alternator. 3. Turnthe ignitionswitchON (ll).
Doesthe charging system lightcomeon?
Repairthe short to ground in the WHT/BLUwire.
[ ]: Canadamodel
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(cont'd)
4-25
ChargingSystem Troubleshooting(cont'dl '97 modol:
Alternator Control System Test {U.S.A.model)
NOTE:Beforetesting,checkproperoperationofthe ELDby checkingfor a DTC(seesection.11). BATTERY Chockfor a short in the circuit IALTCline): 1. Disconnectthe 4P connector from the alternator. 2. Startthe engine,and turn the headlights thigh beamiON. 3. Me8surevoltage between the 4 P c o n n e c t o tre r m i n a lN o . 2 and the positiveterminal of the battery.
CAUTION: Be sure to use a voltmeter with ils positive terminal connectedto battery positive and hs negative terminalto the 4P connectorterminal No. 2.
{WHT/GRNI ALTEFNATOR 4P CONNECTOR
Wiresideof femaleterminals
ECM/PCMCONNECTOR A I32PI
,/1./
lstherelVorless?
1 t4
./ l./
8
26 27 Check for an open in the wire (ALTClinel: 1 . T u r n t h e h e a d l i g hat n d i g n i tion switchOFF. 2. Disconnectthe 32P connector from the ECN4/PCM. 3. Checktor continuitybetween the EcM/PcM 32P connector terminalNo.30 and alternator 4P connectorterminalNo.2-
ls therecontinuity?
R€prir short in the wire between the altornator and the ECM/PCM.
4-26
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2A 29 30
Wire side of femaleterminals
I
femaleterminals
21 32
] ALTC I tWHT/cRNl
tl
WHT/GRN)
1
ALTERNATOR irP CONNECTOR
Repairopen in the wi.e betwoen the atternatorand ECM/PCM.
ls therecontinuity?
Check for a shorl in the wiro IALTCline): 1 . T u r n t h e h e a d l i g hat n d i g n ; , I|on swrtcnUFF 2. Disconnect the 32Pconnector from the EcM/PcM. 3. Checktor continuitybetween the ECM/PCN4 32P connector t e r m i n a lN o . 3 0 a n d b o d y ground.
10
1 6 1 7 1 8 t9 20 21
ECM/PCMCONNECTOR A {32P} 4
,/ ,/
,/1,/
14
6 8 1 6 l 7 t 8 '19 20 21
10
27
:t2
2A 2S 30
Wire side of femaleterminals Subslitute a known-good ECM/ PCM,and recheck. It prescribedvoha96 b now available, replacethe original ECM/ PCM.
23 21
I ALTC {WHT/GRNI f)
'98 -'9O modols: Alternator Contlol SYstemTe3t (U.S.A'model) NOTE:Beforetesting,checkproperoperationof the ELDby checkingfor a DTC(seesection11) EATTERY
R
'oR
Chock tor . short in tha circuit IALTClino): 1. Disconnoctthe 4P connector Irom the alternator. 2. Startthe engine,and turn the headlights(highbeam)ON. 3. Measurevoltage between the 4P connectorterminal No. 2 and the positive terminal oI the battsry.
CAUTION: Be surc to uso a voltmetor with its oo3itive torminel connccted to battery po3hivo tnd its negativo teami' nal to the 4P connectortorminal No 2.
c IWHT/GRN) Wire sideol femaleterminals
ALTERNATOR 4P CONNECTOR
l s t h e r e1 V o r l e s s ?
Check for an opon in the wire IALTCline): 1 . T u r n t h e h e a d l i g hat n d i g n i tion switchOFF. 2. Disconnect the 31Pconnector from the ECM/PCM. 3. Checktor continuitybetween th6 ECM/PCM31P connector terminalNo. 2 and alternator 4PconnectorterminalNo. 2.
ECM,/PCM CONNECTOR c {31P) Wire sideol temaleterminals
Ropairopen in the wiro between the ahornrtor and ECM/PCM.
C {31P} ECM/PCMCONNECTOR ALTC IWHT/GBNI Chack lor a rhort in tho wire {ALTClincl: ' ! . T u r n t h e h e a d l i g hat n d i g n i ' tion switchOFF. the 31Pconnector 2. Disconnect Irom the ECM/PCM. 3. Ch6ckfor continuitybetween the ECM/PCM31P connector terminalNo. 2 and body ground.
lu
Substituto . known-good ECM/ PCM,.nd rochock. lf prdcdb€d voltage b now av.ilable, repl.ce the original ECM/
rcM. Rcpair rhort in thc wire b.twcon th. ahGrn.tol.nd the EcM/PcM.
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(cont'd)
4-27
GhargingSystem
I
(cont'd) Troubleshooting Alternator/RegulatorTest NOTE:Makesurethe batteryis sufficientlycharged(seesection23). Alternator/RegulatorTest: 1 . C o n n e c ta S u n V A T - 4 0( o r e q u r v a l e ntte s t e r ) ,a n d t u r n the selectorswitchto position 1{sraning). 2. Shift to neutral(A/T in E or , n d s t a r tt h e N) positiona e n g a n eH. o l d t h e e n g i n ea t 3,000rpm with no load until t h e r a d i a t o rf a n c o m e s o n , then let it idle. 3 . R a i s et h e e n g i n es p e e dt o 2,000rpm, and hold it there.
l s t h e v o l t a g e o v e r 1 5 . 1V ?
(BED)
FIELD SELECTOR TEST
NEGATIVE TESTER CABI.E{BLKI
swtTcH Ahernator/Regulator Test (cont'd)l I Releasethe accelerator pedal, and let the engineidle. 2 Makesure all accessories are turned off. Turn the selector switchto posjtion2 (charging). 3 Removethe inductivepickup, and zerothe ammeter. { P l a c et h e i n d u c t i v ep i c k - u p over the batterygroundcable so that the arrow pointsto the bafterynegativeterminal. 5 . R a i s et h e e n g i n es p e e dt o 2 000rpm, and hold ir there.
t
VOLTMEIER POSmVE
INDUCTIVE PICK.UP {GRN)
TESTER CABLEIREDI
I
WHTWIRE
(
T
l s t h e v o l t a g e l e s st h a n 1 3 . 5V ?
Altarnator/Regulator Test (cont'd: Apply a load with a VAT-40 until the battery voltage drops to b e t w e e n 1 2 - 1 3 . 5V .
To next page
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4-28
I
Frompreviouspage
ls the amperage65 A or more?
Aharnator/Regulator Tesl (cont'd): W i t h t h e e n g i n e s p e e ds t i l l a t 2.000rom,fulllield the alternator.
The charging sy3tem b OK. CAUTION:The voh.ge will tise quickly whon th. ahornato. is tull-li.lded Do not allow the voltage to exceod18 V; it mry damagothe .loctrictl 3yaiGm. into the tull field NOTE: Attach a probe to a VAT-40Iull tield test lead,and inseft the probe "A lGround)"posiaccessholeat the backof the altemator'Switchthe fieldselectorto the and checkthe amperagereadrng. tion momentarily. REGULATOR (Locatedinside the ond coverl FULLFIELD ACCESSHOLE
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4-29
ChargingSystem AlternatorReplacement
l I
v
' t . Disconnect the batterynegativeterminalfirst, then
}
^
the positiveterminal.
Removethe adjustingbolt and mounting nut, then removethe alternatorbelt.
N ir
Disconnectthe 4P (or 3P) connectorand WHT wire from the alternator.
Pullout the throughbolt,then removethe alternator.
T n
THROUGH BOLT
WHT WIRE
MOUNTINGNUT 10x 1.25mm 44 N.m 14.5kgf.m. 33 tbtftt
LOCKNUT 8 x 1.25 mm 24 N.m (2.4kgt m, 17 lbl.ft,
Installthe alternatorin reverseorderof removal. o.
4-30
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'll
l
Adjust the alternatorbelt tension after installation (seepage4-34).
t
AlternatorOverhaul
PULLEY
NOTE:Do not removethe pulley unlessthe front bearing needsreplacement. To loosenthe pulley locknut,use the tools as shown. lf necessary, usean impactwrench.
,T PULLEYLOCKNUT 111N.m (11.3kgf.m,81.7lbf.ft)
BEARINGINSULATOR
FRONTBEARING
PULLEY
CAUTION: Do not get grease or oil on the slip rings.
"'^.^t% BRUSHHOLDER INSULATOB
THROUGHBOLT
RECTIFIER ASSY Test.page4 32
PULLEYLOCKNUT 111N.m {11.3kgf.m,81.7lbf,ft)
REARHOUSING
COVER www.emanualpro.com
4-31
ChargingSystem RectifierTest
AlternatorBrushInspection
NOTE:The diodesare designedto allow currentto pass in one directionwhile blockingit in the oppositedirec t i o n . S i n c et h e a l t e r n a t o r e c t i f i e ri s m a d e u p o f e i g h t diodes(four pairs),each diode must be testedfor conti nuity in both directionswith an ohmmeterthat hasdiode checkingcapability;a total of 16 checks.
1.
Removethe end cover,thentakeout the brushholder by removing its two screws.
2.
M e a s u r et h e l e n g t ho f t h e b r u s h e sw i t h a v e r n i e r calrper.
'l.
Checkfor continuityin eachdirectionbetween - t h e B a n dPt e r m i n a l s . - E ( g r o u n da) n d P t e r m i n a l s . A l l d i o d e ss h o u l dh a v ec o n t i n u i t iyn o n l y o n e d i r e c tion.
Alternator Brush Length: Standard(Newl:10.5mm 10.41inl ServiceLimit: 1.5mm {0.06in)
VERNIERCALIPER
2.
lf any of the diodesfails,replacethe rectifierassembly. (Diodesare not availableseparatelv.)
4-32
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lf the brushesare lessthan the servicelimit, replace the alternatorbrushassemblv.
I
Stator Test
RotorSlip RingTest 1.
betweenthe slip rings. Checkthe resistance Thereshouldbe 1.8- 3.0ohms. go to step2 . lf resistance meetsthe specification, . 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.
1.
Checkthat there is continuitybetweeneach pair of leads. LEADS
ROTORSHAFT
corLcoRE SLIPRINGS
Checkthat there is no continuitybetweeneach lead and the coil core. It the coil fails either continuitycheck,replacethe alternator.
Checkthat there is no continuity betweenthe slip ringsand the rotoror rotor shaft. lf the rotor fails eithercontinuitycheck,replacethe alternator.
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4-33
ChargingSystem AlternatorBelt Inspectionand Adjustment 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 afterrunningenginefor five minutes. Deflection methodi A p p l ya f o r c eo f 9 8 N ( 1 0 k g t , 2 2 l b l l , a n d m e a s u r et h e deflectionbetweenthe alternatorand crankshaftpulley. Detlection: UsedBelt:8.5- 11.5mm (0.33- 0.45inl New Beft: 5.5 - 8.0 mm 10.22- 0.31 inl NOTErlf the belt is worn or damaged,replaceit.
Measurehere
4-34
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Belt tension gauge m6thod: Attachthe belttensiongaugeto the beltand measurethe tension.Followthe gaugemanufacturer's instructions. Tension: Used Belt:340 - /€0 N (35 - 50 kgf, 77 - 1r0 tbf) New Belt: 690 - 880 N (70 - 90 kgf, 150- 200 tbt) NOTE:lfthe belt is worn or damaged,replaceit.
lf adjustment is necessary: 1.
Loosenthe mountingnut and the locknut.
2.
Move the alternatorto obtain the proper belt tension,then retightenthe nuts.
LOCKNUT 8 x 1 . 2 5m m 24 N.m (2.4kgtm,'17lbf ft)
NUT MOUNTING 10x 1.25mm 14N.m{4.5kgl.m.33lbf.ft)
Recheckthe deflectionor tensionof the belt. NOTE: For the power steeringpump belt and A,/C referto section17 and compressorbelt adjustments, section22.
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4-35
GruiseControl
I
ComponentLocationIndex CRUISEINDICATORLIGHT (Builtinto gaugeassembly) BulbLocations. section23
BA
(
SET/RESUMESWITCH Test,page 4 40 Beplacement, page4-40
CRUISECONTROLUNIT Input Test,page 4 38
swtTcH Test, page 4-44
CLUTCHINTERLOCK
swrTcH{M/T)
PedalHeightAdjustment, section19.
Test,page 4-43 Switchposkionadjustment, section12 ACTUATOfiASSEMBLY and VACUUMTANK Test,page4 41 SolenoidTest,page4 44
A/T GEABPOSITION swlTcH (A/Tl '14 Test,section www.emanualpro.com
+36
ACTUATORCAELE Adjustment,page4-43
I
GircuitDiagram IGNITON SWITCH
FUSEi RELAY BOX UNDER.HOOD
FUSARELAYBOX UNDER.OASH
COMEINATON L GH'I SWITCH
No41(100A) No42(404)
f7 I
RED/BLK
INDICATOR LIGHT (0.84W)
lP
IOSET
J
5
BRAK€ LGHTS
2 1
6 1
7 1 2 C R U I SCEO N T R OUTN L T 1 1
8
1
3 10
4
CRUISE PNK CONTROL ACTUATOR
BLK
It
4F\ /lr,mcern
t'
BLK
*: '98 00 modelswith AutomaticTransmission.
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n: G202
BLK
L_ll I I
Y{"^i?tr'.flffi'JF )l t
I
rereasedl /l loN: Pedar
8LK
BLK
G101
G401
T
I 4-37
CruiseControl ControlUnit Input Test and proceduresin the SRS SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations.precautions, section(241beforeperformingrepairsor seryice. '1. Removethe driver'sdashboardlowercoverand kneebolster{seesection20). 'l4P connectorfrom the controlunit.
2.
Disconnect the
3.
Inspectthe connectorand socketterminalsto be surethey are all makinggood contact and recheckthe system. lf the terminalsare bent,loose,or corroded,repairthem as necessary, lf the terminalslook OK, makethe followinginput testsat the connector. - lf any test indicatesa problem.find and correctthe cause,then recheckthe system. - lf all the input testsproveOK,the controlunit must be faulty;replaceit.
*: '98- 00 modelswith AutomaticTransmission.
4-38
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Wire sideol femaleterminals
Disconnestthe lilP connectorfrom the control unit. Csvity
Wire BRNAr'VHT
1
BRN
11
BRN/BLK
2
GRY
BLK
5
GRNMHT
LT GRN/ RED 7
LT GRN/ BLK
Under all conditions
Checkfor resistanceto groundl There should be 40 - 60 0.
Under all conditions
Checkfor resistanceto ground: There should be 70 - 110 O.
lgnitionswitch ON (ll), main switch ON and brakepedaldepressed, then released
Checkfor voltageto ground: There should be 0 V with the pedal depressedand batteryvoltagewith the pedal released.
. Faultybrakeswitch . An openin the wire
Under all conditions
Checkfor continuityto ground: There should be continuity.
. Poor ground (G401) . An open in the wire
Brakepedaldepressed, Checkfor voltageto ground: thenreleased There should be batteryvoltagewith the pedal depressed,and 0 V with the pedal released.
Setbuttonpushed
l4
PNK
B l o w nN o . 5 21 ' 1 A 5 lfuse inthe under-hoodfuse/relaybox Faultybrakeswitch An open in the wire
Checkfor voltageto ground: There should be batteryvoltage.
BlownNo.52 {'15A} fusein the under-hood fuse/relay box Faultyhornrelay Faultysevresume switch Faultycablereel An openin the wire
Attach to ground: Cruiseindicatorlight in the gauge assemblyshould come on.
E l o w nb u l b Blown No. 25 (7.5A) tuse in the under-dashfuse/relaybox Faultydimming circuit in the gauge assembly An open in the wire
Check for voltage between the ELUA/VHT @ and BLK O terminalsl There should be 0 - 5 V or more -0 - 5 V or more repeatedly.
Faultyvehiclespeed sensor(VSS) An open in the wire
lgnitionswitch ON {ll} and main switch ON
Checkfor voltageto ground: There should be batteryvoltage.
Blown No. 14 (7.5A) fuse in the under-dashfuse/relaybox Faultymain switch An open in the wire
A'/T:Shift leverin E, E otE lvl/T:Clutchpedal releaseo
Checkfor continuityto ground: There should be continuity. NOTE: There should be no continuity when the shift lever is in other positionsor when the clutch pedal is oepresseo.
Faulty A/f gear position switch 1A,/Tl Faultyor misadjustedclutch switch
Resumebuttonpushed
RED/BLU
LT GRN
Faultyactuatorsolenoid Poorground(G202) An openin the wire
Checkfor resistanceto groundl There should be 80 - 120 o.
lgnitjonswitch ON {ll} and main switch ON; raisethe front of the ELU^r'r'HT vehicle,block one wheel and rotatethe other wheel slowly.
r3
Possiblecause it result is not obtained
Under all conditions
lgnitionswitch ON lll)
10
Test: Desiredresult
Test condition
fi{/r) P o o rg r o u n d( G 1 0 1 ) An open in the wire
R€conn€cttho 14PconnGctorto the control unit.
BLU
Start tho engine.turn the main switch ON, and drive the vehicleover 25 mph (40 km/h)with the crursecontrol set
Checkfor voltageto ground: There should be approx.5 V
. Faultycruisecontrol unit . Shod to ground
*: '98 - 00 modelswith AutomaticTransmission.
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4-39
CruiseControl Main Switch Test/Replacement 1 . Carefullypry the switchout of the instrumentpanel. Disconnect the 6P connectorfrom the switch,
Set/ResumeSwitch Test/Replacement 1 . Disconnectthe bafterynegativecable,then disconnectthe positivecable,and wait at leastthree minutes.
Terminal sideof male rermtnats
Disconnect the driver'sairbagand front passenger's airbagconnectors(seesection24). 6P CONNECTOR
Removethe dashboardlowercoverand kneebolster. 4.
Disconnect the 6P connectorbetweenthe cablereel sub harnessand the main wire harness.
/
BULES{0.84Wt Checkfor continuitvbetweenthe terminalsin each switchpositionaccordingto the table. Terminal -_\ 5
\
6
Wire sideof temaleterminals
;;; OFF
G-
@o
ON
G
@
G
(9 ,{)
-o o- @ -o
lf there is no continuity,replacethe switch.
Checkfor continuity betweenthe terminalsof the 6P connectorin each switch position accordingto the table. \
Terminal
;;;
--_l
2
o-
S E T( O N ) (ON) RESUME
Cf-
-o c
lf there is continuity.and it matchesthe table, the switchis OK. a lf there is no continuityin one or both positions, go to step 6.
4-40
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ActuatorTest 6. Removethe two screws.then removethe switch. nn-
1 . Disconnect the actuatorcabletrom the actuatorrod and the 4Pconnector.
SET/RESUME
Connect battery power to the No. 4 terminal and groundto the No. 1, No. 2 and No. 3 terminals,
,s
Connecta vacuumpump to the vacuumhose.Then applyvacuumto the actuator. r. VACUUMPUMPGAUGE 0-30 in.Hg. A973X-041-XXXXX
7 . Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the table. Terminal -__\
\
t*,r* SETION) (ON) RESUME . .
1e to
l
2
3
---o oo- ---o
lf there is continuity,and it matchesthe table, replacethe cablereel. lf there is no continuityin one or both positions, replacethe switch.
Terminalside ot maleterminals The actuatorrod shouldpull in completely.lf the rod pulls in only part-wayor not at all, checkfor a leaking vacuumIineor defectivesolenoid.
ACTUATOBROD
lf all tests prove OK, reconnectthe cable reel subharnessconnector. 9 . Reconnectthe driver'sairbagand front passenger's airbagconnectors,and reinstallthe accesspanelon the steeringwheel.
l
1 0 . Reconnectthe batterypositivecable.then the negative cable. 1 1 . A f t e r c o n n e c t i n gt h e a i r b a gc o n n e c t o r sc, o n f i r m
proper system operation:Turn the ignition switch ON (ll);the SRSindicatorlight shouldcome on for about six secondsand then go off. (cont'd)
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4-41
CruiseGontrol ActuatorTest (cont'dl 5.
With voltageand vacuumstill applied,try to pull the actuatorrod out by hand.You shouldnot be able to pull it out. lf you can.it is defectrve.
ActuatorReplacement ' t . Pullbackthe boot. and loosenthe locknut.Then dis-
I
Ar 1.
connectthe cablefrom the bracket. Disconnect the cableend from the actuatorrod.
.J.
groundfrom the No. 3 terminal.The actuDisconnect ator rod should return.lf it does not return,but the vent hose and filter are not plugged,the solenoid valve assemblyis defective. 7.
Repeatsteps 2 through 5. and disconnectground from the No. l terminal. The actuator rod should return. lf it does not return,but the vent hose and filter are not plugged,the solenoidvalve assembly is defective.
8.
lf you replacethe solenoidvalveassembly,be sure to use new O-ringson eachsolenoid.
9.
powerand groundfrom the 4Pconnector. Disconnect Disconnectthe vent hose from the actuator.Connect a vacuumpump to the actuatorvent hose port, and applyvacuum.The actuatorrod shouldpull in comp l e t e l y .l f n o t , t h e v a c u u m v a l v e i s s t u c k o p e n . Replace the actuator,
4-42
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3.
Disconnect the 4Pconnectorfrom the actuator.
4.
Disconnect the vacuumhosefrom the vacuumtank. Pullout the vent hose. Removethe three mounting bolts and the actuator with the bracket.
ACTUATOR CABLE
I 4.
ACTUATOR
6.
lf necessary, disconnectthe cableend from the linkage over the acceleratorpedal,then turn the grommet 90' in the bulkhead.and removethe cable.
7.
Installin the reverseorder of removal,and adjust free play at the actuator rod after connectingthe cable(seepage4-43).
I
ActuatorCableAdiustment
ClutchSwitch Test
'1.
1.
Checkthat the actuator cable operatessmoothly with no bindingor sticking. Startthe engine.Hold the engineat 3,000rpm with no load (A,/Tin E or E position, M/T in neutral) untilthe radiatorfan comeson, then let it idle.
Disconngctths 2P connector from the clutch switch.
CLUTCHSWITCH2P CONNECTOR Terminalsideof maleterminals
Measurethe amount of movementof the actuator rod until ths cable pulls on the acceleratorlever (enginespeed startsto increase).Free play should b e 1 1t 1 . 0m m ( 0 . 4 3i 0 . 0 4i n ) .
ACTUATORROD
LOCKNUTFREEPLAY:11 t 1.0 mm 10.43r 0.04 in)
2.
Removethe clutchswitch,
5.
Checkfor continuitybetweenthe terminalsaccording to the table.
lf free play is not within specs,loosenthe locknut, and turn the adjustingnut as requirsd, NOTE: lf necessary,check the throttl€ cable frso play (s€esection11),then recheckthe actuatorrod free play.
Terminal
\
Clutch Switch
\
OEPRESSED
RELEASED
o
o
Retightenthe locknut,and recheckthe free play. 4.
lf necessary,replacethe switch or adjustthe pedal height(seesectiont2).
st te
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4-43
CruiseControl ActuatorSolenoidTest
BrakeSwitch Test 1.
Disconnect the 4Pconnectorfrom the switch,
2.
Removethe brakeswitch.
1.
the 4P connectorfrom the actuator. Disconnect
I
ACTUATOR
{P CONNECTOR
of Terminalside maleterminals Checkfor resistancebetweenthe terminalsaccording to the table.
il',",""*(t)
_\
3
1
o- - o
VENTSOLENOID 40-600 Check for continuity between the terminals according to the table.
\
Terminal
;;;;-t RELEASED PUSHED
1
O-
5
---o o- -o
I
Terminal
\
Terminalsideof male termtnals
VACUUM SOLENOID SAFEWSOLENOID 40-600
---o
o
30-500
---o
o-
NOTE: Resistancewill vary slightly with temperais at 68"F(20"C). ture;specifiedresistance
lf necessary,replacethe switch or adjust pedal height (seesection19). VACUUM VALVE
To VACUUM TANK
4-44
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I
ActuatorDisassembly
ACTUATORCABLE
ACTUATORERACKET
VACUUM TANK
)rd'
!l l
VALVES Test, page 4-44
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4-45
E ngine EngineRemovaUlnstallation ................ 5-1 CylinderHead/Valve Train ................... 6-1 E n g i n eB f o c k. . . . . . . . . . ...........7-1 EngineLubrication ...........8-1 IntakeManifold/Exhaust System ........ 9-1 Cooling ......... 10-1
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EngineRemovaUlnstallation EngineRemoval/lnstallation . . . . . . . . . . . . . . . . . . .5. -. .2. . . Removal .....................5-12 lnstallation
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EngineRemovaUlnstallation Removal @
4.
a Make sure iacks and safety stands are placedproperly and hoist brackets are attached to the correct oositions on the engine. . Make sure the vehicle will not roll oft stands and fall while you are working under it.
BATTERY BASE
NOTEI . U s e f e n d e rc o v e r st o a v o i d d a m a g i n gp a i n t e ds u r faces. o To avoid damage.unplugthe wiring connectorscarefully while holdingthe connectorportion. lvlarkall wiring and hosesto avoid misconnection. Also, be surethat they do not contactother wiring or hoses,or interferewith otherparts. 1.
Securethe hood in the open position.
2.
Disconnect the batterynegativeterminalfirst,thenthe positiveterminal.
Removethe battervand battervbase.
I x 1.25mm 24 N.m (2.4kgf.m, 17 tbnft) -t'.-e
F F Y
Disconnectthe batterycablesfrom the under-hood fuse/relaybox and batterypositiveterminal.
5.
Removethe intakeair duct and air cleanerhousino.
INTAKE AIB
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I
6.
7.
6.
Disconnect the enginecontrolmodule(ECM)/powerfrom the ECM/ traincontrolmodule(PCM)connectors PCM.
7.
Disconnect the main wire harnessconnector.
L
Disconnectthe enginewire harnessconnectorson the left sideof the enginecompartment. ENGINEWIRE HARNESSCONNECTORS
CONNECTOR
Removethe grommetand wire harnessclamps,then pull out the EcM/Pclvlconnectors. 6x1.0mm 11 N.m 11.1kgl.m,8lbf.ftl
GROMMET
(cont'd)
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5-3
EngineRemoval/lnstallation Removal(cont'dl 1 0 . Removethe cruisecontrolactuator(seesection4). 1 t . R e m o v et h e m o u n t i n g b o l t a n d l o c k b o l t , t h e n removethe P/Spump belt and pump. MOUNNNG BOLT 8 x 1.25mm 2a N.m 12.4kg{.m, 17 lbtftl
P/S PUMP BELT
13. Relievefuel pressure{seesection11). Do not 3mok6 whil€ working on th6 @ tugl systsm. Koep open flam€ or spark away from the work area. Drain fuel only inlo an approved container. 14. Removethe evaporativeemission (EVAP)control canisterhoseand tuel feed hose. 33 N.m (3.4kgt.m,
2s tbf.ft)
LOCKBOLT I x 1.25mm 24 N.m {2.4kgtm, '17lbf.ftl
1 2 . Loosenthe idler pulley bracketbolt and adjusting bolt, then remove the air conditioning(A,/C)compressorbelt. ADJUSTINGBOLT LOCKNUT 8 x 1.25mm 24 N.m {2.4kgf.m, 17 lbf.ftl
ID1TR PULI.f,Y ARACKETBOLT 10r 1.25mm a{ N.m 14.5lgtm,33 lbf.ft)
5-4
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,%l *ryft 'fltr \'t,f EVAPCC CANISTERHOSE
he '.n
'15. Removethe brakeboostervacuumhose,fuel return hoseand vacuumhose. '97 - 98 modals:
!d
BRAKEBOOSTER VACUUM HOSE 'ol
'16. Removethe throttlecableby looseningthe locknut, then slip the cable end out of the acceleratorlinkage.Take care not to bend the cablewhen removing it. Always replaceany kinkedcablewith a new one. 97 - 98 modeb:
FUELRETURN HOSE
99 - 00 modob: '99 - 00 modob: BRAKEBOOSTER VACUUM HOSE
THROTTLE CABLE
LOCKNUT ADJUSTING NUT
(cont'd)
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5-5
EngineRemoval/lnstallation Removal(cont'd) 17. Disconnect the powersteeringpressure{psp} switch connector,and removethe wire harnessclamo.
19. Disconnect the transmissiongroundcable(M/T).
GROUNDCABI."E
1 8 . Removethe slavecylinderand clutch hose bracket
(Mrr).
NOTE: . Do not disconnectthe pipe/hoseassembly. . Do not operatethe clutch pedal once the slave cylinderhas beenremoved. . Takecarenot to bendthe pipe/hoseassembly.
R e m o v et h e c o t t e r p i n s , t h e n r e m o v e t h e s t e e l washers,plasticwashers,shiftcable,and selectcable from the levers(M/T).
sElEcr CABI."E 21. Removethe cable bracketfrom the clutch housing (M/T).
5-6
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30. Disconnectthe primary heatedoxygen sensor(prlthen removeexhaustpipeA mary HO2S)connector.
22. Removethe radiatorcaP. use care when removing the radiatol !@ cap to avoid scalding by hot coolani or steam.
'97 - 98 U.S. models (Cslifornia):
23. Raisethe hoistto full height 24. Removethe front tires/wheels. 25. Removethe guardbar and splashshield.
PRIMARYHO2S CONNECTOR
SPLASH
GASKET Replace. NUT SELF-LOCKING 8 x 1.25mm NUT 22 N.m 12.2kgf.m, 8 x 1.25mm 16 lbf.ftl 16 N.m {1.6 kgf.m. Replace. 12 tbt.ftl Replace.
6x1.0mm
NUT SELF.LOCKING 10x 1.25mm 54 N.m 15.5kgf.m, .() tbf.frl Replace.
8 x 1.25mm 2,1N.m {2.4 kgf,m, 17 lbl ft)
BAR 9.8N.m{1.0kgf.m, GUARD 7.2tbf.rr) 26. L o o s e nt h e d r a i n p l u g i n t h e r a d i a t o r .D r a i n t h e enginecoolant(seepage10-51. the drain oil or fluid. Reinstall 2 7 . Drainthe transmission plug using a new washer lsee section 13 (M/T)or section 14 (ly'T)]. 28. Drainthe engineoil. Reinstallthe drain bolt using a new washer{seepage8-4). 29. Bemovethe A,/Ccompressor.Do not disconnectthe !y'C hoses.
'97 - 98 U.S. mod€ls {ExceptCalifornia): '99 - 00 models: PRIMARYHO2S CONNECTOR GASKETS Replace.
ER lC EB
GASKET Replace. SELF.LOCKING 8 x 'l.25mm 22 N.m (2.2kgf m, 16 rbf.ftl Replace.
NUT SELF.LOCKING 8 x 1.25mm 16 N.m 11.6kgf.m, 12 tbt fr) Replace.
10 x 1.25mm 54 N.m 15.5kgt.m, 40 rbt.ftl Replace.
{cont'd)
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5-7
EngineRemovaUlnstallation Removal(cont'dl 31. Removethe shift cable.Take care not to bend the cablewhen removingit. Always replaceany kinked cablewith new one (Afl-).
Make marks on the transfercompanionflange and propellershaftas shown.Usethesemarksto set the propeller shaft in the proper position when reinstalling(4WD).
OOI{TROLPI
Removethe four bolts securingthe propellershaft, then separatethe propellershaft from the transfer companionflange(4WD).
SNAPPIN
sHtFTCABtt OOVEB
8 x 1.25mm t2 N.m 12.2lgtr'l'',, 16tbf.ftl
Removethe right damperfork (seesection18). Disconnect the suspensionlowerarm balljoints(see section18),
34. Removethe driveshafts(see section t6). Coat all precision-finished surfacewith cleanengineoil. Tie plasticbagsover the driveshaftends. E x 1.25mm
32 N.m 13.3lgt.m, 24 lbt'ftl Repl€ce. 37. Lowerthe hoist,
5-8
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rd te n-
3 8 . R e m o v et h e u p p e r a n d l o w e r r a d i a t o rh o s e sa n d heaterhoses.
4 1 . Removethe radiator(seepage10"4). 42. Removethe IVC hoseclamp.
A/C HOSE
rt, BT
3 9 . R e m o v et h e t r a n s m i s s i o ng r o u n dc a b l ea n d h o s e clamp(A,/T). 9.8 'm lt.o klt m, l.2tutal
GBOUI{DCABLE
6 x l1,0 6x ,0m mm m 11 N.m 11.1lof'm, I tbf.ftl
40. Remove the ATF cooler hoses, then plug the ATF cooler hoses and, n"" lAfI).
(cont'd)
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5-9
EngineRemovaUlnstallation Removal(cont'dl 43. Attachthe chainhoistto the engine.
5-10
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44. Removethe left and right front mounts and brackets
46. Removethe uDperbracket.
UPPER
Replace.
M/T:
47. Removethe transmissionmount bracket,then remove the transmissionmount. MOUNT/BRACKET
TRANSMISSION
Alf I
45. Removethe rearmount bracketmountingbolt.
MOUNTBMCKET
REABMOUNT
is completelyfree Checkthat the engine^ransmission hoses, and electriand coolant hoses, fuel of vacuum calwiring. 150mm (6 in)' 49. Slowlyraisethe engineapproximately wires are disconhoses and Checkonce again that all nectedfrom the enginenransmission. 50. Raisethe engineall the way, and removeit from the vehicle.
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5 - 11
Engine Removal/lnstallation Installation Bracket Bolts Torque Specifications:
P/S PUMP BRACKET
SIDEEIIGII{E i'OUT{T BRACKET
t t 1.25m.D 2a 'tn (2,4 kgt ft, 17 tbtftl
10 x 1.25mm 54 t$m 15.5tgfm, iO lbflrl
10 x 125 mm il,a t*m {4.5 tgt'm, d, tbtft)
ALTERI{ATOR BNACKET A/C @MPRESSOR BRACIGT
t0 r 125 ]nm a,l t+Jnll.5 lgf-rn, 3 tbf{tl 8 r 1.25mm 24 N.m 12.4kg{.m;
17tbtfrl
5- 12
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10 x 1.25mrn ,L il.tn {1.5 tgt m, :|:l lbf'ft}
Installthe upper bracket,then tightenthe nuts in the numberedseauence.
2.
EngineInstallation: lnstallthe enginein the reverseorderof removal. Reinstall the mount bolts/nutsin the followingsequence Failureto follow these proceduresmay causeexcessrve noiseand vibration.and reducebushinglife. 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 a n d b r a c k e t t. h e n tighten the bolts on the frame side. Do not tighten the bolts/nutson the transmissionside.
O 12 x 1.25mm 7a N.m {7.5kgf'm, 54 tbf.trl
A 12r1.25mm 7il N.m 17.5kgl'm, 5,r lbt.ft)
A/T: TM'{SMISSION MOUNT
12x 1.25mm 6,aN.m16.5kgtr.m, 47 tbt f0
R R
3.
Installthe rear mount bracketmountingbolt. Do not tightenthe bolt.
TRANSMISSION MOUNT BRACKEY
M/T:
TRANSMISSION MOUNT
12x 1.25mm 64 N.m {6.5kgt.m, 47 tbl.ft) !, m,
MOUNN G BOLT Replace.
(cont'd)
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5-13
EngineRemovaUlnstallation (cont'd) Installation 4.
T i g h t e nt h e b o l t / n u t so n t h e t r a n s m i s s i o nm o u n t bracketin the numberedsequence.
5.
Tightenthe rear mount bracketmountingbolt.
AIT:
@ 12 x 1.25mm ?4 N.m {t.5 kgt.h, 5,4lbf.ftl
O 12x 1.25mm 6l .m (6.5kgtm, 47 tbt{r}
M/T: i?. 12 x 1.25mm 74 N.m {7.5kgf'm.
s/rtbr.ftl
,,.....\.L} @'...,'..4:
a1l12 x 1.25mm 64 N.m {6.5kgf.m, 47 lbf.ft)
5 - 14
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12 x 1.25mm 59 N.m {6.0 lgl'm, ait lbf.ftl Replace.
6.
then tightenthe Installthe rightfront mounvbracket, boltsin the numberedsequence.
7.
Installthe leftfront mount,then tightenthe bolts/nut in the numberedseouence. O t2 r 1.25mm 8il N.m18.5kgt.m,el |bfftl
A/T: Loosen th is nut,
i! 12x 1.25mm g N.m {6.5 kgf.m, 47 lbf.ftl Replace.
(D to x t.zs mm 44 N.m{4.5kgfm, 33 lbf.ft)
O 12 x 1.25mm 59 N.m 16.0kgt ln, ,€ lbfttl Replace.
@ lo x 1.25mm a,aN.m14.5kgf.m, 33 tbf.trl
M/T: Loosenthis nut.
O 10x r.25mm 4/tN.m14.5kgt.m,33lbf.ft) O 12 x 1.25mm 64 N.m 16.5kgf.m.47 lbf.ft) Replace.
{cont'd)
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5-15
EngineRemoval/lnstallo cton Installation(cont'd) 8.
Tightenthe nut on the right front mount. AlTi
59 .m 16.0tgt m, (l lbfftl Replace.
MlTi
12 x'1.25mm 59 N.m 16,0kgt m, /(} lbt ttl Reolace.
5-16
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9.
Performthe followingchecksand adjustments: . Checkthat the springclip on the endsof the driveshaftand intermediate shaftclicksinto place.Use new springclips. . Adjustthe shiftcable(seesectionl4). . Adjustthe throttlecable(seesection11). . Refillthe enginewith engineoil (seepageg-4). . Refillthe transmissionwith oil or fluid (seesect i o n 1 3o r 1 4 ) . . Refillthe radiatorwith enginecoolant(seepage 10_5). . B l e e da i r f r o m t h e c o o l i n g s y s t e mw i t h t h e heatervalveopen (seepage l0-5). . Cleanthe batterypostsand cableterminalswith sandpaper,assemblethem, then apply greaseto Dreventcorrosron. . Inspectfor fuel leakage(seesection1l). After assemblingfuel line pans,turn on the ignition switch (do not operatethe starter)so that the fuel pump operatesfor approximatelytwo secondsand the fuel Iine pressurizes. R e p e a t h i s o p e r a t i o nt w o o r t h r e e t i m e s ,a n d checkfor fuel leakageat any point in the fuel line.
Mount and Brackst Bolts/Nuts Torqus Value Specitications: A: '10x 1.25mm 64 N.m 16.5kgI.m, 47 lb{.ftl B: 12 x 1.25mm 59 N.m 16.0kgf.m, 43 lblft) Replace. C : 1 4x 1 . 5m m 8:l N.m (8.5kgt.m, 6r lbl'ft) Replace. D: 10x 1,25mm ,t4 N.m (4.5 kgf'm,33 lbIft) Er 12x 1.25mm 83 N.m 18.5kgf.m, 61 lbl.ftl
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5-17
CylinderHead/ValveTrain .............6-2 Camshafts SpeciafTools ..............6-22 lnspection ValveClearance Valves,Valve Springsand Valve Seals ............6-3 Adiustment ................, 6-23 Removal ValveSeals ............. 6-29 lnstallation Replacement(cylinderhead 6-5 removalnot requiredl................. Valve Guides CrankshaftPulleyand PulleyBolt 6-25 ValveMovement............,,,,.,............ .........6-7 Replacement .........6-25 Replacement Timing Belt .................6-27 Reaming 6-8 Illustratedlndex ............................... Valve Seats ............., 6-9 Inspection ......6-28 Reconditioning 6-9 TensionAdjustment........................ ...........,..... 6-10 Removal .............6-11 lnstallation (CKFI Fluctuation Speed Crankshaft Sensor .........6-13 Replacement CylinderHead 6-14 lllustratedlndex ............................... .................6-16 Removal ................6-27 Warpage ............. 6-30 lnstallation
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SpecialTools
Ref. No.
I
o
Tool Number 07JAA- 001020A 07JAB- 00'10204 OTMAB_ PY3O1OA 07757- PJ1010A 07942- 6570100 07984- 657010D
,61
A)
a!)
a!)
c--E-rr------------
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6-2
Description Socket,19 mm H o l d e rH a n d l e PulleyHolderAttachment,50mm, Offset ValveSpringCompressorAnachment ValveGuideDriver,6.6 mm ValveGuideReamer,6.6 mm
(Xy 1 1
r 1 1 'l
I
PageRefereflce
|
6-1 6-7
I 6-7 I |
6-23,29 6-25,26 6-27
ValveClearance Adiustment Adjustthe valvesonly when the cylinderheadtemperature is lessthan 100"F(38"C). 1.
Removethe cylinderheadcover. Removethe middlecover(seepage6-11). "UP" mark on the Set the No. 1 pistonat TDC.The pulleysshouldbe at the top, and the TDC markson the pulleysshouldalignwith the pointerson the back
Adjustthe valveson No. 1 cylinder. Intake: 0.08- 0.12mm (0.003- 0.005inl Exhaust:0.16- 0.20 mm (0.006- 0.008in) Loosenthe locknut,and turn the adiustmentscrew until the feeler gauge slides back and forth with a slightamountof drag.
LOCI(NUT 9 x 0.75m.n 25 N.m 12.5kgf.m, 18lbf.ft)
POINTER
POINTER
Adiusting Screw Locations: INTAKE
No.4
No.3
No.2
No. 1
EXHAUST
(cont'd)
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6-3
v
ValveClearance Adjustment(cont'dl 6.
Tightenthe locknut,and checkthe clearanceagajn. Repeatthe adjustmentif necessary.
to brinq 8. Rotatethe crankshaft180"counterclockwise No. 4 pistonto TDC. The "UP" marksshould be pointingstraightdown. Adjustthe valveson No. 4 cylinder.
"UP" MARKS
GAUGE
7.
(camshaft Rotatethe crankshaft180"counterclockwise pulleyturns90'). The "UP" marksshouldbe on the exhaustside.Adjust the valveson No.3 cylinder.
.UP" MARKS
to brino Rotatethe crankshaft180'counterclockwise No.2 pistonto TDC. The "UP" marksshouldbe on the intakeside.Adiust the valveson No. 2 cylinder.
"UP" MARKS
1 0 . Installthe cylinderheadcover(seepage6-32). 1 1 . Retorquethe crankshaftpulleybolt (seepage6-7).
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ValveSeals 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 YA8845-2A7/8" auachment). Use approved eye protection. 1. Turn the crankshaftso that the No. 1 and the No. 4 pistonsare at top deadcenter(TDC). 2.
Removethe cylinderheadcover.
3.
Removethe distributor.
4.
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 g b e l t f r o m t h e camshaftpulleys.
5.
at.
Selectthe 7/8 in. diameterlong compressorattachment,and fastenthe attachmentto the front hole of the leverarm with the speedpin supplied.
9 . Positionthe pistonat TDC,and insen an air adaptor into the spark plug hole. Pump air into the cylinder t o k e e p t h e v a l v e c l o s e dw h i l e c o m p r e s s i n gt h e springsand removingthe valvekeepers. 10. Put shop towels over the oil passagesto prevent t h e v a l v e k e e p e r sf r o m f a l l i n g i n t o t h e c y l i n d e r head. OIL PASSAGE
Removethe camshaftholderbolts.then removethe camshaftholders,the camshaftsand rockerarms.
lntake Valve Seals 6. Usingthe 6 mm boltssuppliedwith 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.
Insertthe cross shaft through the top hole of the two uprights,
OIL PASSAGES
't1. Position the 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.Usethe rear positionslot on the leveras shown,
(cont'd)
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6-5
ValveSeals Replacement(cylinderheadremovalnot requiredl(cont'dl 12. Usingan upwardmotionon the leverarm,compress the valve spring and removethe keepersfrom the valvestem.Slowlyreleasepressureon the spring.
22. Put shop towels over the oil passagesto prevent t h e v a l v e k e e p e r sf r o m f a l l i n g i n t o t h e c y l i n d e r neao.
1 3 . Repeatstep 11 for the othervalvein that cylinder. 1 4 . Removethe valveseals(seepage6-24). 1 5 . Installthevalveseals(seepage6-29). 1 6 . lnstallthe springs,the retainersand the keepersin reverseorderof removal. '17. Repeatsteps9 to 16 for the otherthreecylinders. Exhaustvalve Seals 18. Usingthe 5 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. 19. Insert the cross shaft through the bottom hole of the two uprights.
20. Selectthe 7/8 in. diametershort compressorattach ment,and fastenthe attachmentto the No. 4 hole of the leverarm with the speedpin supplied. t1
Positionthe pistonat TDC,and insertan air adaptor into the spark plug hole. Pump air into the cylinder t o k e e p t h e v a l v e c l o s e dw h i l e c o m p r e s s i n gt h e springsand removingthe valvekeepers.
23. Positionthe lever arm underthe crossshaft so the leveris perpendicular to the shaftand the compressor attachmentrests on top of the retainerfor the spring being compressed.Usethe rear positionslot on the leveras shown.
24. Using a downward motion on the lever arm, compressthe valvespringand removethe keepersfrom t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e spring. Repeatstep24 for the othervalvein that cylinder. Removethe valveseals(seepage6-24). 2 1 . Installthe valveseals(seepage6-29). 28. Installthe springs,the retainersand the keepersin reverseorderof removal. 29. Repeatsteps21 to 28 on the otherthreecylinders.
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o-o
CrankshaftPulleyand PulleyBolt Replacement When installingand tighteningthe pulley,follow the procedurebelow. Clean,removeany oil, and lubricatepointsshown below. C: Clean x I Removeany oil a: Lubricate CRANKSHAFT PULLEY WASHER
CRANKSHAFT
X
X
X
X
X X
o oooo o o o - oooo o
X X
^ oooo o o o o
6r. R o".
Crankshaftpulley bolt size and torque value: 14 x 1.25mm 177N'm (18.0kgf.m,130lbt.ftl NOTE:Do not use an impactwrenchwhen installing.
HOLDERATTACHMENT. 50 mm, OFFSET OTMAB- PY3OlOA SOCKET,19 mm 07JAA- 001020A available} {or Commercially
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6-7
TimingBelt lllustratedIndex HEAD CYLINDER COVER Referto page6-32 when installing.
kgf.m, 7.2 tbtft)
HEADCOVERGASKET Replacewhen leaking, damagedor deteriorated. Apply liquidgasketat the eightcornersof the
\ @ Cl
WASHER Replaceif damaged or deteriorated,
k6
TIMING BELT page6-9 Inspection, Adjustment,page6-9 Removal,page6-10 page6-11 Installation, SEAL RUEBER Replaceil damaged ot detetiorated.
8 x 1.25mm 37 N.m (3.8kst.m,27lbf ftl
MIDOLECOVER 6x1.0mm 9.8N.m {1.0kgf.m, 1.2lbt.ftl
SEALS RUBBER when damaged Replace or deteriorated, LOWERCOVER ADJUSTINGBOLT 10 x 1.25mm 54 N.m (5.5kgl.m, 40 lbf.ft)
TIMINGBELT ORIVEPULLEY
PULLEY CNANKSHAFT page6-7 neplacement,
R e p l a c e m e n t ,p a g e 6 ' 7
lnstallwith concave surfacefacingout, Removeany oaland clean, SPEEO CRANKSHAFT FLUCTUATIONICKF} SENSOR
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6x1.0mfi 1 1N . m{ 1 . 1k g t m , 8.0 rbtft)
6x1.0mm 9.8Nm(1.0kgl.m, 7.2 tbl.ft)
BOLT 14 x 1.25mm 177N.m (18.0kgf'm, 130 tbf.fr) Replacement, Page6-7 Do not usean impact wrenchwhen installing.
Inspection
TensionAdjustment
1 . Removethe cylinderheadcover.
NOTE: . Alwaysadjustthe timing belt tensionwith the engine coto. . Always rotatethe crankshaftcounterclockwise when v i e w e df r o m t h e p u l l e ys i d e . R o t a t i n gi t c l o c k w i s e m a y r e s u l ti n i m p r o p e ra d i u s t m e not f t h e b e l t t e n sion.
2.
lnspectthe timing belt for c.acksand oil or coolant s o a k i n g .R e p l a c et h e b e l t i f i t i s o i l o r c o o l a n t soaked.Removeany oil or solventthat gets on the belt.
'1. Removethe cylinderheadcover
lnspectthis areafor wear.
2.
Set the No. 1 pistonat TDC(seepage.6-12).
3.
Rotatethe crankshaftfive or six revolutionsto set the belt.
4.
Set the No. 1 pistonat TDC.
5.
Loosenthe adjustingbolt 1/2turn (180')only.
ADJUSTINGBOLT 5,4N.m (5.5 kgf.m, 40 tbtftl For adiustmentonly,
rotation,
Rotatethe crankshaftcounterclockwise three teeth on the camshaftpulley. 3.
After inspecting,retorquethe crankshaftpulleybolt to 177N.m (18.0kgnm,130lbf.ft).
7.
Tightenthe adjustingbolt to the specifiedtorque.
8.
After adjusting,retorquethe crankshaftpulleybolt to 177N.m (18.0kgf.m,130lbf.ft).
9.
Installthecylinderheadcover(seepage6-32).
Installthe cylinderheadcover(seepage6-32).
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6-9
Timing Belt Removal Replacethe timing belt at 105,000miles (168,000km) accordingto the maintenanceschedule{normalconditions/severe conditions).lf the vehicleis regularlydriven in eitherof the following conditions,replacethe timing belt at 60,000miles(U.S.A.l100.000km (Canada). - ln very high temperatures(over 110'F,43"C). - In very low temperatures(under-20"F.-29"C).
5.
Loosenthe mountingnut and locknut,then remove the altefnatorbelt. LOCKNUT I x 1.25mm 2a N.m 12.4kgt m, 17 lblftl
1 . Turn the crankshaftpu\ley so the No. 1 piston is at top deadcenter(TDC). 2.
Removethe guard bar and splashshield (seepage 5-7).
,l
Loosenthe mountingbolt and lockbolt.then remove the power steering(P/S)pump belt. MOUNNNGBOLT 8 x 1.25rnm 24 N.m {2.4 kgt.m, 17 lbf.ftl 10 x 1,25mm 4,1N.m (,1.5kgt m, 33 lbtftl AELT
6.
Removethe cruisecontrolactuator(seesection4).
7.
S u p p o r tt h e e n g i n ew i t h a j a c k ,t h e n r e m o v et h e u p p e r b r a c k e t .M a k e s u r e t o p l a c e a c u s h i o n betweenthe oil Danand the iack.
12 x 1.25mm 74 N.m (7.5kgf m, 54 lbtftl 24 N.m 12.4kgf.m, lt lbf.ftl BRACKET
4.
Loosenthe idler pulley bracketbolt and adjusting bolt,then removethe air conditioning(lVC)compres sor belt(seepage5-4).
6-10
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Installation 8. Removethe cylinderheadcover.
Installthe timing belt in the reverseorderof removal; Only key pointsare describedhere,
NOTE:Referto page6-32when installingthe cylinder headcover.
1.
9 . Removethe crankshaftpulley(seepage6-7).
GROOVE
POINTER
1 0 . Removethe middle cover and lower cover. Do not usethesecoversto storeremoveditems. MTDDLE COVER
Setthetiming beltdrivepulleyso thatthe No. 1 piston is at top dead center (TDC).Align the groove on the timingbeltdrivepulleyto the pointeron the oil pump.
6x1.0mm 9.8N.m {1.0kgt m,
DRIVEPULLEY Clean. LOWER COVER
2. 9.8N.m(1.0kgt.m,7.2lbf.ftl
Set the camshaftpulleysso that the No. I piston is at TDC.Alignthe TDCmarkson the camshaftpulleysto the pointerson the backcover.
1 1 . Markthe directionof rotationon the timing belt.
CAMSHAFT PULLEY Clean.
12. Loosenthe adjustingbolt 180'.Pushthe tensionerto removetensionfrom the timing belt, then retighten the adiustingbolt.
r-t
AINUSTING BOLT 54 N.m (5,5 kgt m, .(} tbf.rrl
1 3 . R e m o v et h e t i m i n gb e l t .
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POINTER
(cont'd)
6-11
Timing Belt Installation(cont'd) 3.
Installthe timing belttightlyin the sequenceshown. J @ AdjustO Timing belt drive pulley(crankshaft) ing pulley =r @ Water pump pulley r @ Exhaust camshaftpulley--)@ Intakecamshaftpulley.
9. Checkthat the crankshaftpulley and camshaftpulleys are both at TDC.
POINTERON
NOTE: Make sure the timing belt drive pulley and camshaftpulleysare at TDC.
4.
Loosenand retightenthe adjustingbolt to tension the timing belt.
5.
C l e a n .t h e n i n s t a l l t h e l o w e r c o v e r a n d m i d d l e cover. Installthe crankshaftpulley,then tightenthe pulley bolt (seepage6-7).
1.
Rotatethe crankshaftpulleyabout five or six turns counterclockwiseso that the timing belt positions on the pulleys. Adjustthe timing belttension{seepage6-9).
POINTER
1 0 . lf the camshaftpulleys are not positionedat TDC, removethe timing belt.adjustthe positionfollowing the procedureon page6-11.then reinstallthe timing belt. 1 1 . Installthecylinderheadcover(seepage6-32). 1 2 . After installation, adjustthe tensionon eachbelt. . See section4 for alternatorbelt tension adjustmenr. . See section22 for NC compressorbelt tension adjustment. . See section17 for P/Spump belt tensionadjustment.
6-12
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CKFSensor Replacement 1.
Removethe guard bar and splashshield (seepage 5-7t.
4.
Loosenthe locknutand mountingnut, then remove the alternatorbelt. LOCKNUT 8 x 1.25mm 24 N.m (2.4 kgl.m, 17 lbtftl
L o o s e nt h e l o c k b o l t a n d m o u n t i n g b o l t , t h e n removethe P/Spump belt.
MOUNTING BOLT 8 x 1.25mm 24 N.m (2.{ kgf.m, 17 lbf.ttl
PUMP
10 x 1.25 mm a4 N.m (4.5kgt m, 33 lbtft)
BELT BELT E
Removethe cylinderheadcover.
6.
Removethe crankshaftpulley(seepage6-7).
7.
Removethe middlecoverand the lowercover.
aJ.
Disconnectthe CKFsensorconnector,then remove the CKFsensor.
24 N.m 12.4lgf.m, 17 lbl.ftl
Loosenthe adjustingbolt and idler pulley bracket bolt,then removethe Ay'CcomDressorbelt. ADJUSTINGBOLT LOCKNUT 8 x 1.25mm 24 N.m {2.4 kgf.m, 17 lbf.ft)
CKFSENSOR
6x1.0mm 11 N.m {1.r kgnm,8.0lbfft)
|o|'ln PUUCYBMCKETSOLI l0 r 1.25mm 14 .m 14.5kgl.m,3:'lbtftl
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9.
Install the CKF sensor in reverse order of removal.
6-13
GylinderHead lllustratedIndex To avoiddamage,wait until the enginecoolanttemperaturedropsbelow 100'F(38'C)beforeremovingthe cylinderhead.
6x1.0mm 9.8 N.m (1.0kgI.m, 7.2 lbf.ft) WASHER Replace when damaged or deteriorated,
CYLINDERHEAD COVEB Reterto page6 32 when installingcylinderheadcover. HEAOCOVERGASKET Beplacewhen leaking, damagedor deteriorated. Apply liquidgasketat the eightcornersof the
RUBEER SEAL R e p l a c ei f or deteriorated,
8 x 1.25mm 24 N.m (2.4 17 tbtft) 6x1.0mm 9.8N.m (1.0kgf.m. 7.2 tbf.fo Applyengineoil to the threads. Seesection4. CYLINDEB HEADPLUG Replace-
---..-@
CAMSHAFT HOLDER
0+---.."...s<--
KEY
DOWEL PIN OIL SEAL Replace. CAMSHAFT PULLEY 8 x 1.25mm 37 N.m {3.8kgf.m, 27 tbtft)
OILSEAL Replace.
6x1.0mm 9.8 N.m (1.0kgl.m,7.2lbtftl
6-1 4
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gasket.
takecarenot to fold it or damagethe contactsurface. a metal -?Ehandling Priorto reassembling, cleanall the partsin solvent,dry them and apply lubricantto any contactparts.
VALVEKEEPERS
CYLINDERHEADBOLT 1 1x 1 . 5m m 85 N.m {8.7kgf.m,6:} lbf.ft) Tightening,page6'30. Applyengineoilto the threads. END PIVOTBOLT 63 N.m 16.4kgl m, 46 lbf.ft)
\
SPRINGBETAINER
EXHAUSTVALVE SPRING
INTAKEVALVE SPRING INTAKEVALVESEAL Replace.
EXHAUSY VALVE SEAL Replace.
VALVESPRING SEAT
EXHAUSTVALVE GUIDE page6-25 Inspection, page6-25 Replacem6nt, Reaming,page6-27
INTAKEVALVE GUIDE
HEAD Removal,page6-16 Warpage,page6 27 Valveseatreconditioning, page6 28 page6-30 Installation, EXHAUST VALVE INTAKEVALVE Removal,page6-23 page6-29 Installation, CYLINDERHEAO GASKET Replace. OIL CONTROL ORIFICE Clean.
10x 1.25mm 4,0N.m {i1.5kgf.m. 33 rbf.ft)
O.RING Replace.
DOWELPIN
8 x 1.25mm 24 N.m (2.4kgf.m, 17 tbf.ft)
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6-15
GylinderHead Removal Engineremovalis not required for thisprocedure.
6.
Loosenthe locknutand mountingnut, then remove the alternatorbelt.
Make sure iacks and safety stands are
l!@
LOCKNUT 8 x 1.25mm 24 N.m (2.4 kgf.m, 17 lbt.ftl
placed properly, and hoist blackels ale attachgd to the correctposition on the engine. NOTE: o U s e f e n d e rc o v e r st o a v o i d d a m a g i n gp a i n t e ds u r faces. o To avoid damage,unplugthe wiring connectorscarefully while holdingthe connectorportion. . To avoid damagingthe cylinderhead,wait until the enginecoolanttemperaturedrops below 100"F(38'C) beforelooseningthe retainingbolts. . Markall wiring and hosesto avoid misconnection. Also, be surethat they do not contactother wiring or hoses,or interferewith other parts. 1 . Disconnect the negativeterminalfrom the battery.
2.
Drain the engine coolant (see page 10-5).Remove the radiatorcapto speeddraining.
10x 1.25mm 44 N.m (4.5kgt.m. 33 lbf.ft)
BELT Removethe intakeair duct and air cleanerhousing (seepage5-2). 4.
R e m o v et h e m o u n t i n gb o l t a n d l o c k b o l t , t h e n 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 (seepage5-4).
5.
Loosenthe idler pulley bracketbolt and adjusting bolt, then remove the air conditioning(A,/C)com, pressorbelt. ADJUSTING BOLT
7.
Removethe P/SOUmobracket.
ADJUSTINGBOLT LOCKNUT 8 x 1 . 2 5m m 24 N m {2.4ksf.m, 17 lbttt}
l0 x 1.25mm 44 N.m (4.5kgf.m, 33 rbf.ft)
IOLERPULLEYBBACKETBOLT 10 x 1.25mm 44 N.m {4.5 kgtm, 33 lbf ft)
tt\
aA
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o-Io
8.
Removethe throttlecableby looseningthe locknut, then slip the cable end out of the throttle linkage. Take care not to bend the cablewhen removingit. Always replaceany kinkedcablewith a new one. '97 - 98 modols:
9. Relievefuel pressure(seesection11). Do not smoke while working on the @ fuel systom. Ko€p opon flame or sparks away from ths work area. Drain fuol only into an approved containgr. '10, Removethe evaporativeemission (EVAP)control canisterhoseand fuel feed hose.
'!X, - 00 modob:
CANISTERHOSE
{cont'd)
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6-17
GylinderHead Removal(cont'dl '11. Removethe brakeboostervacuumhose.fuel return hose,and vacuumhose. '97 - 98 modsls:
12. Removethe breatherhose and oositivecrankcase ventilation(PCV)hose, '97 98 models:
BRAKEBOOSTER
PCVHOSE BREATHEB HOSE
VACUUM HOSE
'99 - 00 models:
BREATHER HOSE BRAKEBOOSTEB VACUUM HOSE
PCVHOSE
6-18
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13. Removethe upper radiatorhose, heaterhose and water bypasshose.
18. Removethe cylinderheadcover. CYLINDER
WATERBYPASS
UPPEB RADIATOR HOSE
HEATER HOSE R e m o v et h e e n g i n ew i r e h a r n e s sc o n n e c t o r sa n d wire harnessclampsfrom the cylinderheadand the intakemanifold. o Fourfuel injectorconnectors . E n g i n ec o o l a n tt e m p e r a t u r e( E C T )s e n s o rc o n neclor . Radiatorfan switchconnector . Coolanttemperaturegaugesendlngunlt connector . Throttlepositionsensorconnector . Manifold absolute pressure{MAP) sensor connector Primary heatedoxygen sensor (primary HO2S) connector a ldle air control(lAC)valveconnector Distributorconnector
19. Inspectthe timing belt (seepage6-9).
Removethe sparkplug capsand distributorfrom the cylinderhead. Removethe cruisecontrolactuator(seesection4). 1 7 S u p p o r tt h e e n g i n ew i t h a j a c k ,t h e n r e m o v et h e
u p p e r b r a c k e t .M a k e s u r e t o p l a c e a c u s h i o n betweenthe oil pan and the iack(seepage6-10).
(cont'd)
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6-19
CylinderHead Removal(cont'dl Removethe timing belt (seepage6-10).
2' t. Removethe camshaftpulleysand backcover.
22. Bemove the exhaust manifold bracket and self-locking nuts. '97 - 98 U.S. modsls (Californial: GASKET Replace.
EXHAUSTMANIFOLD BRACKET
'r 10 x 1.25mm 44 N.m 14.5kgf,m, 33 rbf.ft) SELF.LOCKING NUT 54 N.m {5.5kgf.m, .{) lbf.ftl Replace. '97 98 U.S. models {Excepi Calitornia}: '99 0O modeb: BACKCOVER GASKETS Replace.
SELF.LOCKING NUT 10 x 1.25mm 54 N.m {5.5kgt.m, 40 lbtft} Replace.
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6-20
10 x 1.25mm 4il N.m (4.5kgf.m, 33 tbf.ftl
2 3 . R e m o v et h e i n t a k em a n i f o l dm o u n t i n gb o l t s a n d water bvDasshose.
25. Removethe camshaftholderbolts,then removethe camshaftholdersand rockerarms.Makenote of the rockerarm Dositions.
ROCKERARM
26. Remove the cylinder head bolts. To prevent warpage,unscrewthe bolts in sequence1/3turn at a time; repeatthe sequenceuntil all bolts are loosened.
8 x 1.25mm 2,1N.m 12.4kgt.m, 17 tbf.ft)
CYLINDERHEADBOLTSLOOSENINGSEOUENCE: 24. Loosen the locknuts and adjusting screws,
INTAKE
No. 4
No.3
No.2
N o .1
No.3
No.2
N o .1
EXHAUST
27. Removethe cylinderhead.
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6-21
Camshafts Inspection 1 . Loosenthe adjustingscrews.
11. Removethe camshaftholders.Measurethe widest portionof plastigageon eachjournal.
Removethe camshaftholders. Camshatt-toHoldGrOil Clearance: Standard {Newl: 0.030- 0.069mm {0.0012- 0.0027in} ServicoLimit: 0.15 mm (0.006in)
Markthe rockerarms,then removethem. 4. R e i n s t a l tl h e c a m s h a f ta n d h o l d e r s .T i g h t e nt h e
camshaftholderbolts in a crisscrosspattern,beginning with the innerbolts. 9.8 N.m (1.0kgf.m.7.2lbf.ft) Seatthe camshaftsby pushingthem toward the distributorend of the headwith a screwdriver. Z e r o t h e d i a l i n d i c a t o ra g a i n s tt h e e n d o f t h e camshaft, push the camshaft back and forth and readthe end play. CamshaftEnd Play: StandardlNewl: 0.05- 0.15mm 10.002- 0.005in) ServiceLimit: 0.5 mm (0.02in) 12. lf camshaft-to-holder oil clearanceis out of tolerance: . A n d t h e c a m s h a f th a s a l r e a d yb e e n r e p l a c e d , you must replacethe cylinderhead. . lf the camshafthas not beenreplaced,first check total runout with the camshaftsuoDortedon Vblocks. CamshaftTotal Runout: Standard (N6w): 0.03 mm (0.001in) max. ServiceLimit 0.04 mm (0.(X)2in)
7 . Unscrewthe camshaftholder bolts two turns at a t i m e , i n a c r i s s c r o s sp a t t e r n ,T h e n r e m o v e t h e camshaftholderboltsfrom the cvlinderhead. 8. L i f t t h e c a m s h a f t so u t o f t h e c y l i n d e rh e a d .w i p e them clean,then inspectthe lift ramps,Replacethe camshaftif any lobes are pitted, scored,or excessivelyworn.
Rotat6camshatt while measuring.
Cleanthe camshaftjournal surfacesin the cylinder head,then set the camshaftback in Dlace.Placea plastigagestrip acrosseachjournal.
1 0 . Installthe camshaftholders.and torquethe boltsto the valuesand in the sequenceshownon page6-31.
-
lf the total runout of the camshaftsis within tolerance,replacethe cylinderhead
-
lf the total runout is out of tolerance,replacethe camshaftsand recheck.lf the oil clearanceis still out of tolerance,replacethe cylinderhead.
NOTE: Do not rotatethe camshaftsduring inspection.
6-22
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Valves,Valve Springs
and ValveSeals Removal 13. Measurethe cam lobe height. Cam Lobe Height Standard (Newl '97 - 98 models: INTAKE: 33.20,1mm(1.3072in) EXHAUST:33.528mm (1.3200inl '99 - 00 models: INTAKE: 33.716mm 11.327t1in) mm (1.3200in) EXHAUST:33.528
l d e n t i f yt h e v a l v e s a n d v a l v e s p r i n g sa s t h e y a r e removedso that eachitem can be reinstalledin its original Dosition. 1.
socketand plasticmallet. Usingan appropriate-sized retainer to loosenthe valvekeeP lightlytap the valve ers beforeinstallingthe valvespringcompressor'
2.
Installthe spring compressor.Compressthe spring and removethe valvekeeper.
Inspectthis arealor wear.
VALVESPRINGCOMPRESSOR KD No. 3&!. whh *'5 JAW o.
VALVESPRINGCOMPRESSOR ATTACHMEUT 07757- PJ1010A (cont'd)
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6-23
Valves,Valve Springs and Valve Seals Removal(cont'dl 3.
Installthe valveguide sealremover.
VALVEGUIDESEALREMOVER LISLEP/N 57900or KD3350or equivalent (Commerciallv available)
Intake Valve Dimensions A Standard{New}: 30.85- 31.15mm B Standard (New): G Standard {Newl: C ServiceLimiti D StandardlNewl: D Service Limit: 4.
Removethe valveseal.
6-24
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- 1.226inl 11.21s - 10/t.10 103.80 mm
{i[.087- 4.098in) 6.580- 6.590mm (0.2591- 0.2594in) 6.55 mm (0.258inl 1.35- 1.65mm (0.053- 0.05s in) 1.15mm (0.045in)
Exhausi Valv€ Dimensions A Standard(Newl: 27.85- 28.15mm 1 1 . 0 9-61 . 1 0 8i n ) B Standard (Newl: 10,1.00- 10,1.30mm (il.09i[- it.l06 in) C Standard {New): 6.550- 6.560mm 10.2579- 0.2583inl C ServiceLimit: 6.52mm (0.257inl D StandardlNewl: 1.65- 1.95mm - 0.077in) 10.065 D Service Limit: 1.45mm (0.057inl
ValveGuides ValveMovement
Replacement
c l e a r a n c ew i t h a d i a l 1 . M e a s u r et h e g u i d e - t o - s t e m in the directionof the stem indicatorwhile rocking normalthrust(wobblemethod),
1.
lntake Valve Stem-to-GuideClearance: Standard(Newl:0.04- 0.10mm (0.002- 0.004in) 0.16mm (0.006in) ServiceLimit
As illustratedbelow, use a commerciallyavailable air-impactvalve guide driver attachmentmodified t o f i t t h e d i a m e t e ro f t h e v a l v e g u i d e s . I n m o s t cases,the same procedurecan be done using the sDecialtool and a conventionalhammer.
VALVEGUIDEDRIVER (Commerciallv available) 6.4 mm
ExhaustValve Stem-to-GuideClearance: Standard{Newl:0.10- 0.16mm (0.004- 0.006inl ServiceLimit: 0,22mm (0.009inl
(0.25inl
_,1-r
I
,_T-_
*]-'
sz mm l2.21inl
l r l '11.3mm (0.{,r in}
or VALVEGUIDEDRIVER, 6.6mm 0t9a:I- G5t01q)
l f t h e m e a s u r e m e net x c e e d st h e s e r v i c el i m i t , recheckusinga new valve. 2.
lf the measurementis now within the servicelimit, reassembleusinga new valve.
3.
stillexceedsthe limit,subtractthe lf the measurement O.D.of the valvestem,measuredwith a micrometer, from the l.D. of the valve guide, measuredwith an insidemicrometeror ballgauge. T a k et h e m e a s u r e m e n tisn t h r e e p l a c e sa l o n g t h e valvestem and three placesinsidethe valveguide The differencebetweenthe largestguide measurem e n t a n d t h e s m a l l e s st t e m m e a s u r e m e nsth o u l d not exceedthe servicelimit. lntake Valve Stem-to-GuideClearance: Standard (New): 0.02- 0.05 mm {0.001- 0.002in) ServiceLimit: 0.08 mm (0.003in)
2.
S e l e c tt h e p r o p e r r e p l a c e m e n gt u i d e s .a n d c h i l l t h e m i n t h e f r e e z e rs e c t i o n o f a r e f r i g e r a t o rf o r aboutan hour.
3.
Use a hot plate or oven to evenlyheat the cylinder headto 300"F(150"C).Monitorthe temperaturewith a cookingthermometer.Do not get the head hofter than 300'F (150"C);excessiveheat may loosenthe valveseaIs.
CAUTION: To avoid burns, uss heavy gloves when handling the heated cylinder head.
ExhaustValve Stem-to-GuideClearance: Standard(New):0.05- 0.08mm (0.002- 0.003in) ServiceLimit: 0.11mm (0.004in) (cont'd)
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6-25
ValveGuides (cont'dl Replacement Workingfrom the camshaftside,use the driver and a n a i r h a m m e rt o d r i v et h e g u i d ea b o u t2 m m ( O . l i n ) t o w a r d s t h e c o m b u s t i o nc h a m b e r .T h i s w i l l k n o c ko f f s o m e o f t h e c a r b o na n d m a k e r e m o v a l easier.Hold the air hammerdirectlyin line with the valveguideto preventdamagingthe driver.
8.
Apply a thin coat of cleanengineoil to the outside of the new valve guide. Installthe guide from the camshaftside of the head; use the specialtool to drive the guide in to the specifiedinstalledheight.lf you have all 16 guidesto do, you mav have to reheatthe head.
CAUTION: Always wear satety goggles or a face shield when driving valve guidss. 5.
Turn the head over and drive the guide out toward the camshaftside of the head.
ATTACHMENT
Valve Guide Installed Height: Intake: 13.75- 1i1.25 mm {0.5,[1- 0.561in) Exhaust:15.75- 16.25mm (0.620- 0.640inl
'o C' 6.
li a valve guide won't move, drill it out with a 8.0 mm (5/16in) bit, then try again.Drittguidesonty in extremecases;you could damagethe cylinderhead if the guide breaks.
7.
Removethe new guide(s)from the freezer,one at a tlme, as you needthem.
6-26
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CylinderHead Reaming
Warpage
NOTE:For new valveguidesonly.
oil clearances(seepageG22) NOTE: lf camshaft-to-holder the head cannot be resurare not within specification, faced.
1. Coatthe reamerand the valveguidewith cuttingoil. 2.
Rotatethe reamer clockwisethe full length of the valveguide bore.
oil clearancesare within specificalf camshaft-to-holder tions, checkthe head for warpage.Measurealong the edges,and threeways acrossthe center.
3.
C o n t i n u et o r o t a t e t h e r e a m e r c l o c k w i s ew h i l e removingit from the bore.
.
4.
Thoroughlywash the guide in detergentand water to removeanYcuttingresidue.
5.
Checkclearancewith a valve(seepage6-25).
6 . Verifythat the valvesslidein the intakeand exhaust valveguideswithout exertingpressure.
if warpage is less than 0.05 mm (0.002in) cylinder headresurfacingis not required lf warpageis between0.05mm (0.002in) and 0.2 mm (0.008in), resurfacecylinderhead. Maximum resurfacelimit is 0.2 mm (0.008in) based on a heightof 132.0mm (5.20in). PRECISION STRAIGHTEDGE
REAMERHANDLE
e
mm vALvE GUIDEREAMER,6.6 0798i1- 657010O
Cylind€r Hesd Height: Standard{New}:131.95- 132.05mm - 5.199inl 15.195
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6-27
Valve Seats Reconditioning lf the guidesare worn (seepage6-25),replacethem (see pagee25) beforereconditioning the valveseats. 1.
5.
Renewthe valve seatsin the cylinderhead using a valve seat cutter.
After resurfacingthe seat, inspect for even valve seating:Apply PrussianBluecompoundto the valve face, and insertthe valve in its original locationin the head,then lift it and snap it closedagainstthe seatseveraltimes. ACTUAL SEATING SURFACE
VALVE SEAT o
PRUSSIAN
The actualvalve seatingsurface,as shown by the bluecompound,shouldbe centeredon the seat. . lf it is too high (closerto the valve stem), you must make a second cut with the 60" cutter to move it down, then one more cut with the 45" cutter to restore seat width. . lf it is too low (closer to the valve edge), you must make a second cut with the 30. cutter to move it up, then one more cut with the 45. cutter to restoreseat width.
o
C a r e f u l l yc u t a 4 5 os e a t , r e m o v i n g o n l y e n o u g h materialtoensurea smoothand concentricseat. Bevelthe upperedge of the seatwith the 30. cutter and the lower edge of the seatwith the 60" cutter. Checkwidth of seatand adjustacco.dingly.
NOTE:The final cut shouldalwavsbe madewith the 45" cutter, 7.
Makeone more very light passwith the 45ocutterto removeany possibleburrs causedbv the other cutters.
Insert the intake and exhaust valves in the head, and measurevalvestem installedheioht. Intake Vslve Siem Instslted Height: Standard {Newl: it0.765- 41.235mm - 1.6234inl 11.6049 SarvicoLimit: itl.il85 mm (1.6333in) ExhaustValve Stem Installed H6ight: Standard {New}: 42.755- €.235 mm 11.61137- 1.7022 inl /(|.,185 ServicoLimit: mm (1.7120in)
Valve Seat Width (lntake and Exhaust): Standard {N.w}: 1.25- 1.55mm (0.049- 0.051in) ServicaLimit: 2.0 mm (0.08in)
f-] VALVESTEM INSTALLEDHEIGHT
8.
6-28
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lf valve stem installed height is over the service limit. replacethe valve and recheck.lf it is still over t h e s e r v i c el i m i t . r e p l a c et h e c y l i n d e r h e a d ;t h e valveseatin the headis too deeo.
Valves,Valve Springsand Valve Seals lnstallation 1.
Installthe valvespring and valve retainer.Placethe end of the valve spring with closely wound coils towardthe cylinderhead,
Coatthe valve stemswith oil. Insertthe valvesinto the valveguides. Checkthat the valvesmove up and down smoothly.
Installthe valve spring compressor.Compressthe spring,and installthe valvekeepers.
Installthe springseatson the cylinderhead.
VALVESPRINGCOMPRESSOR lComm6rciallyavailable) KD No. 383,with *35 JAw or
Installthe valvesealsusingthe specialtool. NOTE:Exhaustand intakevalvesealsare not interchangeable. WHITE SPRING
INTAKE VALVE SEAL
BLACK SPRING
EXHAUSTVALVESEAL VALVEGUIDE SEALINSTALLER lCommerciallyavailable) KO3372or equival€nt ot 07GAD- PH70100
VALVESPRIT{G OOMPfiESSOR ATTACHMENT 0775'- PJ1010A 7.
Lightlytap the end of eachvalve stem two or three times with a plasticmalletto ensureproperseating of the valve and valve keepers,Tap the valve stem only along its axisso you do not bendthe stem.
PLASTE
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6-29
CylinderHead Installation Installthecylinderheadin the reverseorderof removal: 1.
Cleanthe cylinderheadand blocksurfaces.
2.
Cleanthe oil controlorifice.Installthe cylinderhead gasket,dowel pins and the oil controlorificeon the cylinderblock.Always use a new cylinderheadgasket.
CYLII{DER HEAD GASKET R€place.
4.
Tightenthe cylinderhead bolts in two steps.In the first step tighten all bolts, in sequence,to about 29 N.m {3.0kgf.m,22 lbf.ft);in the finat step,tighten in the samesequence to 85 N.m(8.7kgf.m,63lbf.ft). Usea beam-typetorque wrench.When usinga preset-typetorque wrench, be sure to tighten slowly and do not overtighten. lf a bolt makesany noisewhile you are torquing it, loosenthe bolt, and retightenit from the 1ststep.
CYLINDER HEADBOLTSTOROUESEOUENCE:
DOWELPIN
O.RING Roplace. DOWEL PIN
T i g h t e nt h e i n t a k em a n i f o l dm o u n t i n gb o l t s ( s e e page6-21). OIL CONTBOL ORIFICE Clean.
Apply clean engine oil to the bolt threads and under the bolt heads.
6 -30
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Installthe exhaustmanifoldbracket.and tightenthe new self-locking nuts (seepage6-20).
7.
L
Placethe rockerarms on the pivots and the valve s t e m s .P u t t h e r o c k e ra r m s i n t h e i r o r i g i n a lp o s i lrons. lnstallthe camshafts,then installthe oil sealswith the open side (spring)facing in. Make sure that the keywayson the camshaftsare facingup and the No. 1 pistonis at TDC.
'10. lnstallthe camshaftholders. NOTE: o " 1 " o r " E ' m a r k sa r e s t a m p e do n t h e c a m s h a f t holders. . T h e a r r o w s m a r k e d o n t h e c a m s h a f th o l d e r s shouldpoint at the timing belt.
't't, Tighten each bolt in two steps to ensure that the rockersdo not bind on the valves. Wipe off the excessliquid gasketfrom the No. 1 and No. 6 camshaftholderswith a shop towel, Specifiedtorque: 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft) Apply engine oil to the bolt ihreads.
Clean and dry the cylinder head mating surfaces. Apply liquid gasket (P/N 08718- 0001 or 087180OO3) to the head mating surfacesof the No. 1 and N o . 6 c a m s h a f th o l d e r s o n b o t h t h e i n t a k e a n d exhaustside.
I?,ITAKE
No. I
EXHAUST EXHAUST
II{TAKE
Apply liquidgasketto th€ shadedareas.
(cont'd)
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6-31
CylinderHead Installation(cont'dl ' 1 3 .A l i g n
t h e m a r k so n t h e c y l i n d e rh e a d p l u g t o t h e cylinder head upper surface,then installthe cylin d e r h e a dp l u gi n t h e e n d o f t h e c y l i n d e hr e a d .
1 7 . Installthe timing belt (seepage6-11).
CYLINOER HEAD
1 9 . T h o r o u g h l yc l e a nt h e h e a d c o v e r g a s k e ta n d t h e groove.
PLUG Replace.
'18. Adjust the valveclearance(seepage6-3).
lnstall the head cover gasket in the groove of the cylinderhead cover. Seatthe head cover gasketin the recessesfor the camshaftfirst, then work it into the groovearoundthe outsideedges.Makesurethe head cover gasket is seated securely in the corners of the recesses with no gap.
1 4 . lnstallthebackcover.
To set the camshaftsat TDC positionfor the No. l p i s t o n ,a l i g n t h e h o l e s i n t h e c a m s h a f t sw i t h t h e holes in the No. l camshaftholdersand insert 5.0 mm pin punchesin the holes.Installthe keys into the camshaftgrooves. KEYS
I x 1.25mm 37 N m (3.8*gl.m, 27 lbt.tr) 6x1.0mm
9.8N.m(1.0kgtm, 7.2|hrftl Pushthe camshaftpulleysonto the camshafts.then tightenthe retainingboltsto the torquespecified.
6-32
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2 1 . Checkthat the matingsurfacesare cleanand dry. 2 2 . Apply liquid gasket,part No. 08718- 0001or 08718 - 0003,to the headcovergasketat the eight corners of the recesses.
25. Tightenthe nuts in tvvo or three steps.In the final step, tighten all nuts, in sequence.to 9.8 N.m (1.0 kgf.m,7.2 lbf.ft).
NOTE: . Do not installthe parts if five minutesor more h a v e e l a p s e ds i n c e a p p l y i n g l i q u i d g a s k e t . Instead,reapplyliquid gasketafter removingold residue. . After assembly.wait at least 30 minutes before filling the enginewith oil.
to Applyliquidgasket areas. theshaded
26. C h e c kt h a t a l l t u b e s , h o s e s a n d c o n n e c t o r sa r e installedcorrectly.
23. Holdthe headcovergasketin the grooveby placing your fingerson the camshaftholdercontactingsurfaces(top of the semicirclesl. O n c e t h e c y l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r head, slide the cover slightly back and forth to seat the headcovergasket. 24. Inspectthe coverwashers.Replaceany washerthat is damaged or dete(iorated.
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6-33
En g i n eB loc k .............7-2 CylinderBlock SpeciafTools lllustratedlndex ................................... 7-3 Inspection ..............7-13 Flywheeland Drive Plate PistonPins Replacement ..,.,....7-5 Removal ..,.......,,..... 7-14 ConnectingRod and Grankshaft Installation ............. 7-15 E n dP l a y . . . . . . . . . . . . . . . . . 7 - 6 Inspection .............. 7-16 MainBearings ConnectingRods -7 -14 Cfearance ...............7 Selection ................7 ................7-8 PistonRings Selection -17 ConnectingRod Bearings End Gap .................7 Clearance ...............7-8 Ring-to-GrooveClearance............... 7 -17 ................7-9 Replacement .........7-18 Selection Pistonsand Crankshaft Alignment .............. 7-18 Removal .................7-9 CrankshaftOil Seal Crankshaft lnstallation ............. 7-19 Inspection .............. 7-11 Crankshaft Pistons lnstalfation .............7-20 fnspection ..............7-12 Oil Seals fnstaflation .............7-20 fnstalfation ....,..,.....7-23
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tl
SpecialTools
Ref, No.
Tool Numbor
I
o
07GAF- PH60300 07HAF- P120102 07LAB- PV00100 07LAD- PT30101 07LAF- PR30100 07948- S800101 07749- 0010000 07973- PE00310 07973- PE00320 07973- 6570500 07973- 6570600
@ @ /6
@
o
@ @ @ @
Oty
Description
PageReterence
,l
PistonPin Baselnsert PistonBaseHead RingGearHolder SealDriver PilotCollar SealDriverAttachment.76 x 80 mm Driver PistonPin DriverShaft PistonPin DriverHead Piston Base PistonBaseSpring
7-14,15 1-'t4,15 1-5 1-23 7-14,15 7-'t9,24 7 -'t9, 24 1-14,15 7-14,15 7-'t4,15 7-14,15
1 I I 1 1 1 1 1 1 1
eE E g
o
a
@
0 o
7-2
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@
lllustratedlndex
I
Luori""t" "tl internalpartswith engineoil during reassembly.
Applyliquidgasketto the matingsurfacesof the right side coverand oil pump casebeforeinstallingthem. Jse liquidgasket,PartNo. 08718- 0001or 08718- 0003. :lean the oil pan gasketmatingsurfacesbeforeinstallingthe oil pan.
WASHER Replace.
76 x 1.0 mm
y' 9
t:n-
l.zxstm, 8.7lblftl
oIL PAN
to page1-22 when installing OIL PAN GASKET Replace.
1 1 x 1 . 5m m 76 N.m {7.8kgl.m, 56 lbf.ft} Appiyengineoilto the bolt threaos. NOTE:Afterlorquing eachcap,turn the crankshaft to checkfor binding.
n
6x1.0mm 9,8N.m (1,0kgf.m, 7.2 tbt.lrl
BEARINGCAP
BAFFI.f PLATE
OOWELPIN
MAIN BEARINGS page7 8 Selection, NOTE:New main bearingsmust be selectedby matchingthe crank and blockidentification markings.
otL 6 x ' 1 . 0m m 9.8 N.m {1.0kgtm, 7.2 tbf.ftl GASKET Replace.
6x1.0mm 9.8N.m 11.0kgt m,
7.2tbt+tl
CRANKSHAFT OIL SEAL Installation, page7-19 1 2x 1 . 0m m Replace. / , 7 1 N n 1 7. 5 ks{ m 5a lbtft) {a/Tl &it
ln
6
OIL PUMP Overhaul,page8-8 Removal/lnspection, page8-9 Applyliquidgasket to mating surface.
WASHERIA/T}
ORIVEPLATEIA/T) Checkfor cracks. 6x1.0mm 9.8 N.m 11.0kgt.m,7.2lbtft)
8 x 1.25mm
2a N.m(2.akgt.m,---\6/
RIGHTSIDECOVER Apply liquidgasket to matingsurface, CRANIGHAFTSEAL page8-10 Installation, Replace-
6x1.0mm 9.8 N.m l'1.0kgf.m,7.2 lbf.ft)
O.RING Replace.
THRUSTWASHERS Groovedsides face outlvard, NOTE:Thrustwasherthickness is lixed and must not be changed by grindingor shimming.
(cont'd)
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7-3
lllustratedIndex(cont'd) NOTE:New rod bearingsmust be selectedby matchingconnectingrod assemblyand crankshaftidentificationmarkings (seepages7-91. DIRECTION: INSTALLANON PISTON parts with engine oil Lubricateall internal EXHAUST during reassembly.
l1\AAtr\
\9q9Q9e/ INTAKE
PISTON PIN Removal,page7-14 page7-15 Installation, Inspection.page7-16
PISTONRINGS Replacement.page 7-18 page7-17 Measurdment, Alignm€nt,page7-18
PISTON page7-12 Inspection,
ENGINCBLOCK Cylinderbore inspection.pago 7-13 Warpage inspoction,Page7-'13 CONNECTING End play, page 7-6 page7-14 Selection,
COiINECI'ING ROD BEARINGS Clearance,page 7-8 Solection.page7-9
RODBEARINGCAP CONNECTING page7-20 lnstallation, NOTE:Installthe capsso the bearingrecessis on the samesideasthe recess in the rod. RODCAPNUT CONNECTING 8 x 0.75mm 31 N.m {3.2kgl.m. 23 tbf.ftl Apply engine oil to the bolt threads.
NOTE:Aftertorquingeachbearing to checkfor cap,rotatethe crankshaft binding.
7-4
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Inspectthe top ot each cylinder bore for carbonbuild up or a ridge beloreremovingthe piston. page7-10 Removethe ridgeif necessary,
Flywheeland Drive Plate Replacement ManualTransmission: Removethe eight flywheelbolts,then separatethe flyflange.After installation, tightwheelfrom the crankshaft en the bolts in the sequenceshown.
ENGINE BLOCK 12 x 1.0mm 103 N.m 110.5kgf.m, 76 lbf.ft)
RINGGEAR Inspectring gear teethfor wear or damage,
RI G GEARHOTDER 07LAB - PV001|X)
AutomaticTransmission: Removethe eight drive plate bolts, then separatethe drive platefrom the crankshaftflange.After installation, tightenthe bolts in the sequenceshown.
/ AzXi{'jA\Ao
12 x 1.0mm 7a N.m (7.5 kgt.m,5a lbf.ftl
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7-5,
ConnectingRod and Crankshaft EndPlay 1.
Measurethe connectingrod end play with a feeler gauge.
3.
ConnectingRod End Play: Stsndard(Nsw):0.15- 0.30mm {0.006- 0.012in) in) ServiceLimit: 0./t0mm 10.016
2.
SCREWORIVER
lf the connectingrod end play is out-of-tolerance, installa new connectingrod. lf it is still out-of-tolerance, replacethe crankshaft {seepages7-9 and 7-20).
CrankshaftEnd Play: Stand.rd (New):0.10- 0,35mm (0.004- 0.014inl 0.45 mm (0.018inl ServiceLimit: 4.
7-6
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Pushthe crankshaftfirmly away from the dial indic a t o r ,a n d z e r o t h e d i a l a g a i n s t h e e n d o f t h e c r a n k s h a f tT. h e n p u l l t h e c r a n k s h a f ft i r m l y b a c k t o w a r d t h e i n d i c a t o rt;h e d i a l r e a d i n gs h o u l d n o t exceedthe servicelimit.
lf end play is excessive,inspectthe thrust washers Reolaceoans as and thrustsurfaceon the crankshaft. n e c e s s a r yT. h r u s t w a s h e r t h i c k n e s si s f i x e d a n d m u s t n o t b e c h a n g e de i t h e rb y g r i n d i n go r s h i m mrng.
MainBearings Clearance lf the plastigagemeasurestoo wide or too narrow, ( r e m o v et h e e n g i n e i f i t ' s s t i l l i n t h e v e h i c l e ) , removethe crankshaft,and removethe upper half of the bearing.Installa new, completebearingwith the same color code (selectthe color as shown on the next page).and recheckthe clearance,Do not f i l e , s h i m , o r s c r a p et h e b e a r i n g so r t h e c a p s t o adjustthe clearance.
1 . T o c h e c k m a i n b e a r i n g - t o - j o u r n aoli l c l e a r a n c e ,
removethe main capsand bearinghalves. 2.
C l e a ne a c h m a i n j o u r n a l a n d b e a r i n gh a l f w i t h a cleanshoptowel.
3.
Placea strip of plastigageacrosseachmain journal. NOTE:lf the engineis still in the vehiclewhen you b o l t t h e m a i n c a p d o w n t o c h e c kc l e a r a n c et,h e weight of the crankshaftand flywheel will flatten the plastigagefurther than just the torque on the cap bolt, and give you an incorrectreading.For an a c c u r a l er e a d i n g ,s u p p o r t t h e c r a n k w i t h a j a c k underthe counterweights and checkonly one bearI n ga I a I r m e .
4.
7.
lf the plastjgageshows the clearanceis still incorrect,try the ne)dlargeror smallerbearing{the color listedabove or below that one),and checkagain.lf the proper clearancecannot be obtained by using the appropriatelarger or smaller bearings,replace the crankshaftand startover.
R e i n s t a ltlh e b e a r i n g sa n d c a p s ,t h e n t o r q u e t h e bolts, 1st step:25 N'm (2.5kgf.m,18lbf.ft) Final siep: 76 N'm 17.8kgl.m, 56 lbf.ftl NOTE:Do not rotatethe crankshaftduring inspectron. R e m o v et h e b e a r i n gc a p a g a i n ,a n d m e a s u r et h e widestpart of the plastigage. Main Bearing.to.JournalOil Clearance: Stand8.d {New): N o .1 , 2 , 4 , 5 J o u r n s l s : 0.02i1- 0.0i12mm (0.0009- 0.0017inl No. 3 Journal: 0.030- 0.0i18mm (0.0012- 0.0019inl ServiceLimit: 0.06 mm 10.002in)
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7-7
ConnectingRod Bearings
Main Bearings Selection
Clearance
Crankshaft Bore Code Location
1.
Removethe connectingrod cap and bearinghalf. Cleanthe crankshaftrod journal and bearing half with a cleanshop towel.
Lettershave been stamDedon the end of the blockas a codeJorthe sizeof eachof the 5 main journalbores. U s e t h e m , a n d t h e n u m b e r so r b a r s s t a m p e do n t h e crank(codesfor main journalsize),to choosethe correct beanngs. lf the codesare indecipherable becauseof an accumulat i o n o f d i r t a n d d u s t . d o n o t s c r u bt h e m w i t h a w i r e brush or sc.aper.Cleanthem only with solventor detergent.
Placethe plastigageacrossthe rod journal. Reinstallthe bearing half and cap, and torque the nuts. Torqus: 31 N.m (3.2 kgf.m. 23 lbf.ft) NOTE:Do not rotatethe crankshaftduring inspection. Removethe rod cap and bearinghalf,and measure the widestpart of the plastigage. ConnestingRod Bearing-to-JournalOil Clearancc: Standard {Newl: 0.020- 0.038mm {0.0008- 0.0015in) ServiceLimit: 0.05 mm {0.002inl PLASTIGAGE
Main Journ.l Cod. Locrtions lNumbcB oi Bar3l
lf the plastigagemeasurestoo wide or too narrow, removethe upper half of the bearing,installa new. completebearingwith the same color code {select the color as shown on the next page),and recheck the clearance.Do not file, shim, or sc.apethe bearings or the capsto adjustthe clearance.
Bearing ld.ntif icrtion Color code is on the edge of the bearing. I
""""""""
c
D
Smallerbearing(rhicker) Green Green
Elacl
7- 8
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Alue
7.
lf the plastigageshows the clearanceis still incor rect,try the next largeror smallerbearing{thecolor listed above or below that one). and check cleara n c e a g a i n .l f t h e p r o p e rc l e a r a n c ec a n n o t b e obtainedby usingthe appropriatelargeror smaller bearings.replacethe crankshaftand startover.
Pistonsand Crankshaft Selection
Removal
Connecting Rod Code Location
1.
Numbershave been stampedon the side of each connectingrod as a code for the size of the big end. Use lhem, and the lettersstampedon the crankshaft(codes for rod journalsize),to choosethe correctbearings. lf the codesare indeciDherable becauseof an accumulat i o n o f d i r t a n d d u s t ,d o n o t s c r u bt h e m w i t h a w i r e brushor scraper.Cleanthem only with solventor detergent.
Removethe oil pan assembly. Removethe right sidecover.
Half of numberis stampedon beanng cap and the othel half is stampedon rod.
Removethe oil screen. Removethe oil pump. Connecting Rod Journal Code Locations {Lettersl OIL SCREEN
8€aring ldentif ication aolor code is on the edge ol tne Deanng.
Larger big end bore
2 ---------------r.
l l A o r tl l l l B o ' l l l l l c o t r l ll l
I l-.. ilril I
t - l
Smaller 'od
Red
OIL PUMP
4
sma er bearino {thicker)
Pink
Pink
Green
3
Brown
Green Brown Black
Elack
Blue
Green Green Brown
5.
Removethe baffleplate.
Smaller beanng (thicker)
(cont'd)
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7-9
Pistonsand Crankshaft Removal(cont'dl 6.
Removethe bolts.To preventwarpage,unscrewthe b o l t s i n s e q u e n c e1 / 3 t u r n a t a t i m e ; r e p e a tt h e sequenceuntil all boltsare loosened.
9 . Removethe upper bearinghalvesfrom the connecting rods,and set them asidewith their respectivecaps. 1 0 . Reinstallthe main caps and bearingson the engine in properorder. 1 1 . lf you can feel a ridge of metalor hard carbon
around the top of each cvlinder,remove it with a r i d g e r e a m e r .F o l l o w t h e r e a m e rm a n u f a c t u r e r ' s i n s t r u c t i o n sl.f t h e r i d g e i s n o t r e m o v e d ,i t m a y damagethe pistonsas they 8re pushedout.
7.
and main caps/bearRemovethe rod caps/bearings in order ings,Keepall caps/bearings
12. Use the wooden handle of a hammer to drive the pistonsout.
Lift the crankshaftout of the engine.being careful not to damagethe journals.
1 3 . Reinstallthe connectingrod bearingsand capsafter rod assembly. removingeachpiston/connecting 1 4 . To avoid mixup on reassembly,mark each piston/ connectingrod assemblywith its cylindernumber. NOTE:The existingnumber on the connectingrod does not indicateits positionin the engine,it indicatesthe rod bore size.
7-10
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Crankshaft Inspection 1.
Cleanthe crankshaftoil passageswith pipe cleaners or a suitablebrush.
2.
Checkthe keywayand threads.
Out-of-Roundand TaDer 4.
Alignment 3.
M e a s u r et h e r u n o u to n a l l m a i n j o u r n a l st o m a k e sure the crank is not bent. The differencebetween m e a s u r e m e n tosn e a c hj o u r n a lm u s t n o t b e m o r e thanthe servicelimit.
Measureout-of-roundat the middleof each rod and main journal in two places.The differencebetween m e a s u r e m e n tosn e a c hl o u r n a lm u s t n o t b e m o r e than the servicelimit. JournalOut-of-Round: Standard(Newl:0.005mm 10.0002 inl max. ServiceLimit: 0.010mm (0.000i1in)
CrankshaftTotal IndicatedRunout: StandardlNew):0.03mm (0.001in) max. ServiceLimit: 0.04 mm {0.002in)
Measureout-ol' roundat middle. DIAL INDICATOR Rotate two complete revolut|ons.
Measuretaper at edges.
Suppon with lathelype tool or V-blocks.
5.
Measuretaper at the edges of each rod and main journal.The differencebetweenmeasurementson e a c h i o u r n a lm u s t n o t b e m o r e t h a n t h e s e r v i c e limit. JournalTaperi Standard{Newl:0.005mm 10.0002 inl max. ServiceLimit: 0.010mm (0.0004inl
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7-11
Pistons
I
Inspection L
Checkeachpistonfor distortionor cracks. Measurethe pistondiameterat distanceA from the bottom of the skirt. A: '97 - 98 models15 mm 10.5inl '99 - 00 models 20 mm 10.8inl
3.
Calculatethe differencebetweenthe cylinder bore diameter(seepage7-13)and the pistondiameter. Piston-to-CylinderClearance: Standard{New):0.010- 0.040mm {0.0004- 0.0016inl Limit: 0.05 mm {0.002in} Service
Piston Diameter: Standard (New): 8:1.980- txl.990mm (3.3063- 3.3067inl Limit: 83.970 mm {3.3059inl Service
SKIRTDIAMETER
lf the clearanceis near or exceedsthe servicelimit, inspectthe piston and cylinderblock for excessive wear.
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7-12
CylinderBlock Inspection M e a s u r ew e a r a n d t a p e r i n d i r e c t i o n sX a n d Y a t three levelsin eachcylinder.lf the measurements in any cylinderare beyond the ServiceLimjt, replace the block.
2.
Checkthe top of the blockfor warpage. Measurealong the edgesand acrossthe centeras shown.
SURFACESTO BE MEASURED
Engine Block Warpage: Standard(New):0.07mm (0.003in) max. ServiceLimit: 0.10mm {0.004inl
PRECISION STRAIGHTEDGE
CvlinderBole Size: Standard{Newl:84.00- 84.02mm {3.307- 3.308inl ServiceLimit: 84,07mm (3.310inl Bore TaDer: Limit: {Difterencebetween first and third measurement) 0.05mm {0.002in)
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7-13
PistonPins
ConnectingRods
Removal
Selection
1 . Assemble the Piston Pin Tools as shown.
Eachrod falls into one of four toleranceranges(from 0 to + 0.024mm {0 to + 0.0009in). in 0.006mm (0.0002in) increments)dependingon the size of its big end bore. lt's then stampedwith a number 1.1.2,3,or 4) indicating the range. Y o u m a y f i n d a n y c o m b i n a t i o no t 1 , 2 , 3 , o r 4 i n a n y engrne.
PISTONBASEHEAO 07HAF -PL20102 PISTONPIN BASEINSERT 07GAF- PH60300
Normal Bore Size:,18.0mm (1.89in) Inspectthe connectingrod for cracksand heatdamage.
CONNECTINGROD BORE REFENENCE NUMBER Half of numberis stampedon bearingcap, the other half on connectno roo.
PISTONBASE 07973- 6570500
Adjustthe lengthA of the pistonpin dflver. A: 49.70mm 11.957 in) PISTONPINDRIVER HEAI 07973- PE00320
\
R Ir1
nT--u ffi-"""-
PISTONPIN DRIVERSHAFT 07973- PEt0310
u_ll
3.
PILOTCOLLAR 07LAF- PR30100 Embossodmarkfacingup.
Placethe piston on the piston base,and pressthe pin out with a hydraulicpress.Make sure that the recessedportion of the piston aligns with the lips o n t h ec o l l a r .
7-14
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PistonPins lnstallation
The arrow must face the timing belt sideot the engineandthe connecting rod oil hole must face the rearof the engine. ROO CONNECTING
otL Hor.E
1.
Adjust the length B of the piston pin driver and shaft. B: 49.70mm (1.957in)
PISTONPIN DRIVERSHAFT 0t973 - P€qxtlo
ffi*r,"ron'nl PILOT COLLAR OTLAF- PF3O1(x'
PISTONPIN BASEINSERT 07GAF- PH6o3ttO PISTONBASE HEAD OTHAF- PL2O102 PISTON BASE 07973 - 6670500
Placethe piston on the piston base and pressthe p i n i n w i t h a h y d r a u l i cpress. Make sure that the recessedportion of the piston alignswith the lugs on the pistonbasehead.
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7-15
PistonPins Inspection 1.
lMeasurethe diameter of the piston pin.
3.
Piston Pin Diameter: Standard lNewl: 20.996- 21.000 mm
Oversize:
{0.8266- 0.8268in} 20.998- 21.002mm (0.8267- 0.8268in)
pistonpins are oversize. NOIE: All replacement Piston Pin-to-PistonClearance: StandardlNewl: 0.010- 0.017mm - 0.0007in) 10.0004
4.
2.
Zeto the dial indicatorto the pistonpin diameter.
M e a s u r et h e p i s t o np i n t o p i s t o nc l e a r a n c el .f t h e p i s t o n p i n c l e a r a n c ei s g r e a t e rt h a n 0 . 0 2 4m m (0.0009inL remeasureusingan oversizedpistonpin.
Checkthe differencebetlveenthe pistonpin diameter and the connectingrod smallend diameter. Piston Pin-to-ConnectingRod Interference: Standard(New):0.015- 0.032mm (0.0006- 0.0013inl
7-16
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PistonRings Glearance Ring-to-Groove
EndGap 1.
U s i n ga p i s t o n ,p u s h a n e w r i n g i n t o t h e c y l i n d e r bore 15 - 20 mm (0.6 0.8 in) from the bottom
After installinga new set of rings, measurethe ring-togrooveclearances:
2.
M e a s u r et h e p i s t o nr i n g e n d - g a pw i t h a f e e l e r g au g e : . lf the gap is too small,checkto see if you have the properringsfor your engine. . lf the gap is too large,recheckthe cylinderbore '13. diameteragainstthe wear limits on page7
Top Ring Clearance: Standard {New}: 0.055- 0.080mm - 0.0031inl 10.0022 Service Limit: 0.13 mm 10,005inl
PistonRingEnd-Gap: Top Ring Standard(Newl:0.20- 0.30mm - 0.012inl 10.008 ServiceLimit: 0.60 mm {0.024inl SecondRing Standard lNew): 0.i10- 0.55 mm {0.016- 0.022inl ServiceLimit: 0.70mm (0.028in) Oil Ring Standard(Newl:0.20- 0.50mm - 0.020in) 10.008 ServiceLimit: 0.70 mm (0.028in)
Second Ring Clearance: Standard{Newl:0.035- 0.060mm {0.001'l- 0.0024inl Service Limit: 0,13 mm 10.005inl
PISTONRING
--:4
ll ENDGAP-1f-
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7-17
PistonRings Replacement
Alignment
1 . Usinga ring expander,removethe old pistonrings.
l.
2.
Installtheringsas shown.
C l e a n a l l t h e r i n g g r o o v e st h o r o u g h l yw i t h a squared-offbroken ring or a ring gtoove cleaner with a bladeto fit the pistongrooves.
TOP RING
The top ring groove is 1.2 mm (0.042in) wide, rhe secondring groove is 1.2 mm (0.042in) wide, and t h e o i l r i n g g r o o v e i s 2 . 8 m m ( 0 . 1 1i n ) w i d e . F i l e down a bladeif necessary.
'97 - 98 models:
Do not use a wire brush to clean ring lands,or cut ring landsdeeperwith cleaningtool. 3.
I n s t a l lt h e n e w r i n g s i n t h e p r o p e rs e q u e n c ea n d position(shownin the right column).
'99 - O0mod€ls:
l-;
NOTE: lfthe pistonis to be separatedfrom the connectingrod, do not installnew ringsyet.
RING EXPANDER
Piston Ring Dimensions:
|-
T f
B
+-
k
' 1 A Top Ring {standard}: A: 3.1 mm (0.12in) B: 1.2mm 10.05inl SecondRing (standard): A: 3.'1mm (0.f 3 in) B: 1.2mm (0.05in) N O T E : T h e m a n u f a c t u r i n gm a r k s m u s t b e t a c i n g upward.
MARK
ropnrNG+S
z:-\
SECONDRING+
,A-\
o**^o(
€ffi+-sPAcER \zu-\
v
7-18
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CrankshaftOil Seal lnstallation Rotatethe rings in their groovesto make sure they do not bind. Positionthe ring end gaps as shownl
SECONDRINGGAP
1.
The sealmatingsurfaceon the blockshouldbe dry Apply a light coat of oil to the crankshaftand to the l i p o f t h es e a l . Drivethe crankshaftoil seal squarelyinto the right sroecover.
DO NOTpositionany ring gap at piston thrust surfaces,
DRIVER
Appror.90"
Appror. 90' TOP RI.IIGGAP DO NOT position any ring gap in linewith the pistonpin hole.
OIL RING GAP SPACERGAP
lnstallsealwith the part numberside facingout.
OIL RINGGAP
is equalall the way around Confirmthatthe clearance with a feelergauge. - 0.8 mm {0.02- 0.03inl Clearance:0.5
0.5-0.8 mm {O.02 0.03 in)
NOTE| Referto pages7 23 and 8-10for installation of the oil oumDsidecrankshaitoil seal.
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7-19
Pistons
Crankshaft
Installation
Installation
1.
1.
Apply a coat of engine oil to the ring groovesand cylinderbores.
It the crankshaftis alreadyinstalled. 2. Setthe crankshattto BDCfor eachcylinder. 3. Removethe connectingrod caps,and slip shortsec tions of rubber hose over the threadedends of the connectingrod bolts. 4. lnstallthe ring compressor, and checkthat the bearangis securelyin place. 5. Positionthe pistonin the cylinder,and tap it in using t h e w o o d e nh a n d l eo f a h a m m e r .M a i n t a i nd o w n ward force on the ring compressorto preventrings trom expandingbeforeenteringthe cylinderbore. 6. Stop afterthe ring compressorpops free,and check t h e c o n n e c t i n gr o d - t o - c r a n jko u r n a la l i g n m e n t beforepushingpistoninto place. 7. Installthe rod caps with bearings,and torque the
Apply a coat of engineoil to the main bearingsand rod bearings. I n s e r t h e b e a r i n gh a l v e si n t h e c y l i n d e rb l o c ka n d connect|ngrods.
3.
Holdthe crankshaftso the rod journalsfor cylinders N o . 2 a n d N o .3 a r es t r a i g hdt o w n .
4.
Lowerthe crankshaftinto the block,seatingthe rod j o u r n a l si n t o c o n n e c t i n gr o d s N o . 2 a n d N o . 3 . Installthe rod capsand nutsfinger tight.
NUISIO:
31 N.m (3.2kgf.m,23tbf.ft) Apply engineoil to the bolt threads. lf the crankshaft is not installed: 2. Removethe rod caps and bearings,and installthe flng compressor. 3 . P o s i t i o nt h e p i s t o n i n t h e c y l i n d e r ,a n d t a p i t i n u s i n gt h e w o o d e n h a n d l eo f a h a m m e r .M a i n t a i n downwardforce on the ring compressorto prevent rings from expandingbefore enteringthe cylinder oore, 4. Positionall the pistonsat top deadcenter.
5.
6.
The arrow must face the timing belt side of the engine.
CONNECTING ROO OIL HOLE
outward. Rotatethe crankshaftclockwise,and seat the jour n a l s i n t o c o n n e c t i n gr o d s N o . 1 a n d N o . 4 , I n s t a l l the rod caps and nuts finger-tight.Installthe caps s o t h e b e a r i n gr e c e s si s o n t h e s a m e s i d e a s t h e recessanthe rod. C h e c kt h e r o d b e a r i n gc l e a r a n c ew i t h p l a s t i g a g e (seepage7 8). then lorque the capnuts. Torque: 3l N.m 13.2kgf.m, 23 lbt.ftl Apply engine oil to the bolt thleads.
7.
I n s t a ltl h e t h r u s tw a s h e r so n t h e N o . 4 j o u r n a l .
RUBBERHOSES
Line up the mark when installing connecting rod cap.
\\
7 -20
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Coat the thrust washer surtacesand bolt threads with oil. Installthemain bearingcaps. Checkclearancewith plastigage(seepage7-7),then tightenthe bearingcap bolts in 2 steps.
1 0 . Cleanand dry the right sidecover matingsurfaces. 1 1 , Apply liquid gasket,part No. 08718- 0001or 08718 - 0003,evenly to the block mating surfaceof the right side cover and to the innerthreadsof the bolt holes.Installit on the cylind€rblock
25 N.m {2.5 kgf'm, 18 lbf'ft} First slsp: Sscond step: 76 N'm (7.8 kgf'm. 56 lbf'ft) SEOUENCE MAIN BEARINGCAPBOLTSTIGHTENING
RIGHTSIDE
NOTE:Wheneverany crankshaftor connectingrod bearingis replaced,it is necessaryafter reassembly t o r u n t h e e n g i n ea t i d l i n g s p e e du n t i l i t r e a c h e s normaloperatingtemperature,then continueto run 15 minutes. it for approximatelY
6x1.0mm 9.EN.m {1.0 kgt m, 7.2 tbf.ft) OOWELPINS
NOTE: . Do not install the parts if five minutes or more h a v e e l a p s e ds i n c ea p p l y i n gt h e l i q u i d g a s k e t . Instead,reapplyliquid gasketafter removingthe old residue. . After assembly,wait at least 30 minutes before f i l l i n gt h e e n g i n ew i t h o i l .
(cont'dl
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7-21
Crankshaft (cont'd) Installation 1 2 . Apply liquid gasketto the oil pump mating surface of the block. 1 3 . Apply a light coat of oil to the crankshaft,the lip of the seal,and the O-rings.
1 6 . Apply liquid gasketon the oil pump and right side covermatrngareas. CYLINDER BLOCK
1 4 . Apply greaseto the lips of the oil seals.
Apply liquid gasket to these pornts,
Align the innerrotor with the crankshaft, then install the oil pump.When the pump is in place,cleanany excessgreaseoff the crankshaft, then checkthat the oil seallips are not distoned.
Applyliquidg€sket to thesepornts. 17. Installthe oil pan gasketand oil pan. Wait no than five minutesafterapplyingliquidgasket.
{ ^
6x1,0mm 9.8 N.m {1.0 kg{.m, ,.2 tbf.ftl
I
OILPAN
"[z
(..6
/
I
GASKET Replace.
6x1.0mm 9,8 N.m 11.0kg{.m,
7.2lbt.trl
,'t
./o,
DowEL PtN //
O-RING Replace.
OIL PUMP
7 -22
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OIL PAN
| 8 x 1.25mm 24 N.m {2.4 kgf.m, 17 tbt.ftl
GASKET Replace.
Oil Seals lnstallation 18. Tightenthe boltsand nutsfingertight at six points.
1.
Dry the crankshaftoil sealhousing. Apply a light coat of greaseto the crankshsftand to the lips of the seals. Usingthe specialtool, drive in the timing pulley-end sealuntilthe driverbottomsagainstthe oil pump. When the seal is in place,clean any excessgrease off the crankshaftand checkthat the oil seal lip is not distorted,
SEALDRIVER OTLAD- PT3O1OA lnstallsealwiththe partsnumberside facingout.
1 9 . Tighten all bolts and nuts, startingfrom nut O. clocktighteningcan cause wise in three steps.Excessive distortionot the oil pangasketand oil leakage. Torque: 12 N.m (1.2 kgt.m,8.7 lbtft)
(cont'd)
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7-23
Oil Seals (cont'dl Installation 4.
l/easurethe flywheel-endsealthicknessand the oil seal housingdepth.Usingthe specialtool, drive the flywheel end seal into the rear cover to the point where the clearancebetweenthe bottom of the oil seal and the right side cover is 0.5 - 0.8 mm (0.020.03in) (seepage 7-19).Align the hole in the driver attachmentwith the pin on the crankshaft.
<: DRIVER ATTACHMENT 76x80mm 07948- 5800101 I n s t a lsl e a l w i t ht h e n u m b e rs i d ef a c i n g out,
7 -24
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EngineLubrication ...".""'8-2 S p e c i aTf o o l s . . . . . . . . . . .'...8-3 l l l u s t r a t e dI n d e x. . . . . . . . . . . E n g i n eO i l . . . . . . . . . . . . ' . . ' . .8. -' .4. ' Inspection . .-.4. . . . . . . . R e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . . . . . . . . . ' 8 OilFilter R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . .8. .-.5. . . . . . . . . . . Oil PressureSwitch ".....8-7 Testing Oil Pressure ....'.'8-7 Testing OilPump . . . . . . . . . . . , . . . .8. .-.8. . Overhaul..... ....'.'8-9 Removal/lnspection/lnstallation
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SpecialTools
Ret. No.
o
8-2
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I I
Tool Number OTLAD_ PT3O1OA 0 7 9 ' 1-2 6 1 1 0 0 0 1
Description SealDriver Oil FilterWrench
Oty 1 1
i
Pagc Roforance 8-10 8-6
lllustratedIndex
OIL CONTROL ORIFICE
'--
\
/o-RrNG \
,/
\^ O-RING
OILPUMP Overhaul,page8-8 page8 I Removal/lnspection, Apply liquidgasketto matingsurfaceof engineblock.
./
v,/
U
Reptace.
'99 - 00 models: KNOCKSENSOR 31 N.m {3.2 kgf.m.23 lbl.ft)
ENGINEOIL PRESSURE SWITCH 18 N.m {1.8kgtm, 13lbl.ft) 1/8in. BSPT(BritishStandard PipeTaper)28 Threads/inch. Useproperliquidsealant.
DOWELPIN 6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbl.ft)
8 x 1.25mm 24 N.m 12.4kgf.m, 17 tbf.ft)
BAFFLEPLATE
6x1.0mm 9.8 N.rn{1.0kgtm,7.2 lbtftl
OIL PAN GASKET Replace.
Replace.
OILPAN Befertopage7 22 w h e ni n s t a l l i n g .
6x1.0mm 9.8 N.m 11.0kgf m, 7.2 tbf.ftl SCREEN
WASHEB Replace.
6x1.0mm 12 N.m 11.2kglm,8.7 lblftl
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DRAINBOLT 4,1N.m{,1.5kgf'm,33lbf ft) Do not overtighten.
8-3
EngineOil Inspection
Replacement
1 . Parkthe vehicle on level ground, and turn off the e n g i n e .A l l o w t h e o i l a f e w m i n u t e st o d r a i n b a c k into the oil pan so the dipstickwill show the actual levet,
CAUTION:Removethe drain plug caretuly white the engino is hot; the hot oil may causescalding.
2.
2.
Make certainthat the oil level indicatedon the dipstick is betweenthe upper and lower marks.Insert the dipstickcarefullyto avoid bendingit.
1 . W a r mu p t h e e n g i n e . D r a i nt h e e n g i n eo i l .
l f t h e l e v e l h a s d r o p p e dc l o s et o t h e l o w e r m a r k , add oil until it reachesthe uppermark.
ORAINBOL 4il N.m {4.5kgtm,33 lbf.ft) Do not overtighten.
3.
WASHER R€place.
Reinstallthe drain bolt with a new washer,and refill with the recommendedoil. Requirement API ServiceGrade:Use "Energy " SJ "Energy Conserving or Conservingll" SH gradeoil. SAE 5W - 30 preferred:You can also usean oil that bearsthe API CERTIFICATION mark. Capacity
3 . 5{ ( 3 . 7U S q t , 3 . 1l m p q t ) at oil change. 3 . 8/ ( 4 . 0U S q t , 3 . 3l m p q r ) at oil changeincludingfilter. 4.6{ (4.9US qt, 4.0 lmp qt) afterengineoverhaul.
Change Inlerval
Every7,500miles(12,000km) or 12 months(Normalconditions) Every3,750miles(6,000km) or 6 months(Severeconditions).
N O T E : U n d e r n o r m a l c o n d i t i o n s t, h e o i l f i l t e r shouldbe replacedat everyother oil change.Under severeconditions,the oil filter should be replaced a t e a c ho i l c h a n g e .
8-4
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Oil Filter Replacement The numbersin the middle of the API Servicelabeltell you the oil's SAE viscosityor weighl. Selectthe oil for your vehicleaccordingto this chart:
CAUTION: After the engine has been tun, ths exhaust pipes will be hot; be carelul when working around the exhaust manitold.
AmbientTemperature
1 . R e m o v et h e o i l f i l t e r w i t h t h e s p e c i a lo i l f i l t e r wrench. lnsoectthe threadsand rubbersealon the new filter. Wipe off the seaton the engine block,then apply a light coatof oil to the filter rubberseal. 1 0 0F
-30
-20
-10
40c
NOTE:Useonly filterswith a built-inbypasssystem.
Inspect threads and
A n o i l w i t h a v i s c o s i t yo f 5 W - 3 0 i s p r e f e r r e df o r i m p r o v e df u e l e c o n o m ya n d y e a r - r o u n dp r o t e c t i o ni n the vehicle.You may usea 10 W - 30 oil if the climatein your area is limited to the temperaturerangeshown on the chart.
-G oil to rubberseal Deroreinstalling.
API SERVICELABEL
4.
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R u n t h e e n g i n et o r m o r e t h a n three minutes,then checkfor oil leakage.
(cont'd)
8-5
Oil Filter Replacement(cont'd) Installtheoil filter by hand.
Some filtershave eight numbers(1 to 8) printedon the surfaceof the filter.
A f t e r t h e r u b b e r s e a l s e a t s ,t i g h t e n r h e o i l f i l t e r clockwisewith the specialtool.
The followingexplainsthe procedurefor tightening filtersusingthesenumbers.
Tighten: 7/8 turn clockwise Tighteningtorque:22N.m (2.2kgt'm 16lbt.ft)
l) Makea markon the cylinderblockunderthe number that showsat the bottomof the filterwhenthe rubbersealis seated. 2) Tighten the filter by turning it clockwiseseven numbersfrom the makespoint.For example,if a mark is made underthe number2 when the rubber seal is seated,the filter should be tightened untilthe number1 comesup to the markedpoint.
OIL FILTERWRENCH 07912-61 10001
MARK Numberwhen rubber seal is seated.
Numberafter tightening.
N u m b e rw h e n r u b ber sealis seated Numberaftertightening 5.
5 8
1
2
3
4
6 7
IJ
6 7
After installation.fill the engine with oil up to the specifiedlevel,run the enginefor more than three minutes,then checkfor oil leakageand oil level. GAUTION: Installation using other than the above procedurecould result in serious engine damage due to oil leakage.
8-6
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Oil PressureSwitch
Testing
Testing L
Oil Pressure
wire from the engineoil presRemovethe YEL/RED sureswrtcn. Checkfor continuitybetweenthe positiveterminal and the engine{ground).Thereshouldbe continuity with the enginestopped.Thereshould be no continuity with the enginerunning.
lf the oil pressurewarning light stayson with the engine running,checkthe engineoil level.lf the oil levelis correct: L
Connecta tachometer.
2.
Remove the engine oil pressure switch. and install an oil pressure gauge. GAUGE OILPRESSURE ADAPTER (1/8" - 28, BSTP) available) {Commercially (Commercially available)
ENGINE OILPRESSURE SWTTCH MOUNNNG HOt-E
PRESSURE SWTCH 18 N.m {1.8kgf.m, 13 tbr.ftl Apply liquidsealant to the threads,
lf the switch fails to operate,checkthe engine oil level.lf the engineoil level is OK, checkthe engine orl pressure.
Startthe engine.Shut it off immedjatelyif the gauge registersno oil pressure.Repairthe problembefore continuing. 4.
Allow the engineto reachoperatingtemperature(fan comeson at leasttwice).The pressureshouldbe: Engino Oil Temperature:176'F (80'C) Engine Oil Pressure: At ldle: 70 kPa (0.7 kgt/cm', 10 psil minimum Ai 3,000rpm: 3/r0 kPa {3.5 kgt/cm', 50 psi) minimum lf oil pressurein not within specifications,inspectthe oil pump (seepage8-9).
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8-7
Oil Pu mp Overhaul
OUTERROTOR pages8-9,1O Inspection,
6x1.0mm 5 N.m {0.5kgt m. 4lbtft}
DOWELPIN 6xl.0mm 9.8 N m (1.0kg,tm, 7.2 lbf ftl
PUMPCOVER
pages8-9,10 lnspection, Apply liquidgasket to the matingsurfaceof the cylinderblock when anstalling.
REI-IEFVALVE Valvemust slidefreely in the housingbore. Replace the valveif it is scored. 8 x 1.25mm 2{ N.m (2.4 kgf m, 17 tbf.fi)
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8 -8
RemovaUlnspection/lnstallation 1.
1 0 . Removethe screwsfrom the pump housing,then separatethe housingand cover.
D r a i nt h e e n g i n eo i l .
2. Turn the crankshaft,and align the white groove on the crankshaftpulleywith the pointeron the lower cover.
3. Removethe cylinderheadcoverand middlecover. Removethe power steering pump belt, air conditioner belt and the alternatorbelt. 5.
R e m o v et h e c r a n k s h a f tp u l l e y , a n d r e m o v e t h e lowercover.
6.
Removethe timing belt.
7.
Removethe drive pulley.
8.
Removethe oil pan and oil screen.
9.
Removethe oil pump.
l l . Checkthe inner-to-outerrotor radial clearanceon
rotor clearance the pump rotor. lf the inner-to-outer e x c e e d st h e s e r v i c el i m i t . r e p l a c et h e i n n e r a n d outer rotors. lnner Rotor-to Outar Rotor RadialClearance Standard{Newl:0.04- 0.16mm {0.002- 0.006inl ServiceLimit: 0.20 mm (0.008in)
orL PUMP OLRING Replace.
Checkthe housing-to-rotoraxial clearanceon the pump rotor. lf the housing-to-rotoraxial clearance exceedsthe service limit. replacethe set of inner and outer rotorsand/orthe pump housing. Housing-to-RotorAxial Clearance Standard {New): 0.02- 0.07 mm {0.001- 0.003in) So|' ice Limit: 0.15mm (0.006inl
OIL SCREEN
HOUSING
(cont'd)
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8-9
Oil Pump Removal/lnspection/lnstallation(cont'd) 1 3 . Checkthe housing-to-outer rotor radialclearance.lf the housing-to-outer rotor radialclearanceexceeds the servicelimit, reDlacethe set of inner and outer rotorsand/orthe pump housing, Housing-to-OuterRotor RadialClearance StandardlNewl: 0.10- 0.19mm {0.004- 0.007in} ServiceLimit: 0.20 mm {0.008inl
1 7 . R e a s s e m b lteh e o i l p u m p , a p p l y i n gl i q u i dt h r e a d lockto the pump housingscrews. 1 8 . Checkthat the oil pump turnsfreely. 1 9 . Apply a light coatot oil to the seallip.
20. Cleanand dry the oil pump matingsurfaces. 2 1 . Installthe two dowel pins and a new O-ringon the cylinderblock. Apply liquid gasket,part No. 08718-0001 or 087180003,to the cylinderblockmating surfaceof the oil pump. Apply the liquid gasketevenly,in a narrow beadcenteredon the mating surface.Do not apply liquidgasketto the O-ringgrooves. Apply liquid gasketto the inner threadsof the bolt noles. Apply liquid gasket alongthe brokenline.
1 4 . Inspectboth rotorsand the pump housingfor scoring or otherdamage.Replacepans if necessary. 1 5 . Removethe old oil sealfrom the oil pump. PUMPHOUSING
1 6 . Gentlytap in the new crankshaftoil seal until the specialtool bottomson the pump.
NOTE: .
Do not installthe pans if five minutesor more have elapsedsinceapplyingliquid gasket.Instead,reapply liquidgasketafter removingold residue. . After assembly,wait at least30 minutesbetorefilling the enginewith oil.
8-10
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24. Apply greaseto the lip of the oil pump seal. Installthe oil pump onto the crankshaft.When the pump is in place,clean any excessgreaseoff the crankshaftand checkthat the oil seal lip is not distorted. lnstallthe oil screen.
2't. Installthe oil pan {seepage7-22).
8 x 1.25mm 24 N.m 12.4kgf.m, '17tbf.ft)
O-RING Applyengineoil Replace. DOWEL PIN
6x1.0mm 9.8 N.m {1.0kgf.m, 1.2lbfitl
OIL PUMP
6x1.0mm 9.8Nm(1.0kgf.m, 7.2 tbt ft)
6x1.0mm 9.8N.m (1.0kgf.m. 7.2 tbtftl
OIL SCBEEN
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8-11
IntakeManifold/ExhaustSystem IntakeManifold Rep1acement ....................................... 9-2 ExhaustManifold Replacement ....................................... 9-4 ExhaustPipeand Muffler Replacement ....................................... 9-6
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IntakeManifold Replacement NOTE: . Use new O-ringsand gasketswhen reassembling. . Checkfor folds or scratcheson the surfaceof the gasket. . Replacewith a new gasketif damaged. '97 - 98 models: INTAK€ MANIFOLD R e p l a c ei f c r a c k e d o r i f m a t i n g s u r f a c e sa r e oamageo,
INTAKEAIR TEMPERATURE {IATISENSOR 22 N.n 12.2kgl.m, 16 rbf.ftl
8 x 1.25mm 22 N.m 12.2kgtm. 't6 tbf ft)
8 x 1.25mm 22 N.m |.2.2kgl.rn, '16tbt ftl
I x 1 . 2 5m m 24 N m 12.4kgf m. 17 tbf.ft) INTAK BRAC} INTAKEMANIFOLO BRACKETB ('98 modell I x 1.25mm 24 N.m 12.4kgf.m, 17 tbf.ft)
8 x 1.25mm 24 N.m (2.4kgf.m, 17 tbf.ft)
9-2
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8 x 1.25mm 23 N m (2.3kgt m, 17 tbf.ftl
'99 - O0modol3: 6x1.0mm 9.8 N.m 11.0kg{.m, 7.2 tbtltl
NESONATOR
6x1.0mm 9.8 N.m {1.0 kgf.m, 7.2 rbr.ftt RESONATOR CHAMBER BRACKET
O-RING Replace. Applyoil to O-RING betoreinstalling.
GASKET Replace.
IATSENSOR 2:2N.ml2.2kgl.n, 16tbtftl
l ("\"-\
W\qu N,1\J
K\*}Gt
u
'n\ .a,,-\\J " \ G)s INTAKEMANIFOLD Replaceit crackedor if matingsurfacesare oamageo.
O.RING Replace.
O.RING Replace. 8 x 1.25mm 22 N.m 12.2kgl.m, 16 rbf.ftt
IAC VALVE 8 x 1.25mm 23 N.m (2.3 kgf.m, 17 tbf.ft, 8 x 1.25mm 24 N.m 12.4kgt m, 17 tbt frl INTAKEMANIFOLD
22 N.m 12,2kgl.m, 16 rbfftl
BRACKET
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9-3
ExhaustManifold Replacement NOTE: . Use new gasketsand self-lockingnutswhen reassembling. . Checkfor folds or scratcheson the surfaceof the gasket. . Replacewith a new gasketif damaged. '97 - 98 U.S. models (Calilornia):
8 x 1.25mm 31 N.m (3.2kgf.m, 23 lbtft) Replace. I x 1.25mm 24 N.m (2.4kgl.m, 1? tbf.ft) 8 x 1.25mm 24 N.m (2.i1kgt.m, 17 lbf.ftl
NN
EXHAUST MANIFOLO 10 x 1.25mm 44 N.m 14.5kgf.m, 33 lbf.ft) NUT SELF.LOCKING 8 x 1.25mm 31 N m 13.2kgt.m, 23 lbt'ft) Replace.
EXHAUSTMANIFOLD BRACKET 10 x 1.25mm 44Nm{4.5kg{.m. 33 lbf.ftl
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9-4
'97 - 98 U.S. models {ExceptCalifornia): '99 - 00 models:
8 x '1.25mm 31 N.m {3.2kgl.m,23lbl.ft) Beplace. COVER
(v/\
NL-] \\ r-------. 'r \\'
\F= \\/ ,l 8 x 1.25mm 31 N.m {3.2 kgf.m.23 lbf.ft) Replace.
MANIFOLD BRACKET 6x1.0mm 9.8 N m 11.0kgf.m, 7.2 lbf.ft) 44 N.m {4.5kgf.m, 33 lbtftl
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9-5
ExhaustPipeand Muffler Replacement NOTE:Use new gasketsand self-lockingnutswhen reassembling. €7 - 98 U.S. models (Calitornial:
MUFFLER
GASKET Replace.
NUT SELF.LOCKING I x 1.25mm 22 N.m (2.2 kg{.m, 16lbt'ftl Replace. Tightenthe nuts in stePs, alternatingside-to-side.
NUT SELF.LOCKING 10 x 1.25mm 33 N.m {3.4kgt m, 24 lbl.ft) Replace.
SECONDARY HO2S 4il N.m lil.5 kgtm, 33 tbf.ft)
PRIMARYHO2S 44 N.m {{.5 kgl.m, 33 tbt.ft)
GASKET Replace.
S*S:--t-..-_ TWC Inspection, seesection1 l GASKET Replace.
EXHAUST PIPEA
NUT 10 x 1.25mm 54 N.m 15.5kgi.m,40lbf'tt) Replace.
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NUT SELF.LOCKING 8 x 1.25mm 16 N.m {1.6kgt.m, 12 tbt fr) Replace.
NUT SELF.LOCKING 8 x 1.25mm 22 N.m (2.2 kgf.m, r 6 tbt.ft) Replace. Tightenthe nuts in steps,a'ternating side-to-side.
6x1.0mm 9.8N.m (1.0kgf.m, 7.2 tbt.ltl
'97 - 98 U.S. models (ExceptCalifornial: '99 - 00 models:
GASKET Replace.
MUFFLER
SELF.LOCKING NUT 8 x 1.25mm 22 N.m (2.2kgf.m, 16 lbl.ft) Replace. Tightenthe nuts in steps, alternatingsideto side.
NUT SELF.LOCXING l0 x 1.25mm 33 N.m 13.4kgl.m, 24 lbtft) Replace.
SECONDARY HEATED OXYGENSENSOR HO2SI {SECONDARY 4il N.m 14.5kgl.m, 33 tbf.ftl
PRIMABYHEATED OXYGENSENSOR (PRTMARY HO2S) 44 N.m (4.5 kgf.m, 33 tbf.ftl
THREEWAYCATALYTIC (TWCI CONVERTER
GASKETS Replace.
NUT 10x 1.25mm 5a N.m (5.5kgl.m,40 lbf ftl Replace.
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l n s p e c t i o n ,s e e s e c t i o n 1 1
SELF-LOCKING NUT 8 x 1.25mm 16 N.m 11.6kgf.m, 12 tbf.ftt Replace.
NUT SELF.LOCKING 8 x 1.25mm 22 N,m 12,2kgi'm, 16 tbf.ftl Replace. Tightenthe nuts in steps,alternating side-to-sade.
x 1.0mm 9.8 N.m {1.0kgf.m, 7.2 rbf.ft)
Cooling ff f u s t r a t e dI n d e x. . . . . . . . . . . . . . . .1 O - 2 Radiator R e p | a c e m e n.t. . . . . . . . . . , . . . . , . . . . . . . . . . . .1. 0 . .-. 4. . . . . . EngineCoolantRefillingand Bleeding . . , . , . . . . . . . . . . . .1. .0.-. 5 . C a pT e s t i n g . . . . . . . . . . . . . . .1. .0. .-.7 Testing ......10-7 Thermostat R e p | a c e m e n.t. . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 0 . .-. 8. . . . . . Testing ......10-9 Water Pump l l l u s t r a t e dl n d e x . . . . , . . . . . .. 10-10 Inspection . 10-11 R e p l a c e m e n.t. . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 0 . .-. 1.1. . , . . FanGontrol ComponentLocationIndex ............... 10-12 C i r c u i tD i a g r a m . . . . . . . . . .1 . .0. - 1 3 FanMotor Testing .........10-14 RadiatorFanSwitch Testing ............. 10-14 CoolantTemperatureGauge G a u g eT e s t i n g . . . . . . . . . . . .1. .0.- 1 5 CoolanttemperatureSending UnitTesting . . . . . . . . , . . . .1.0. .- 1 5
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lllustratedIndex
CAUTION:The system is under high pressurewhen the engineis hot. To avoid dangerol releasingscaldingengine coolant,removethe cap only when the engineis cool. Total Cooling System Capacityfincluding 0.6 I (0.63 US qt, 0.53 lmp qt) for heater and reservoirl: A/T: 5.9{ {6.2US qt, 5.2 lmp qt) M/T: 6.0f (6.3US $, 5.3 lmp qt) 6x1.0mm 9.8 N.m 11.0kgf.m. 1.2 tbl.ftl
l f a n y e n g i n ec o o l a n ts p i l l so n t h e paintedportionsof the body, rinse it off immediately. C h e c k a l l c o o l i n g s y s t e m h o s e s f o r d a m a g e ,l e a k so r deterioration and replace if necessar,. Check all hose clamps and retighten if necessary.
RADIATOR Enginecoolantrefillingand bleeding, page10-5 Leaktest,page10 7 Inspectsolderedjointsand seamsfor leaks. Blow out din from between corefins with compressed air. lf insects,etc.,are clogging radiator,wash them off with RADIATORCAP low pressurewater. Pressuretest, page 10-7
ATF COOLER HOSE Relerto section14 when installing. LOWER
cusHroN
FAN MOTOR 6x1.0mm 7 N.m (0.7kgf.m, 5 lbf ftl
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10-2
EngineHoseConnections:
FASTIDLETHERMO VALVE(A/T onlyl IDLEAIR CONTROL IIAC}VALVE
TEF BYPASS HOSE
THERMOSTAT HOUSING
CONNECTING PIPE
VALVE
HOSES
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10-3
Radiator Replacement 1.
D r a i nt h e e n g i n ec o o l a n t .
5.
R e m o v et h e f a n s h r o u da s s e m b l i easn d o t h e rp a r t s from the radiator.
2.
R e m o v et h e u p p e r a n d l o w e r r a d i a t o rh o s e s ,a n d ATFcoolerhoses.
6.
lnstallthe radiatorin the reverseorderof removal.
3.
Disconnect the fan motor connector.
4.
Removethe radiatorupper bracket,then pull up the raotalor, 6x1.0mm 9.8 N.m 11.0kgf.m, 7.2 tbl.trl
NOTE: . Setthe upperand lower cushionssecurely. . Fillthe radiatorwith enginecooiantand bleedthe air.
RADIATORCAP RADIATOR
6x1.0mm 7 N.m (0.?kgd.m,5 lbl.ftl UPPERMDIATOR HOSE
rriItriiii Relerto section14 when installing. LOWERCUSHION CONDENSER FAN,/SHROUD ASSEMBLY
DRAINPLUG
RADIATOR ASSEMBLY
6x1.0mm 7 N.|n 10.7kgt.m, 5 tbt.ftl
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10-4
LOWER
TOR HOSE
EngineCoolantRefillingand Bleeding 1.
Slidethe heaterlemperaturecontrol lever to maxi mum heat. Make sure the engine and radiatorare cooi to the touch.
2.
Removethe radiatorcaP.
3.
L o o s e nt h e d r a i np l u g ,a n dd r a i nt h e c o o l a n t .
Apply liquid gasketto the drain bolt threads,then reinstallthe bolt with a new washer and tighten it securely. 6.
Tightenthe radiatordrain plug securely.
7.
Remove,drain and reinstallthe reservoir'Fill the tank halfwayto the MAX mark with water,then up to the MAX markwith antitreeze.
DRAINPLUG
4.
Removethe drainbolt from the cylinderblock.
DRAINBOLT 78 N.m {8.0ksl.m, 58 lbtft}
(cont'd)
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10-5
Radiator EngineCoolantRefillingand Bleeding(cont'dl M i x t h e r e c o m m e n d e da n t i f r e e z ew i t h a n e q u a l amountof water in a cleancontainer. NOTE: . Always use GenuineHonda Antifreeze/Coolant. Using a non-Hondacoolantcan result in corros\on, ca\rsng t\e coo\\ng sys\em \o ma\lunct\on o. fail. For best corrosion protection,the coolant conc e n t r a t i o nm u s t b e m a i n t a i n e dy e a r - r o u n da t 50% minimum.Coolantconcentrations lessthan 50%may not providesufficientprotectionagainst c o r r o s i o no r f r e e z i n g .C o o l a n tc o n c e n t r a t i o n s greaterthan 60% will impair cooling efficiency and are not recommended. Do not use additionalrust inhibitorsor anti-rust products;they may not be compatiblewith the coolant.
9. Pour coolantinto the radiatoruD to the baseof the filler neck.When pouringenginecoolant.do not let coolantspill on any electricalpans or the paint. lf any coolantspills,rinseit oft immediately.
Engine Coolant Refill CapacityIincluding 0.6 / 10.63 US $, 0.53 lmp qtl for hoater and ressrvoirl: A/T: 3.9 f {4.1 US $, 3.4 lmp qtl M/T: 1.Ot 14.2US $, 3.5 lmp qrl
1 0 . Startthe engine,and let it run until it warms up (the radiator fan comes on at leasttwice). 1 1 .Turn off the engine.Checkthe level in the radiator, add coolantif needed. 1 2 . Put the radiatorcap on tightly.then run the engine againand checkfor leaks.
10-6
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Testing
CapTesting 1.
Removethe radiatorcap, wet its seal with engine coolant,then installit on the pressuretester.
2.
Applya pressureof 93 - 123kPa(0.95- 1.25kgflcm' , 1 4- 1 8p s i ) .
3.
1.
Wait until the engineis cool, then carefullyremove t h e r a d i a t o rc a p a n d f i l l t h e r a d i a t o rw i t h e n g i n e c o o l a ntto t h e t o p o I t h e f i l l e rn e c k .
2.
Attachthe pressuretesterto the radiator,and apply a pressureof 93 - 123kPa (0.95- 1,25kgf/cm' ,14 1 8p s i ) .
3.
Inspectfor enginecoolantleaksand a drop in pressure.
4.
Removethe tester,and reinstallthe radiatorcap.
5.
t n d / o rc o o l a n it n C h e c kf o r e n g i n eo i l i n t h e c o o l a n a t h e e n g i n eo i l .
Checkfor a drop in pressure. lf the pressuredrops,repiacethe cap.
TESTER RADIATORPNESSURE available) lCommercially RADIATOR
RAOIATOR PRESSURE TESTER (Commercially available) ADAPTOR (for 32 mm neck, low profile)
ADAPTOR (for 32 mm neck,low Profile)
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10-7
Thermostat Replacement
THERMOSTAT HOUSING
RUBBERSEAL Replace. THERMOSTAT COVER
THERMOSTA Installwith pin up.
RADIATOBFAN
swtTcH 24 N.m {2.4kgtm, l7 lbt.ftl
10-8
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6 x '1.0mm 12 N.m (1.2kgl.m, 8.7 tbtftl
Testing Replacethe thermostatif it is open at room temperature. To test a closedthermostat: 1.
Suspendthe thermostatin a containerof water. Do not let the thermometertouch the bottom of the hot container.
THERMOMETER
THERMOSTAT
Heat the water, and checkthe temperaturewith a thermometer.Checkthe temperatureat which the thermostatfirst opens,and at which it is fully open. Measurethe lift heightof the thermostatwhen fully open. STANDARDTHERMOSTAT above8.0 mm (0.31in) Lift height: 169- 176'F(76- 80'C) opening: Starts 194'F(90'C) Fullyopen:
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10-9
Water Pump lllustrated Index
ENGINECOOLANT TEMPERATURE IECTI SENSOR 18 N.m 11,8kgt.m,
13tbt.ftl COOLANT TEMPERATURE GAUGE UNIT 9 N.m {0.3kgf.m, 7 tbf.ftt Applyliquidgasket to the threads. 6x1.0mm 9.8 N'm (1.0 kgf.m, 7.2 tbt frl
WATEROUTLET COVER Apply liquidgaskerpart No. - 0001or 08718- 0003 087'18 to the mating surface.
RADIATORFAN SWITCH 2il N.m (2.i1kgl.m, 17 tbfft)
WATERPUMP page10-11 lnspection,
O-RING Replac€.
CONNECTING PIPE
6x1.0mm 12 N.m 11.2kgf.m, 8.7 tbtftl
10-10
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6xl,0mm 12N.tnn.2 lgl.rn, 8.7 tbf'ft)
Replacement
Inspection 1.
Removethe timing belt (seesection6)
1.
Removethe timing belt (seesection6).
2.
Turn the water pump pulley counterclockwise. Checkthat it turnsfreely.
2.
Removethe water pump by removingfive bolts
3,
Inspect,repairand cleanthe O-ringgroove and the matingsurfacewith the cylinderblock.
Checkfor signsof sealleakage. NOTE:A smallamountol holeis normal.
"weeping"from the bleed
-
@-
II
Replace.
6x1.0mm 't2 N.m 112 kgf m. 8.7 tbf.ftl 4.
lnstall the water pump in the reverse order of removal.
BIIED HOLE
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1 0 - 11
FanControl ComponentLocationIndex
ftflEffltrl
t lrt
UNDEB.HOOD FUSE/RELAY BOX
r-1 a-l
@u!lfl]l
RADIATORFAN RELAY Test,seesection23
BADIATORFAN Removal,page 10-10 Test, page 10-14
BADIATORFAN MOTOR Removal, page 10-2
CONDENSER FAN MOTOR
10-1 2
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CircuitDiagram
IGNITIONSWITCH No.41{100A) N0.42140A)
UNDER OASH FUSEiRELAY BOX
6;\ E;';l wHTsLka rtF',*",El-l I
IL^,^,.,
BLK/RED
T*' I B LK
I
I
oro,
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RAOIATOR FAN SWITCH f C l o s e d: A b o v e ) { 9 3 0 CJ) L 199oF
FanControl FanMotor Testing
Radiator Fan Switch Testing
1 . D i s c o n n e ct ht e 2 Pc o n n e c t o r .
Removingthe radiator fan switch while E@ the engine is hot can causethe coolant to spray out, seriously scalding you. Always let the enginc and radiator cool down before removing the radiator fan switch.
RADIATORFAN MOTOR
Terminalside of maleterminals Test the motor by connectingbatterypower to the N o .2 t e r m i n aal n d g r o u n dt o t h e N o . 1 t e r m i n a l . lf the motor fails to run or does not run smoothly, reptacert.
1.
Removethe radiatorfan switchfrom the thermostat housing(seepage10 '10).
2.
S u s p e n dt h e r a d i a t o rf a n s w i t c h i n a c o n t a i n e ro f water as shown.
Heat the water, and checkthe temperaturewith a thermometer.Do not let the thermometertouch the bottomof the hot container. Measurethe continuitybetweenthe A and B terminalsaccordingto the table. Terminal
\
Tr"ip".a*" \.
op".*i-
196- 203"F {91- 95.C) 5 - 14"F(3 - 8.C) SWITCH lower than the temOFF p e r a t ur e w h e n i t goeson ON
B o- --o
Bleedthe air from the coolingsystemafterinstalling the radiatorfan switch(seepage10-5).
10-1 4
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Gauge GoolantTemperature GaugeTesting
CoolantTemperatureSendingUnit
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 beforetestin9.
1.
2.
Testing
Make sure the ignition switch is OFF,then disconnect the YEL/GRNwire from the coolant temperat u r es e n d i n gu n i t .a n dg r o u n di t w i t h a j u m p e rw i r e .
the YEUGRNwire from the coolanttem Disconnect peraturesendingunit. COOLANTTEMPERATURE
COOLANTTEMPERATURE
POSITIVE TERMINAL
WIRE YEL/GRN (Covered with insulation) YEL/GRN WIRE 2. T u r n t h e i g n i t i o ns w i t c hO N { l l ) .C h e c kt h a t t h e p o i n t e ro f t h e c o o l a n tt e m p e r a t u r eg a u g e s t a r t s " H " m a r k .T u r n t h e i g n i t i o n movingtoward the "H" on the switch OFF beforethe pointer reaches g a u g ed i a l .F a i l u r e t o d o s o m a y d a m a g et h e g a u g e . l f t h e p o i n t e ro f t h e g a u g e d o e s n o t m o v e a t a l l , wire. checkfor an open in the YEL/GRN 5.
lf the wires are OK, replacethe coolanttemperature gauge. l f t h e c o o l a n tt e m p e r a t u r eg a u g ew o r k s ,t e s t t h e coolanttemperaturesendingunit.
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3.
Using an ohmmeter,measurethe change in resistance betweenthe positiveterminaland the engine ( g r o u n dw ) i t h t h e e n g i n ec o l d a n d w i t h t h e e n g i n e at operatingtemPerature. 1A5- 212F
Temperature
133.F(56'C)
(8s- 100'c)
Resistance (0)
137
46-30
lf the readingsare substantiallydifferentfrom the speciticationsabove, inspectthe coolant level and t h e c o o l i n gs y s t e m .l f t h e c o o l i n g s y s t e m i s O K , replacethe sendingunit.
10-15
Fueland Emissions ...................... 11-2 SpecialTools Component Locations . . . . , . .1. .1 - 3 l n d e x. . . . . . . . . . . . . . . . . . . . . . Svstem Description V a c u u mC o n n e c t i o n .s. . . . . . . . . . , . . . . , . , . . . . . .1.1. .-.9. . . . . . . . .5. . . . . E l e c t r i c aClo n n e c t i o n.s. . . . . . . . . . . . . . . . . . . . . . . 1. .1. -. 1 S y s t e mC o n n e c t o r .s, . , , . , . . . . . . . . . . . . . . . . . . . .1.1. .-.3. .6. . , . , . Troubleshooting T r o u b l e s h o o t i nPgr o c e d u r e s , . , . . . . . . . . . . . .1. .1. -. .6. 0. . . Conttol EngineControlModule/Powertrain 11-67 ModuleTerminalArrangement.............., 1t-75 DiagnosticTroubleCodeChart .................... I 1-79 How to ReadFlowcharts.......,.....,.,...............
PGM-FlSystem 11-80 SystemDescription.................,.,.,,,............... Flowcharts Troubleshooting EngineControlModule/Powertrain ........11-52 ControlModule 11-90 ManifoldAbsolutePressureSensor............. 11-95 IntakeAir TemperatureSensor .................... 11-99 EngineCoolantTemperatureSensor.,..,.,.... I 1'103 ThrottlePositionSensor ...........,.....,.,.,..,...... PrimaryHeatedOrygenSensor(Sensor1) ... 11-110 SecondaryHeatedOxygen Sensor . . . . . . . . . . . . .1. 1 . .-.1. 1 7 { S e n s o2r l 11-121 HeatedOxygenSensorHeater ..................... ......11-124 FuefSupplySystem 11-126 ,....,.,..... RandomMisfire 11-128 MistireDetectedin One Cylinder .....-........... . . . . . . . . . . . .1. 1 . .-. 1 3 0 K n o c kS e n s o r C K P / T D C / C YSPe n s o r. . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .-.1. .3. .1. . . .... V e h i c l eS p e e dS e n s o r. . . . . . . . . . . . . . . . . . . . . . . . .1.1. .-.1. .3, 5 11-137 BarometricPressureSensor .....,...,...,.,,........ 11-138 ElectricalLoadDetector...,.,.......................... '11-112 ................,.,, CKFSensor 11'117 ECM/PCMlnternafCircuit ............................. .,.,.,.11-148 HO2SReplacement
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ldle Control System ............ 11-149 SystemDescription TroubleshootingFlowcharts ......11-150 ldle ControlSystem 11-152 fdleAir ControlValve ......................,............. A i r C o n d i t i o n i nSgi g n a l. . . . . . . . . . . . . . . . . . . . . . .I. 1. .-.1. .5. .5. . . .5. .9. . . . A l t e r n a t oFr RS i g n a l. . . . . . . . . . . . . . . . . . . . . . . . . . 1. .1. -. 1 t l-161 StarterSwitch Si9na1.................................... PowerSteeringPressureSwitch Signal......11-162 . .6. . . . B r a k eS w i t c hS i 9 n a 1. . . . . . . . . . . . . . . . . . . . . . . . . .1. .1. .-.1. 6 . .6, .8, . , . F a s tl d l eT h e r m oV a l v e. , . , . . . . . . . . . . . . . . . . . . . . . . .1. .1. -. 1 .............. 11-169 ldle speed setting
FuelSupply System . . . . . . . . . . . . . . . . . . . .1. 1. .-.1. .7. .1 F u e lL i n e s 11-175 Fittings..................... FuefTube/Ouick-Conneci ............ 11-178 SystemDescription . . . . . . . . . . . . . . . .1. 1 . .-.1. .7 8 F u e lP r e s s u r g ................,..... 11-179 FuelIniectors , .1. . . , e e 9 u 1 a t o. r. . . . . . . . . . . . . . . . . . . . . . . . .f .1. .- ,1. 8 F u e lP r e s s u rR ....,.,.,.,,,,.,............11-142 FuefFifter . . . . . . . . . . . . . . . . . . .1. .1. -. .1.8. .3 F u e lP u m p . . . . . . . . . . . . . . . . . . 1. .1. .-.1. .8.4 F u e lG a u g e . .8. .5. . . F u e lG a u g eS e n d i n gU n i t . . . . . . . . . . . . . . . . . . . . . . . .I. .1. -. 1 11-185 Low FuelIndicatorSystem ...........,.,..,............... . . . . . . . . . .1. .1.- 1 8 7 P G M - FM I a i nR e l a y . . . . . . . . . .1. .1.- 1 9 1 Fue|Tank................
IntakeAir System SystemDescription AirCleanel ThrottleCable T h r o t t l eB o d y . . . . . . . .
............ 11-193 , . , . , . . . . . . . . . . . . . 1. .1. .-.1. .9.4 ..................... 11-194 . . . . . . . . . . 1. .1. .- 1 9 6
EmissionControl System ...,....,.,. 11-199 SystemD$cription 11-199 ............... TailpipeEmission 11-199 ThreeWay CatalyticConverter..................,.,...,, 11-2O1 PositiveCrankcaseVentilationSystem .,.,,,,.,.., 11-203 EvaporativeEmissionControls.........,.,.,............
SpecialTools SpecialTools Tool Number
Ref.No.
q t3' , 3 ) l
6
r
I
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11-2
l
Description
Oty
A 9 7 3 X _ 0 4 1_ X X X X X
V a c u u mP u m p / G a u g e -, 03 0 i n . H g
07JAZ 0010008 07PAZ, 0010100
Vacuum/Pressure Gauge,0 4 in.Hg SCSServiceConnector
1 1
07sAz - 001000A 07405- 0040001
BackprobeSet FuelPressureGauge
2 1
PageReference '11-201 . 208,214, 2 1 5 , 2 ' t 6 , 2 1, 27 2 0 , 221, 222,223,224 11 207, 224 11-60,83,88, 1 16, 128,200,205 11-62 1 1 - 1 7 81 ,8 1
ComponentLocations lndex '97 - 98 models:
MANIFOLDABSOLUTE PRESSURE IMAP} SENSOR Troubleshooting, Page11-90 THROTTLEPOSITION(TP} SENSOR page11-103 Troubleshooting,
toLEAtRCONTROL llAcl VAI-VE page11-152 Troubleshooting,
INTAKEAIRTEMPERATURE IIATISENSOR page1'l-95 Troubleshooting.
EMISSION(EVAP) EVAPORATIVE CONTROLCANISTERVENT SHUT VALVE t'98 mod€ll page11'213 Troubleshooting,
POWERSTEERINGPRESSURE
ELECTRICAL LOAD DETECTOR IELD)(USA modol) page11-138 Troubleshooting,
lPsPlswtrcH page11-162 Troubloshooting,
VEHICLESPEED SENSOR(VSS) Troubleshooting, p a g e1 1 ' 1 3 5
CRANKSHAFT POSTTtON/ TOP OEADCENTER/ CYLINDER POStTtON SENSOR {CKP/TDC/CYP} (Builtinto the distributor) page1l-131 Troubleshooting, ENGINECOOLANT TEMPERATURE IECTISENSOR page11 99 Troubleshooting,
CMNKSHAFT SPEED FLUCTUATION ICKF}SENSOR page1'!-142 Troubleshooting.
EVAPORATIVE I€VAP)PURGECONTROL SOLENOIDVALVE Troubfeshooting,page 11'2o5,213
(cont'd)
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11-3
ComponentLocations Index (cont'dl 39 - 00 models: MANIFOLDABSOLUTE PRESSURE IMAPISENSOR page11-90 Troubleshooting, THROTTLEPOSITION{TP) SENSOR page11-103 Troubleshooting,
IDLEAIR CONTROLOACIVALVE page11-152 Troubleshooting, EVAPORATIVE EMISSION (EVAPIPURGECONTROISOLENOIDVALVE page11-2'13 Troubleshootang,
EVAPOBATIVE EMISSION{EVAPI CONTROLCANISTERVENTSHUT VALVE page11-213 Troubleshooting,
INTAKEAIR TEMPERATURE (IAT)SENSOR page11 95 Troubleshooting,
ELECTRICAL LOAO OETECTOR {ELD)IUSA modet) Troubleshooting, page I 1-138
POWEBSTEERING PRESSURE tPsPtswtTcH page11162 Troubleshooting,
VEHICLESPEED SENSORIVSSI Troubleshooting, p a g e1 1 ' 1 3 5
CRANKSHAFT POSTTTON/ TOP OEADCENTER/ CYLINDER POStTtON SENSOR {CKP/TDC/CYP) (Builtinto the distributor) page11 131 Troubleshooting, ENGINECOOLANT TEMPERATURE {ECT)SENSOR Troubleshooting, page11 99
11-4
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CRANKSHAFT SPEED FLUCTUATION ICKN SENSOR page11-142 Troubleshooting, SENSOR page'11130 Troubleshooting,
DATA LINKCONNECTOR {DLC)I16P} page11'60 Troubleshooting Procedures, PRIMARYHEATEDOXYGENSENSOR 1) HO2SI{SENSOR {PRIMARY page11 110 Troubleshooling,
PGM-FI MAIN RELAY RelayTesting,page11-l87 Troubleshooting. page1'1188
,a'=_-_
WAY CATALYTIC HEATEDOXYGEN SECONDARY SENSOR HO2S){SENSOR2) {SECONDARY page11-117 Troubleshooting, '97 - 98 models: AIR CLEANER page11'194 Replacement,
SERVICECHECKCONNECTOR {2PI page11-60 Troubleshooting Procedures,
page1'l-200 Troubleshooting,
POWERTRAIN CONTROLMODULE (PCM)(A/TI page11-60 Troubleshooting Procedures, page11'82 Troubleshooting.
THROTTLEBODY(TB) page11 196 Inspection, Removal,page11-197 page11-'198 Disassembly,
THROTTLECABLE page11-194 Inspection/Adjustment, page11-195 Installation,
VENTILATION(PCV)VALVE page11-201 Inspection, FASTIDLE
VALVE (A/T}
I n s p e c t i o n ,p a g e 11 - 1 6 8
(cont'd)
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11 - 5
ComponentLocations Index{cont'd) 39 - q, models:
THROTTLEBODYITB) page11-196 Inspection, Removal,page11-197 page11 198 Disassembly,
THROTTLECABLE page11 194 Inspectaon/Adjustment, page I l'195 Installation,
AIR CLEANER page11-194 R€placomenl,
CRANKCASE VENTILATIONIFCVIVALVE page11 201 lnspection, FASTIDLETHERMOVALVEIA/T) page11'168 Inspection,
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11 - 6
FUELPRESSURE REGULATOR T e s t i n gp, a g e1 1 - 1 8 1 page11 181 Replacement,
'97 model:
FUELPUMP Testing,page11 183 page11 183 Replacement, FUELGAUGESENDINGUNIT page11 185 FUELVAPORPIPE Testing,
FUELFEEDPIPE FUELFILTER page11 182 Replacement,
FUELFILL CAP
FUELPULSATIONDAMPER
EVAPORATIVE EMISSION IEVAP)CONTROLCANISTER page1'l-205 Troubleshooting.
EVAPORATIVE EMISSION IEVAPITWO WAY VALVE Testing,page11 224 TANK R e p l a c e m e n t ,p a g e 1 1 1 9 1
-CONNECT FUEL FITTINGS page11-175 Precautions, page11 175 Disconnection, page11-176 Connection, FUELINJECTORS page11-179 Replacement,
'98 model: FUELFEEDPIPE FUELFILTER page11 182 Replacement,
FUELVAPORPIPE
FUEI-TANK FUELPUMP Replacement, Testing,page11 183 p a g e1 l 1 9 1 page11 183 Replacement, FUELGAUGESENDINGUNIT Testing,page1l'185
FUELPULSATIONDAMPER
FUELFILLCAP
EVAPORATIVE EMTSSTON IEVAPI CONTROL CANISTER VENT SHUTVALVE Troubleshooting, p a g e1 1 ' 2 1 3
FUELTANK PRESSURE SENSOR page1l-209 Troubleshooting,
EVAPORATIVE EMISSION IEVAPICONTROLCANISTER page11-213 Troubieshooting, FUELRAIL
FUEL
FUELTUBE/OUICK.CONNECT FITTINGS page11 '175 Precautions, page11 175 Disconnection, page11 176 Connection,
page11-179 Feplacement, FUELPRESSURE NEGULATOR Testing,page11-181 Replacement, Page11 181
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EVAPORATIVE EMISSION {EVAP)EYPASS SOLENOIDVALVE page11'213 Troubleshooting,
€VAPORATIVE EMISSION {EVAP)TWO WAY VALVE Testing,page11 224 (cont'd)
GomponentLocations Indexlcont'd) '99 - (X)modols:
FUELTANK Replacement, p a g e1 1 - 1 9 1 FUELVAPORPIPE FUELPUMP '11 Testing,page 183 page11_183 Replacement, FUELGAUGESENDINGUNIT Testing,page11-185
FUEL FEEDPIPE
FUELFILTER page11 182 Replacement,
EVAPORATIVE EMtSStON IEVAP) CONTROL CANISTER VENT
FUELFILLCAP
SHUTVALVE Troubleshooting, p a g e1 1 - 2 1 3
FUELTANK PRESSURE SENSOR page1'l'208 Troubleshooting,
EMISSION EVAPORATIVE IEVAP)CONTROL page11-213 Troubleshooting,
FUELPULSATIONDAMPER
FUELRAIL FUEL page11-179 Replacement, FUEL PRESSURE REGULATOR Testing,page11-181 page11 181 Replacement,
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EVAPORATIVE EMISSION {EVAP)TWO WAY VALVE Testing,page11-224
,CONNECT FITTINGS page11-175 PrecaLrtions, page11-175 Disconnection, page176 Connection, EVAPORATIVE EMISSION {EVAPIBYPASS SOLENOIDVALVE page11 213 Troubleshooting,
FUEL
VacuumGonnections '97 model:
To EVAPORATIVE EMISSIONIEVAPI TWO WAY VALVE
EVAPOBAIIVE EMtSStON IEVAPI CONTROL CANISTER
EVAPORATIVE EMtSStON t€vaP) PURGECONTROL VALVE SOLENOID
FRONTOF VEHICLE
PBESSURE REGULATOR
{cont'd)
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11-9
System Description (cont'dl VacuumConnections '97 model:
ENGINE COOLANT
IT
r|ll
HEATED oxYGENsENsoR{PRIMARY Ho2s, O PRIMARY SENSOR lt HEATED oxYGENsENsoR{SECoNDARY O SECONDARY HO2S.SENSOR 2l (MAPISENSOR ABSOLUTE PRESSURE €) MANIFOLD cooLANTTEMPERATURE @ ENGINE {EcT}sENsoR (IAI} sENsoR AIRTEMPERATURE O INTAKE SPEED FLUCTUATION @ CRANKSHAFT ICKFISENSOR O |DLEArRcoNTRoL{tAc)vALvE @ FASTIDLETHERMovALvE EoDYITB) O THRoTTLE @ FUELINJEcTon oAMPER O FUELPULSATIoN @ FUELFILTEn (} FUELPRESSURE REGULATOR
11 - 1 0
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@ FUELPUMP
(D FUELTANK (D FUELTANK EVAPORATIVEEMISSION(EVAPIVALVE
o AIRCLEANER
@ RESONATOR (} POSITIVECRANKCASEVENTILATION{PCVIVALVE EMISSION{EVAP}PURGECONTROL @ EVAPORATIVE SOI.'ENOID VALVE EMISSION{EVAP)CONTROLCANISTER @ EVAPORATIVE EMISSION{EVAPITWO WAY VALVE @ EVAPORATIVE (TWC) @ THREEWAY CATALYTICCONVERTER
'98 model:
To EVAP THREE WAY VALVE
To EVAP TWO WAY VALVE
EVAP PURGE CONTROL SOLENOID VALVE
FRONTOF VEHICLE
(cont'd)
www.emanualpro.com
11-11
System Description VacuumConnections(cont'dl '98 model:
-i*'";-t
G/T only)
f\
I
I
COOLANTJ
t
U
I
C PRIMARYHEATEOOXYGENSENSOR(PRIMARYHO2S, SENSOR1) (, SECONDARY HEATEOOXYGENSENSORISECONDARY HO2S,SENSOR2) (!)\\\\ss\SNBSS\\\ETRESS\RE\\NQ\SE\SSR (ECT)SENSOR G) ENGINECOOLANTTEMPERATUBE {IAT}SENSOR O INTAKEAIRTEMPERATURE (CKFISENSOR SPEEDFLUCTUATION @ CRANKSHAFT O IDLEAIR CONTROL(IAC)VALVE @ FASTIDLETHERMOVALVE(A/T) O THROTTLEBODY(TBI (0) FUELINJECTOR .1' FUELPULSATIONDAMPER .14 FUELFILTER (i FUELPRESSURE REGULATOR 14 FUELPUMP (D FUELTANK EMISSION{EVAPIVALVE @ FUELTANK EVAPORATIVE
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11-12
C] AIR CLEANER (O RESONATOR 1iC POSITIVECRANKCASEVENTILATION (PCV)VALVE 6 \$REE$IN\ gN\ NL$\C CON\ER\ER (TNC\ ti\ q\ rpos,xr\tE qN\rssros \E\ aP\ cqN\RoLcaNtsr€R EMISSIONIEVAP)PURGECONTROL @ EVAPORATIVE SOLENOIDVALVE q3 EVAPORATIVE EMISSTON IEVAP}CONTROLCANISTER VENT SHUTVALVE EMISSION(EVAP)TWO WAY VALVE @ EVAPORATIVE EMISSION{EVAP)BYPASSSOLENOID €i EVAPORATIVE VALVE SENSOR €9 FUELTANK PRESSURE EMISSION{EVAP)THREEWAY VALVE Oi EVAPORATIVE Qd PURGEJOINT
'99 - 00 models:
To EVAPTHREE WAY VALVE
To EVAP TWO WAY VALVE EVAP PURGE CONTROL SOLENOID VALVE
FUEL PRESSURE REGULATOR FRONTOF VEHICLE
(cont'd)
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11 - 1 3
System Description VacuumConnections(cont'dl '99 - q) models:
ENGINE COOLANT
t
o PRIMARYHEATEDOXYGENSENSORIPRIMARYHO2S, SENSOR1l o SECONDARYHEATEDOXYGENSENSOR{SECONDARY HO2S.SENSOR2l o MANIFOLDABSOLUTEPRESSURE(MAPISENSOR IECN SENSOR @ ENGINECOOLANTTEMPERATURE
o
@ @ @ @ @ @ @ @ @
(t
INTAKEAIR TEMPERATURE IIATI SENSOR SPEEDFLUCTUATION CRANKSHAFT {CKF)SENSOR KNOCKSENSOR(KS} IDLEAIR CONTROLIIACIVALVE FASTIDLETHERMOVALVE{A/T} THROTTLEBODY(TB} FUELINJECTOR FUELPULSATIONDAMPER FUELFILTER FUELPRESSURE REGULATOR FUELPUMP FUELTANK FUELTANK EVAPORATIVE EMISSION(EVAPIVALVE
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11-14
@ @ @ @ @ @ @ @ @ @ @ @
AIR CLEANER RESONATOR POSITIVECRANKCASE VENTILATION(PCV}VALVE THREEWAY CATALYTICCONVERTERITWCI EVAPORATIVE EMISSION{EVAPICONTROLCANISTER EVAPORATIVE EMISSIONIEVAPIPURGECONTROL SOLENOIDVALVE EVAPORATIVE EMISSION{EVAPICONTROLCANISTEF VENTSHUTVALVE EVAPORATIVE EMISSIONIEVAPITWO WAY VALVE EVAPONANVEEMISSION{EVAPIAYPASSSOLENOID VALVE FUELTANK PRESSURE SENSOB EVAPORATIVE EMISSIONIEVAPITHREEWAY VALVE PURGEJOINT
-'97 Model Electrical Connections --- --- -t
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ila
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: FUSES (DBACKuP (RADro)(7.sr0. @ "o^n ttot (tuo)' * (DBATfERY(IOOA) (4oA)* rcl o
(DFt E/ flsA). @ No.13 FUELPU P ('l5A) O No. 2s METER(7.5A) (D NO.'I5 ALTERNATORSP SENSOB(7.5A)* O No. 3i STABTERSIGNAL (7.5A) *: In lhc und?r.lrood tu$/rclay bor (cont'd)
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11 - 1 5
SystemDescription -'97 Model(cont'dl Electrical Connections
VALVE EVAPPUFGECONIROI SOLENOIO
SP€EOSENSOR COUNERSHAFI SPEEDSENSOF
CONTNOL SOIENOID VALVE A
PFESSUhECOI{TFOL
sotENotDvALvE
Tor lEiLocK coNtFol UNlt
IERi'INAL LOCATIONS
11 - 1 6
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YEL/BLU FED/BI(
(SEr€OR r) HO2S
l-
(cont'd)
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11-17
System Description -'97 Model(cont'dl Electrical Connections
No.2 FUELIIUECIOF cl09
11-18
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BLK,TELJflI BLU rdHT , -----L+ alx
Frrt\rFEl L-fJl ||
|
l-
CONDENSERFANFELAY
*1 : USA
(cont'd)
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11 - 1 9
SystemDescription -'97 Model(cont'dl Electrical Connections
-Fc
h- -FE rF ARN
B R N :BLK eLKr
BLKj
BLxj
8Rt,l,'BLxj ARN,'BI.K.
c113
E
11-20
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cat.,auxt LT GAN
BLVBLU
RED
GRN BLU,
an12 GAUGEASSEI'BLY
i
I enr2-{
I I
A,ryGEABPOSINONSWITCH
*".r".o'-
) Inor.".o"*
CONTROL UNIT
(cont'd)
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11-21
SystemDescription -'97 Model lcont'd) ElectricalGonnections
t,l
T
/8LU l
|l
I
U
,J I
IVTII/BLU -
WHT/€LU
l wltT/BLr(. (c352 WHT/BLK
rcl ({0A} HOiXsIOf 05A) wltT/GRt{
CRN/FEO
GRI{/F€O
BLU/ORN
ALU/'IVHT UNOER]IOOD fUSE,/FEIAY 8OX
T"*,,*. ".*_f
I
Btur,tvrr I-.'|
r'tc3rsrAaIES SG|I|^L 05 )
BLU/W8T
,ato"nL
;rfi
""r _g!:f BLK/FED
'I_
FUSE/BELAY BOX
11-22
www.emanualpro.com
*2: USA
(Fromp!9.1r-221
ca32
**r2",-*J-1 YEVGRN YEvErK --
I
___-I BLU?'I'HT -GRN,/YEL I YEVGnN--
"*
--1
PGII.FI UAIN RELAY
C56-2
trru^n --
-
_BLK
I dL
www.emanualpro.com
-
-] i\
(
//--\
,
)
- \_-,/ , / FUELPUMP
11-23
SystemDescription -'98 - 00 Models Electrical Connections
:
lg il T t ( 1 1 BATTERY \ ffi \ t. ro3Ecl,|{r / STAFIEF F q,t REL Y
I
FUEL IUECIONA
lo ^/c clwclr hEL Y lo iADIAIORFAl{iEt Y, coittct{3€F F l{ FCLAY Yo|/C all'lc8
att
OAT'OE alsErELY"
tr POSll|O|l S TClt
ovEi-odYE
*1: A/T '2: USA *3: '98 modol *il: '!X) - 00 model!
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(DEAGKuP (RADlo)(75A). @ HoB sroP (rsAr (tood' O BATTERY (Drci (4oa)' O Fl E/trl(lsA)r (ONo.13FUELPUmP(l5A) O No.2s HETERO.5a) (DNo.15AITERNATOB SPSENSoR(7.5A)' @r.ro.3l STAnTERstcNAL (7.5A) t: in tha und!..hoodfule/irl.y box
TESTTACHOiIETER coNr{EctoB lo CRUISECoNTEOLUNIT+r TANK PRESSUFE SENSOF SOIENOIDVAIVE EVAPPURGECONTROL
EVAPCONIFOLCANISTEFVETITSHUTVALVE
sp:rosENsoF*1 COUNIERSHAFT SPEEDSENSOR'T coNlRo! solENotDvALvEA*1
H02S (SENSOF1)
COI'TIFOLUNIT*! TOINTEFLOCK
rcrocrsgrson*'
TERI/lINALLOCATIONS
(cont'd)
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11-25
SystemDescription ElectricalConnections- '98 - 00 Models (cont'dl
G] - l ct sEt{goh
' c14t I J/C
llo23 (SEltgOi O
l!to2srfic
11-26
www.emanualpro.com
SECOiD hY HO2a (aE toh 2)
Iil I I
Y sExsoF I
t1 t r- : r E
I ll Y s . n s oI R l | IL|
. - ac x P I Y sErsonl
tl ll
I f-=-r '"" ILfr l-
I
I I|
FI
t q l r-__:__-)
{o.l
FUELIIUECIOF
No. 3 FUE! IiUECIOn
r - l l _ , I
(cont'd)
www.emanualpro.com
11-27
SystemDescription -'98 - 00 Modelslcont,dl Electrical Connections
+
l M
l--
sL( yEL JJ{FiE-l sLUwnf li,"+l
+ _
8rk
_{lr]]]]]]]
|
F >rt i
-4.
w;i-nu-
" l---r
' a
r q - v--J
t_.1
K
CONOEflSERFANRELAY
rlrA/T .2: USA *4: '99 - 00 models
11-28
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elrcvrlJ-l
".o"*'-{l -- 3 | CONTROI soLENOroVALV€
ca6l
,o""r"*Jffil "."** {H I
tT GFtt/wxt
sotEtrolo vALvE
'.,r".u-fffil ,.YGRN'-I f+<-l
GR/8LX'-11-
|
FUEI TAIIX PRESSUBE SENSOF
To CRt ISE coNtFol u|{lt
*1 : A/T (cont'd)
www.emanualpro.com
11-29
SystemDescription -'98 - 00 Models(cont'dl ElectricalConneetions
fJ-
l
F l
fJ
T
fJ
f:t
!l T 9RN/ BRN/
BRN/ gLxl aLKl
atx'
F]
Tl
BLKt
BRN/ aLKl c121
r=r BRN/
eLxr
STNFT @NTFOL SOICNOIDVALVE
c115
IIAINSIIAFI SPEEDSENSOF c119
clll --l
|
3
|
A/t cLulctl PFESSURE COIiTTHOL SOIENOID VALVE
t
11-30
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n"t,lonrJ 1"r.]
g
L : ]
-*"{
r-YEL.cRN--_l l--
- GRN/BLK I-
I
LTGRN1
-BIK/BLU
REO BtuT
] -.,]
r.I= -*i-
] -::'",1
*I : A/T +3: '98 model
(cont'd)
www.emanualpro.com
11 - 3 1
SystemDescription -'98 - 00 Models(cont,dl Electrical Connections
OVE&ORVEOFF [{DtcatoR LlfP
C UqEAASEr|ELY
A/I GEAA PO3MON SWITCH
*tnzaeo'
) ,r*ear_oo,
@lillFo|. ur{tT
* 1 :N f *4: '99 - 00 modets
11 -3 2
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F
c$3 c.r'
L*_"."{h
cl/I
crxl
I *,,,,".u:][
-*^;1n-;"*, u
l
-
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,-wnrzEr-x{
8uc{rHr --l
-!"'* clfz
u|,|oEF-ftooD BOI FUAE/NEIAY
=-
B ITEFY
r-t
Lh-v
I
BMIG STITCH
E|.UflTT' YEVORN cal7 9q/wHr Et&{lll BLX/WFI
YEL
{cont'd)
www.emanualpro.com
11-33
SystemDescription -'98 - 00 Models(cont'dl Electrical Connections
PGU.FI MAII{BEIAY
-YEL/GBN-BLx--
|
_L
cssr
11-3 4
www.emanualpro.com
cs6-2 ,z-_\ p \ -f l- \ ./
"---.,
FUELPUI{P
SystemDescription SystemGonnectors[EngineCompartmentl-'97 Model
MAIN WIRE HARNESS
UNOER.HOOD FUSE/RELAY
..'.'.'
80x ct21 cl11
cl16
11 - 3 6
www.emanualpro.com
cl15
cl11
A
I 3 l . l
w
f,_rr'Hr-lwHr'-------
--l Ft RE!'wr lll ft'-cRN/sLK,
t l
2 l
l r , r l
c 6 eFr 1 1 2 l
cl.t7 r-r=l r 2 l
T!-Isrf,-*--/r*".er* I]]ll -;-BLi'uF
c129 .__1-..']..-r 1 1 2 3 l
ffl.E*-------lO
stx,YEL
I
TtlBru/"Nr----
c35l
c354.'
l4;i;1_s;:a
'-{-l-r
riiiltTf,n
fd,sLK rHr-----l
t-rlBL( 19
cFNnEo
I
I
*2: USA
NOTE:o Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem {for example,YEUBLKl and YEUBLK,are not the same). O: Relatedto Fueland EmissionsSystem. - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals(singleoutline):View from wire side
(cont'd)
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11-37
SystemDescription SystemGonnectors[EngineCompartment]-'97 Model {cont'd)
MAIN WIRE HARNESS
ENGINE WIBE HARNESS
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cr03
c105 tusAl
r__F2 1 1
-+ l l 2 l
l
cr07
c105
r#-r
l r , 2 3 l
cr08
rfjl
1 1 2 l
l l . 2 l
l 3 l . l
I T'*--film----t
[--1;N,/ruo; l]]l] t,Id&Y€r
|.-T;s,,€. -
cltxt
l';FELM
. .
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A
r--= lr 2l
u)
----l li
I
e@;----
lEl*",]!
o
N O T E :.
t F l
tl
tildK"ri t ltlB$jrma -
t0
r--q ll 2 l
lEl;.
titna.
l
{ ' ) \:) t.;ERN,€f Ttl;Eor-L
-_-]l -
o I
D i f f e r e n tw i r e s w i t h t h e s a m e c o l o r h a v e b e e n g i v e n a n u m b e r s u f f i x t o d i s t i n g u i s ht h e m ( f o r e x a m p l e , YEUBLK1 and YEUBLK'are not the same). O: Relatedto Fueland EmissionsSvstem. - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals{singleoutline):View from wire side
11 - 3 9
System Description SystemGonnectorslDashand Floor]-'97 Model
DASHBOARDWIRE HANNESS MAIN WIRE HARNESS
REARHEATEDOXYGEN SENSOR SUAHARNESS
WIREHARNESS
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cat2
titT T)l
t]l filsl].Mr
FT-I l5l'ri":'*l]]l
lwittost crui.! comrol) 3
1
,t\./
9 t0 1'l
I
2
1
r\.2
18 t,/
20
/
9
5
1ol,/ /
1 3 1 a 1 1 5 16 ./
6
ta
l
r
w
2
lolZmlvv{-l -l l@is',t'A' t-l
f.Tt.-f f
I
l
r$r
l t 4 . l' l riTLiGN--]]l
I111
rtTa*
lo-6dN'!Hnl .]l
[tltu/cs
c426 rrFr-r | 1 1 23 l . l
t';l;Kvi-l
fol**"---
NOTE: o Different wires with the same color have been given a number suffix to distinguish them (for example.
YEUBLKland YEUBLK'are not the same). a O: Relatedto Fueland EmissionsSvstem.
-
www.emanualpro.com
Connectorwith maleterminals(doubleoutline):View from terminalside Connectorwith femaleterminals(singleoutline):View from wire side
(cont'd)
11-41
SystemDescription SystemGonnectors[Dashand Floor]-'97 Model (cont'dl
DASHEOARDWIRE HARNESS
MAIN WIRE HARNESS
11-42
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o
a
I
1 t 12 13
9 to
5 l6
'11
l 8 l9
-t i
(}
NOTE: o Differentwires with the same color have been given a number suffix to distinguish them (for example,
YEUBLKIand YEUBLK'are not the same). a O: Relatedto Fueland EmissionsSvstem. a - Connectorwith maleterminals(doubleoutline):View from terminalside
-
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Connectorwith femaleterminals(singleoutline);View from wire side
(cont'd)
11-43
S)stern Dessr\ptron SystemConnectorslDashand Floor]-'97 Model {cont'd)
MAIN WIRE HARNESS ENGINE WIRE HARNESS
//l tao,
c1z2
(PCM.AI
{PCM.D}
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11-44
c124 (PCM,B)
ct23 {PCM-Al
1 2 \ 3 1 5 6 1 8 1 1 1 2 1 3 r a 1 5 1 6 '11 l 8
iJq
.t
o
o
o
n
a
,,
cr26 tPicM-ol
cr25 tPCM-Cl
1 2 3 a 5 X r r l 1 2 13 l a t 5 t 6
6
7
A
9 1 0
1 1 t 8 19 20
ii)
o
D
!t
o
o
o n n
lit
1
2
1 1 1 1 2 t 3 !il
5
6 '16 I t
a
8
9 1 0
't8 t9 20
NOTE:o D i f f e r e n w t i r e s w i t h t h e s a m e c o l o r h a v e b e e n g i v e n a n u m b e rs u f f i x t o d i s t i n g u i s ht h e m ( f o r e x a m p i e , YEUBLKT and YEUBLK2 are not the same). O: Relatedto Fueland EmissionsSvstem. - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals(singleoutline):View from wire side
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11-45
System Description SystemConnectorslEngineGompartment]-'98 Model
MAIN WIRE HARNESS
UNDER.HOOD FUSE/RELAY BOX
ENGINE w|RE HARNESS
*2: USA
11-46
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ctt5
t'ltl [.1.1 lSlwHr
-------
lo GnNAUC I TdTBLx/YEL-----1 fdBtx vNP
fr
\,v tdTiaotfi-----l ---l IETcRll,aLX'
ct10
fr
fr
fr
I6rc;iEiF--l- ll IltIYEr,
ffi
ct19
fr
f'Ttfrl
-'l
l6lcnN' lo eLU'
tdFLxr-----l
SLKI
,
L4.lrl
LrsLU
T
cRY
T
I O BL|^EL l6l6tu/rJHr'
I -
c354*'
NOTE;. . .
-1|
fr
16T816rr-----l lol "." I lO
tsTYE'J€rr
G361
r'ft] GF&aEp
ldTcRN/BrF----lO iEo/BL(
lSTLr GRr/wHr--F ]ilwH----I
Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1 and YEUBLK,are not the s8me). O: Relatedto Fueland EmissionsSystem. - Connectorwith maleterminals(doubleoutline);View from terminalside - Connectorwith femaleterminals(singleoutlinel:View from wire side (cont'dl
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11-47
System Description SystemConnectorslEngineCompartmentl-'98 Model (cont'd)
MAIN WIRE
ENGINE WIRE HARNESS
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c t5
{usa)
r'ftr
t'ltl I'l.l Ttlrsrtsu
ftT,,tHr/FEpi
.
IET$'rmc' -- I ftlarxrEl-l ftlwn/srt l
NOTE: o Differentwires with the same color have been given a number suffix to distinguish them (for example,
YEUBLKland YEUBLK,are not the same). o: Relatedto Fueland EmissionsSvstem, a - Connectorwith maleterminals(doubleoutline):Viow from terminalside - Connectorwith femaleterminals{singleoutline):View from wire side (cont'd)
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11 - 4 9
SystemDescription SystemGonnectorslEngineCompartment]-'99 - 00 Models
MAIN WIRE HAENESS
UNDER.HOOO FUSE/RELAY BOX
ENGINE WIRE HARNESS
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cl11
A
ffir lilrl t-lwHn-----t I ' IGRNtsLI'
f"l".*,.
15
c114
ft
ffi
,g 1lI
c116
cl17
c118
ffi
ffi
Effi-ffiffi
rdTnEDlllHr-----l6lcRN/Buc -
----
ffi
trhlx,l/vH?
c121
c129
ffi
f'ftf '1)
c135
Gt51
t6-tBrK
-----_l
l€ lBrxrEr lShLU^,/Nrr
l]l I
Gt52
ElzTt) IiTY€vnED-----l TdTcFN/rHr, FfREp/cFr l
Gt54.'
-Ell 1 l 23 l
ldTBLxr'rtvii-----l TitlBL. I o cFN/Frp l
*2:USA NOTE:o Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1 and YEUBLK,are not the same). a O: Relatsdto Fueland EmissionsSystem, a - Connectorwith maleterminals{doubleoutline):View from terminalside - Connectorwith femaleterminals(singleoutline):View from wire side (cont'd)
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11-51
System Description SystemGonnectors[EngineCompartment]-'99 - 00 Models{cont'dl
MAIN WIRE HARNESS
11-52
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c105 (usA)
c104
c103
Ir zl
lslrl ----
f -T;iE;;n
tll
lrlBR,r
FIrt
l1 2l
I '
WNT]FEDI
L
filBLKry.L ll]I fu-,wHrcn[ l]l ftl-wNr/sr't ---l TaTtNanEc!
c105 {Canadal
c108
c107
r'fifl -'-l fi'Iw|r/nE D. -_-l T'TBt(ryEL t]l
t lnrtsrr
ffi
ffi |iTYEU€LX' --
-rfnri-r
I
FfBLK//EL---l-l l -IREor/Ar
c134 c109
c133
10
ffi
ffi ---l l-!. IYEUBLK.
c137
c303
----l FEp/Bru
N O T E :. . .
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v
riaF.\rjrr. - l]l I ttInEoYEr,
1 " 1 " " '-
fil
A
Differenw t i r e s w i t h t h e s a m e c o l o r h a v e b e e n g i v e n a n u m b e rs u f f i x t o d i s t i n g u i s ht h e m ( f o r e x a m p l e . YEUBLK'and YEUBLK'are not the same). O: Relatedto Fueland EmissionsSvstem. - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals{singleoutline):View from wire side
11 - 5 3
System Description SystemConnectors[Dashand Floorl-'98 - 00 Models
DASHBOARD WIRE HART{ESS
Ita|l{ wtRE HARIIIESS
REARHEATEDOXYGEN SENSOR SUBHAR ESS LEFTSIDE WIREHAR ESS
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1 1 -5 4
\
c4r2
ll,Vt'll 6fswYv-ii----
E-r-
F lwir,€L(
n
--
-l
!E!E!t LT GRN
o
I
9
2
a
3
/l/lt
rolrr
tHrBLt
l/
r . l , / za
/te
a
tol./ /llEl1.lt6
a
r . l/
tl
l
lwlrhot|t crub. 6.trroll
-ftr
w
rdT6iffi---l ET----- ---l l.T--
r'TfifiI
I'X.l l ' l . l l-i'f iifiN ftTGRY fdlGiffil fdlw{rcftr
-----l ----
TdliL,,rw{r----1
I l @ c R M/ H r ' lO wt{r €D' ---l I TofuLr/,txl-
NOTE:o Differentwires with the same color have been given a number suffix to distinguish them (for example, YEVBLK1 and YEUBLK' arenot the same). a O: Relatedto Fueland EmissionsSystem. a - Connectorwith maleterminals(doubleoutline):View from terminalside (cont'd) - Connectorwith femaleterminals(singleoutline):View from wire side
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11 - 5 5
SystemDescription SystemConnectorslDashand Floorl-'98 - 00 Models(cont'd] c510
DASHBOARDWIRE HARNESS
MAINWIEE HARNESS
'4: '99 - 00 models
11 - 5 6
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rE0
c508 2 3 a 1 l 12 13
6 E 9 10 1 5 1 6 1 1 1 8 1 9 20
|l!
.,
1-t""'
-----l
lo lLrcRN, I O IsLKM/Hr l r l I t lYErr€LU T-ilcirrlLrr
I t
rdTYEcii-----lll I
ETGRN/Brxi - lll fSliaGFNr-
mJv
, - + , ,
lrl2l3l1l
l.f.T'-]
F6EFN-----
ftTcll-l
t 2 l
I
''l
ftTYEUsr. t TstYEr *4:'99 -00 models
IO IBLK
I
ftTwHr/BL(---'1 f.ft1.
(for example, Different wires with the same color have been given a number suffix to distinguish them
and YEUBLK'are not the samol. YEUBLKT O: Relatedto Fueland EmissionsSystem a - Connectorwith maleterminals{doubleoutline):View from terminalside - Connectorwith femaleterminals{singleoutline);View from wire side
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YEL
I l]l I
c76t*.
c760
NOTE: .
\:9
vl5l6l
l--l
I a l Y E U c n NftTYEL'BrK
a.a
r,'ffijt
trLtzl |.-l.T'|
ffi rcrBr.
c546
c580
c552
(cont'd)
11-57
System Description SystemConneetorslDashand Floorl-'98 - 00 Models(cont'dl
DASHBOARD WIREHARNESS
MAIN WIB€ HARNESS
ENGINE WIRE HARNESS
n lno,
c,47 (ECM/PCM.A} c121 (ECM/PCM-8)
(PCM.D}
www.emanualpro.com
t
cl25 tECM/PCM-C)
c124 {ECM/PCM.B}
c't22
1 I 2 3 a 12 t 3 l t a 't5 t 0 1 1 t 8 t 9
tt
c126 (PCM-O)*,
c127'.
c121*3
c132
C,r47(ECM/PCM-Al
ot33 6
3 1 t 12 l 3
,
10
l 6 17 la t9
o
*1:4,/T *3: '98model '4:'99- 00models NOTE:. . .
www.emanualpro.com
'1all
Differentwires with the same color have been given a number suffix to distinguish them {for example, and YEUBLK' arenot the same). YEUBLK1 O: Relatedto Fueland EmissionsSvstem. - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals(singleoutline):View from wire side
11-59
Troubleshooting TroubleshootingProcedures How To BeginTroubleshooting When the MalfunctionindicatorLamp(MlLl has beenreportedon, or there is a driveabilityproblem,usethe appropriate procedurebelowto diagnoseand repairthe problem. A. Whenthe MIL hascome on: 1. Connectthe Honda PGM Testeror an OBD Il scantool to the 16PData Link Connector(DLC)locatedbehindthe right sideof the centerconsole. Turn the ignitionswitchON (ll). Checkthe DTCand note it. Also checkand note the freezeframe data. Referto the DiagnosticTroubleCode Chart and begintroubleshooting.
NOTE: . SeetheOBDll scantool or HondaPGMTesteruser'smanualsfor specificoperatinginstructions. . The scantool or testercan read the DiagnosticTroubleCodes(DTC),freezeframe data,currentdata,and other EngineControlModule(ECM}/Powertrain ControlModule(PCM)data. . Freezeframe data indicatesthe engineconditionswhen the first malfunction,misfireor fuel trim malfunctionwas detected.lt can be usefulinformationwhen troubleshootino. B. Whenthe MIL has not come on, but there is a driveabilityproblem,referto the SymptomCharton page 11-64. C. DTCswill be indicatedby the blinkingof the MalfunctionIndicatorLamp{MlL)with the SCSserviceconnectorconnected. Connectthe SCS serviceconnectorto ServiceCheckConnectoras shown. {The 2P ServiceCheckConnecrorrs locatedbehindthe right side of the centerconsole.)Turn the ignitionswitchON 0l).
DATA LINKCONNECTOR I16PI
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11 - 6 0
ll.
ControlModule{PCM)ResetProcedure EngineControtModule(EcM)/Powertrain Eitherof the followingactionswill resetthe ECM/PCM. .
(see the oBD ll scan tool or s use the oBD ll scantool or Honda PGM Testerto clear the ECM' s/PCM'memory. instructions ) operating specific for manuals Tester user's HondaPGM
. Turn the ignitionswitchoFF. Removethe BACKUP (RADIO)(7.5A) fuse from the under-hoodfuse/relaybox for seconos.
10
BACKUP {RADIOII7,5 AI FUSE
FUSE/RELAYBOX
lll. FinalProcedure{this proceduremust be done afterany troubleshooting) and there are no 1. Removethe SCSServiceConnectorif it is connected.lf the SCSserviceconnectoris connected. (ll). oN is turnsd switch ignition when the on will stay the MIL DTCSstoredin the ECM/PCM, 2. Do the ECM/PCMResetProcedure. 3. Turn the ignitionswitchOFF ( the OBD ll scantool orHonda PGMTesterfrom the DataLinkConnector16P)' 4. Disconnect
(cont'd)
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11 - 6 1
Troubleshooting TroubleshootingProcedures(cont'd) lf the inspectionfor a particularcode requiresvoltageor resistance checksat the EcM/pcM connectors,removethe right kick panel.Unboltthe EcM/PcM.and connectthe backprobesetsand a digitalmultimeteras describedbelow, checkthe systemaccordingto the proceduredescribedfor the appropriatecode(s)listedon the followingpages.
@@)@)c,
How to Us6 tho BackprobeS6ts connectthe backprobeadaptersto the stackingpatchcords.and connectthe cordsto a multimeter. Usingthe wire insulation as a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connector from the wire side until it comesin contactwith the terminalend of the wire.
Backp.oboAdapto.
BACKPROBE SET o'SAZ - (xtlqDA lTwo requir.dl
11-6 2
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DIGITAI.MULTIMETER (Commarci.llyrvrilabl.l or KS-AHM-32-@3
CAUTION: . Puncturingthe insulation on a wile can causepoor ot intelmittent electricalconneciions. . Bring the tester probe into contact with th€ terminal from the terminal side of wire htrness Gonnectorsin the engine probe. comoartment. Fol temale connectols,iust touch lightly whh the tester probe and do not insgrt lhe
(cont'd)
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11 - 6 3
Troubleshooting Troubleshooting Procedures(cont'dl Symptom Chart Listedbeloware symptomsand probablecausesfor problemsthat DO NOTcausethe MalfunctionIndicator Lamp(MlL)to come on. lf the MIL was reportedon, go to page 11-60. Troubleshooteachprobablecausein the order listed(from leftto right)until the symptomis eliminated, The probablecauseand troubleshooting pagereferencecan be found below. SYMPTOM
PROBABLECAUSE
Enginewill not start Hardstarting
4 , 2 , 3 , 5 , 2 0 ,' t 5 ,1 2, 4, 12,17,14, 't9
Coldfast idletoo low Coldfast idle too high ldle speedfluctuates
7 ,a , 9 ,6 , 1 7 7,8,9,11,10 9 , 7 , 8 ,' t 1 ,1 0
Misfireor rough running
Troubleshootfor misfire on pages '11-126,1|21 2, 10,11,13,'17,18,20 2 , 4 , 1 2 , 1 , 2 0 , 9 , 5 ',t 6
LOl/\/power
E n g i n es t a l l s OtherProbableCausesfor an enginethat will not start: - Compression - Intakeair leakage - Enginelockedup - Timing belt - Startingsystem - Overheating - Battery ProbableCauseList (Forthe DTCCh8rt, see page ll-75.) ProbableCause 'I
Page
Engine (ecvtffi controtruoaute
I 1-178
Fueloressure PGM-Flmain relav
11-187 5
Section4 't1-'t31,146
6 7
I 't-95 11-152
8
1'l-168
10 12
11-196 11-'194 '1'l-90
14
11- 103 11-137
11-169 '11
15 16 17 18 '19
20
11 -6 4
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System
11-42
Section14 11- 166 r1-194 11 , 1 9 9 11-203
lgnitionsystem positionsensorcircuit Crankshatt Position/Top DeadCenter/Cylinder IntakeAir Temperature(lAT)sensorctrculr ldleAir Control(lAC)Vatve Fastidle thermo valve ldle speedadjustment Throttle body Throftlecable ManifoldAbsoluteP."""rr"ffi ThroftlePosition(TP)sensor Barometricpressur"(gnnoAy'Tgear positionsignal Brakeswitchsignal Air Cleaner Three Way CatalyticConverter(TWC) Evaporative emission(EVAP)control Contaminated fuel
ECM/PCMData By connectingthe OBD ll scan tool or the Honda PGM Testerto the 16Pdata link connector(OLC),variousdata can be The itemslistedin the table belowconformto the SAErecommendedpractice retrievedfrom the ECM/PCM. The HondaPGMTesteralso readsdata beyondthat recommendedby SAE. understandingthis datawill help to find the causesof intermittentfailuresor engineproblems. NOTE: The ',operatingvalues" given below are approximatevaluesand may be differentdependingon the environmentand the individualvehicle. "at Unlessnotedotherwise. idle speed" meansidlingwith the enginecompletelywarmed up, transmissionin position turnedotf. the A,./C and all accessories Parkor neutraland Data Diagnostic TroubleCode (DTC)
EngineSpeed
VehicleSpeed
Desc.iption
lf no problemis detected, lf the ECM/PCMdetectsa problem,it will storeit as a there is no output. codeconsistingof one letterand tour numbers code (Poxxx) Dependingon the problem,an SAE-defined (P'lxxx) will be outputto the code or a Honda-defined tester. Nearlythe sameas computesenginespeedfrom the signals The ECN4/PCN4 tachometerindication sentfrom the CrankshaftPositionsensor. This data is usedfor determiningthe time and amountof At idle speed: '97 - 98 models: fuel iniection. 750t 50 rpm '99 - 00 models: 730f 50 rpm The ECM/PCMconvertspulsesignalsfrom the Vehicle SpeedSensor(VSSIinto speeddata.
The absolutepressurecausedin the intakemanifoldby Manifold engineload and speed. Absolute Pressure(MAP)
FreezeData
YES
YES
Nearlythe sameas speedometerindication
YES
With engin6stopped: Nearlythe sameas atmosphericpressure At idle speed: 2a - 41 kPa{210- 310 m m H g ,8 . 3- 1 2 . 2i n H g )
YES
With cold engine: Sameas ambienttemPeratureand IAT With enginewarmed uP: approx.163- 2'12'F (73- 100"c) 0 . 0- 1 . 2 5V The HeatedOxygenSensordetectsthe oxygencontentin At idle speed: to the gas voltage signals sends exhaust and the controls about0.1- 0.9 Basedon thesesignals,the ECM/PCM ECMiPCM. the airlfuelratio.Whenthe oxygencontentis high (thatis. ratio),the when the ratiois leanerthan the stoichiometric is lower. voltagesignal Whenthe orygen contentis low (thatis, when the ratio ratio),the voltagesignal is richerthan the stoichiometric is higher.
EngineCoolant The ECTsensorconvertscoolanttemperatureinto voltThe sensoris a thermistor age and signalsthe ECM/PCM. Temperature changeswith coolanttemperawhose internalresistance {ECT) ture.The ECM/PCMusesthe voltagesignalsfrom the ECTsensorto determinethe amountof injectedfuel HeatedOxygen Sensor(HO25) (Primary, Sensor1) (Secondary Sensor2)
Op€rating Valuo
YES
NO
(cont'd)
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11 - 6 5
Troubleshooting TroubleshootingProcedures(cont'd) Data HO2S Feedback Loop Status
ShortTerm F u e lT r i m
_
Descliption Loop statusis indicatedas "open" or "closed". Closed:Basedon the HO2Soutput,the ECM/pCMdeterminesthe airlfuelratioand controlsthe amountof injectedfuel. Open:ignoringHO2Soutput,the ECM/pCiM refersto sig, nalsfrom the TP, MAP,and ECTsensorsto controlthe amountof injectedfuel.
Operating Value
Freezo Data
At idle speed:closed
YES
The airlfuelratiocorrectioncoefficientfor correctingthe t:20y" amountof injectedfuel when HO2Sfeedbackis in the closedloop status.Whenthe signalfrom the HO2Sis weak,shortterm fuel trim gets higher,and the ECM/PCM increases the amountof injectedfuel.The airlfuelratio graduallygets richer,causinga higherHO2Soutput. Consequently. the shortterm fuel trim is lowered.and the ECM/PCMreducesthe amountof injectedfuel. This cyclekeepsthe airfuel ratiocloseto the stoichiometricratiowhen in closedlooDstatus.
YES
LongTerm F u e lT r i m
Longterm fuel trim is computedfrom shon term fuel trim and indicateschangesoccuringin the fuel supply systemover a long period. lf long term fuel trim is higherthan 1,00.the amountof injectedfuel must be increased.lf it is lowerthan L00. the amountof injectedfuel must be reduced.
! 20%
I n t a k eA i r Temperature (IAT)
The IAT sensorconvertsintakeair temperatureinto voltage and signalsthe ECrU/PCM. When intakeair temperature is low, the internalresistance of the sensor increases, and the voltagesignalis higher.
With cold engine: Sameas ambienttemperatureand ECT
Throttle Position
Basedon the accelerator pedalposition,the opening angleof the throttlevalveis indicateo.
At idle speed: approx.10%
lgnition Timing
lgnitiontiming is the ignitionadvanceangleset by the ECM/PCM. The ECM/PCMmatchesignitiontiming to the drivingconditions.
A t i d l es p e e d 1 : 6'1 4. BTDCwith the SCSservtceconnectorconnected.
NO
Calculated LoadValue (cLV)
CLVis the engineload calculatedfrom the MAp data.
At idle speed: 2A- 410/o At 2,500rpm with no load: 13 - 260/o
YES
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11 _ 6 6
YES
PowertrainControlModuleTerminalArrangement-'97 Model
Wire sideof lemaleterminals
FCM CONNECTORA (32P) f€rminal numlreJ
Wire color YEL
NOTE:Standardbatteryvoltageis 12V. Telminal nama
lNJ4(No.4 FUEL INJECTOR)
10
l N J 3( N o . 3F U E L INJECTOR) l N J 2{ N o . 2F U E L RED INJECTOR) l N J l ( N o .l F U E L BRN INJECTOR) SO2SHIC(SECONDARY OXYGENSEN BLK WHT HEATED CONTROL) SORHEATER (PRIMARY PO2SHTC HEATEDOXYGEN BLKAr'YHT SENSORHEATER CONTROL} 8RN/BLK LGl (LOGICGROUND} PG1lPOWERGROUND} BLK
l1
YEUELK
12
BLI(BLU
2
5
6 I
BLU
REDryEL
16
GRN/VEL
IGPl lPOWERSOURCE} IACV{IDLEAIR CONTROLVALVE} PCS(EVAPPURGE CONTFOL SOLENOID VALVE) FLR(FUELPUMPRELAY)
19*
ACC (A,/CCLUTCH RELAY} MIL (MALFUNCTION GRN/ORN INDICATORLAMP} ALTC(ALTERNATOR WHT/GRN CONTROL}
20
YEUGRN
22 23
BRN/BLK BLK
24
YEUBLK
27
GRN
11 18
8LI(RED
Description Drives No. 4 {uel injector.
Signal With enginerunning:duty controlled
DrivesNo. 3luel injector. DrivesNo.2 tuel injector. DrivesNo. 1 fuel injector. D ves secondaryheatedoxygen sensorheater. Drivesprimary heatedoxygen sensor heater,
Groundforthe PCMcontrol circuit. Ground for the PCMpower circuit. Power sourcefor the PCMcontrol circuit. Drives IACV. Drives EVAPpurge control solenoidvalve.
DrivesIuel pump relay. DrivesAy'Cclutch relay. DrivesMlL. Sendsalternatorcontrolsignal.
ICM(IGNITION CONTROL Sendsignitionpulse. MODULE) Groundtor the PCMcontrolcircuit. LG2(LOGICGROUND} GROUND} Groundlor the PCMpowercircuit. PG2{POWER Power sourcefor the PCMcontrol IGP2{POWER SOURCE} circuit. FAN Drives radiator{an relay. FANC(RADIATOR CONTROL)
With ignition switch ON {ll): batteryvoltage Withfully warmedup enginorunning:duty controlled With ignition switch ON lll): batteryvoltage with fully warmed up enginerunning:duty controll6d Lessthan 1.0V at all times With ignition switch ON (ll): batteryvoltage With ignition switch OFF:0 V With €nginerunning:duty controlled With enginerunning,enginecoolant below 154'F(68"C):battery voltage With enginerunning,enginecoolant above 154"F(68"C):duty controlled 0 V for two secondsafter turning ignition switch ON lll), then batteryvoltage With comoressorON: 0 V With compressorOFF:bafteryvoltage With MIL turned ON: 0 V With MIL turned OFF:bafteryvoltage With tully warmed-upenginerunning: battery voltage load:0' Duringdrivingwith smallelectrical With ignition switch ON (ll): bafteryvoltage With enginerunning:pulses Lessthan 1.0V at alltimes With ignition switch ON (ll): batteryvoltage With engineswitchOFF:0 V With radiatorfan running:0 V With radiatorfan stopped:bafteryvoltage
*: USA
{cont'd)
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11-67
Troubleshooting PowertrainControlModuleTerminalArrangement-'97 Model (cont'dl PCMCONNECTOR B I25PI
Wire sideof femaleterminals
PCM CONNECTORB I25P} Terminel number
color
1
2
RED
3
8LU//EL
4
GRN/BLK
5
YEL
I
PNK
11
GRN/VVHT
12
WHT/BED GRN/BLK
RED 16
L
Oescription
Signal
LS 1A/TCLUTCH PRESSURE CONTROL SOLENOID VALVE-)
DrivesA,/Tclutch pressurecontrol solenoidvalve
With ignitionswitchON (ll):duty controlled
LS + (A"/TCLUTCH PRESSURE CONTROL VALVE+) SOLENOID CONTROL SHA(SHIFT SOLENOID VALVEA)
DrivesA,/Tclutch pressurecontrol solenoidvalve
With ignitionswitchON (ll)rduty con trolled
LCB (LOCK-UP CONTFOL VALVEB) SOLENOID LCA (LOCK.UP CONTROL VALVEA) SOLENOID
ATPD3(Ay'T GEAR POSITION SWITCH} SHB(SHIFTCONTROL VALVE8} SOLENOID
ILU(INTERLOCK CONTROL UNITi D4IND(04 INDICATOR LIGHT}
In 2nd,R position.in 2nd and 3rd gearin D4, D3 position: Batteryvoltage In lst gearin D4,D3 position,in 4th gear in D4 position:0 V Driveslock-upcontrolsolenoid With full lock-up;Bafteryvoltage valveB, With half lock-up:duty controlled With lock'upON:batteryvoltage Driveslock-upcontrolsolenoid With lock-upOFF:0V gear position DetectsA/T switch In D3 position:0V ln any otherposition:batteryvoltage signal._ DrivesshiftcontrolsolenoidvalveB. In 1st,2nd position,in 1st and 2nd gearin D4,D3 position:Batteryvoltage In R position,;n 3rd gearin 04, D3,in 4th gearin D4 position:0 V Detectsinterlockcontrolunh signal. With ignitionswitchON (ll)and brake pedaldepressed:battery voltage With D4 indicatorlightturnedON:battery DrivesDl indicatorlight. voltage With D4 indicatorlightturnedOFF:0 V D r i v e ss h i f t c o n t r o l s o l e n o i dv a l v e A .
NMSG (MAINSHAFT Groundtor mainshaftspeedsensor. S P E E DS E N S O RG R O U N D }
14
1'l
BLU
18
BRN
22
GBN
23
BLU
24
YEL
25
LT GRN
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NOTE:Standardbatteryvoltageis l2 V. Terminal name
11 - 6 8
NM (MAINSHAFT SPEED SENSOR) ATPR(A"/TGEAR POSITION SWITCH) ATP2(A./TGEAR POSITION SWITCH) ATP1(4,,/TGEAR POSTTTON SWTTCH) NCSG(COUNTERSHAFT SPEEDSENSOR GROUND) NC (COUNTERSHAFT SPEEDSENSOR) ATPD4(M GEAR POSITION SWITCH) ATPNP{A/TGEAR POSITION SWITCH)
Detectsmainshaftspeedsensor srgnal,
With enginerunning:pulses
Detects A/T gear position switch srgnal.
InRposition:0V In any otherposition:batteryvoltage In 2nd position:0 V In any otherposition:batteryvoltage ln lst position:0 V In any otherposition:batteryvoltage
DetectsA/T gear position switch s r gn a l , DetectsA/T gear position switch s r gn a l , Groundtor countershaft speed sensor, Detectscountershaftspeedsensor srgnal. DetectsA,/Tgear positionswitch srgnal. DetectsA/T gear positionswitch signal.
With agnitionswitchON (ll),and lront wheelsrotating:pulses In D4 positionr0 V In any otherposition:batteryvoltage In parkor neutral:0V In any otherposition:about5 V
C (31PI PCMCONNECTOR
Wire sideof femaieterminals
C {31PI PCMCONNECTOR ferminal number
't 2 3 4 5
Wire color
NOTE:Standardbatteryvoltageis 12 V. Terminal name
P CKFP(CKFSENSOR SIDE) P CKPP(CKPSENSOR BLU SIDE) P TDCP(TDCSENSOR GRN SIDE) P CYPP(CYPSENSOR YEL SIDE) ACS(A/CSWTTCH BLU,frED SIGNAL) SWITCH STS(STARTER BLU/ORN SIGNAL) BLUiRED
7
BRN
8
LT BLU
CHECK SCS(SERVICE SIGNAL) K-LINE
10
BACK VBU(VOLTAGE WHT/BLU U P )
11
(CKFSENSORM WHT/RED CKFM
Doscription
Signal
DetectsCKFsensor.
: ulses W i t h e n g i n er u n n i n g p
Detects CKPsensor.
With engine running: pulses
DetectsTDCsensor.
With engine running: pulses
DetectscYP sensor.
With engine running: pulses
DetectsA,/Cswitchsignal.
With AJCswitchON:0 V With A,/CswitchOFF:batteryvoltage With starterswitchON (lll): baftery voltage With stanerswitchOFF:0 V
Detectsstarterswitchsignal. Detectsservicecheckconnector signal(thesignalcausinga DTC indication) Sendsand receivesscantool srgnal. Powersourcetor the PCM controlcircuit.Powersourcefor the DTCmemory
With the connectorconnected:0 V With the connectordisconnected:about 5 V or battery voltage
With ignitionswitchON (ll):pulses Batteryvoltage at all times
Ground for CKFsensorsignal.
SIDE)
12
WHT
13
RED
14
BLK
I\4 Groundlor CKPsensorsignal. CKPM(CKPSENSOR SIDE) M TDCM(TDCSENSOR Groundfor TDCsensorsignal. SIDE} M Groundfor CYPsensorsignal. CYPM(CKPSENSOR SIDE} PSPSW(P/SPRESSURE DetectsPSPswitch signal.
swtTcH)
16
GRN
17
WHT/RED
18
SPEED VSS(VEHICLE BLUA/VHT SENSOR)
FR ALTF(ALTERNATOR SIGNAL)
FRsignal. Detects alternator VSSsignal. Detects
At idle with steeringwheel in straight ahead position:0 V At idle with steeringwheel at full lock: battery voltage With fully warmed up engine running: 0 V-batteryvoltage {dependingon electricalload) Wirh ignitionswitch ON (ll) and front wheels rotating:cycles0 V - 5 V or battery voltage
(cont'd)
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Troubleshooting PowertrainGontrolModuleTerminalArrangement-'97 Model (cont'd) O {16PI PCMCONNECTOR
PCM CONNECTOR D (I6P) f.rminal Wir! color numbcr 1
RED/BLK
T€rminal nam6 TPS ffHROTTLE POSITION SENSOR}
Wiresideof f6maleterminals
NOTE: Standard battery voltage is 12 V. Description DetectsTP sensor signal.
ECT(ENGINECOOLANT DetectsECTsensor signal.
RED,4/VHT TEMPERATURE SENSOR
MAP(MANIFOLD DetectsMAP sensorsignal. RED/GRN ABSOLUTE PRESSURE SENSOR) VCCl (SENSOR YEURED VOLTAGE) E
GRN/WHT
Signal With throttlefullv oDen:about4.8V With throttlefullv closed:about0.5V With ignitionswitchON {ll):about 0.1- 4.8V (dependingon engine coolanttemperature) With ignitionswitchON (ll):about3 V At idle;about 1.0V (dependingon enginespeed)
Pow€rsourcefor MAP sensor.
With ignitionswitchON (ll):about 5 V With ignitionswitchOFF:0 V
BKSW(BRAKE SWITCH)
Detectsbrakeswitch signal.
With brakepedalreleased:0V With brake pedal depressed:battery voltage
(PRIMARY PHO2S HEATED OXYGEN SENSOR 1) SENSOR
Detectsheatedprimary oxygen sensor(sensor1) signal.
With throttlefully openedfrom idlewith fully warmed up engine:above0.6V With throttlequicklyclosed:below 0.4v
IAT (INTAKEAIRTEM. PERATURE SENSOR)
DetectsIAT sensor signal.
With ignitionswitchON lll): about 0.1- 4.8V (dependingon intakeair temperaturel
7
WHT
8
RED//EL
10
YEUBLU
VCC2(SENSOR VOLTAGEI
Providessensor voltage.
With ignitionswitchON (ll):about5 V With ignitionswitchOFF:0 V
11
GRN/BLK
SG2(SENSOR GROUND)
Sensorground.
Lessthan 1.0V at all times
12
GRN/WHT
SGl (SENSOR GROUND)
Groundfor MAP sensor.
Lessthan 1.0V at all times
13
14
SHO2SSG (SECONDARY HEATED RED/YEL OXYGENSENSOR, SENSOR2 GROUND) SHO2S(SECONDARY HEATEDOXYGEN WHT/RED SENSOR, SENSOR2)
Groundfor secondaryheated orygen sensor(sensor2).
Detectssecondaryheated orygen sensor(sensor2) signal,
With throttlefully openedfrom idlewith fully warmed up engine;above0.6V With throttlequicklyclosed:below
0.4v EL (ELD) 16*
GRN/RED
1 -7 0
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DetectsELDsignal.
With parkinglightsturnedon at idle about2.5- 3.5V With low beamheadlightsturnedon a t i d l e :a b o u t1 . 5- 2 . 5 V
ControlModuleTerminalArrangement- 38 - 00 Models Engine/Powertrain A (32P} ECM/PCMCONNECTOR 5
I
a
sca
,/./ t5
,/
It
sTs
l,/ n
2l s!u
CI
Wire sideot femaleterminals
A {32P) ECM/FCMCONNECTOR
NOTE:Standardbafteryvoltageis D93cription
3
BLU LT GRNMHT
5',
BLU
6
RED/YEL
8
ELIOWHT
10
BRN
l4'r
GRN/8LK GRNI/EL
17
AL|(/RED
18
GRN/ORN
19
BLU
2WBS{EVAPBYPASS S O L E N O IV DA L V E )
Drives EVAP bvoass solonoid valve.
W i t h i g n i r i o n s w i t c h O N { l l ) rb a t t e r y v o l t a g e
VSV {EVAPCONTROLCANIS TEBVENTSHUTVALVE) EO N T R OSL I G ' C R S( C R U I SC NAL) PCS(EVAPPURGECONTROL SOLENOIDVALVE)
D.ivesEVAPcontrolcanislervent shut
With ig^ition switch ON (ll): battery voltage
ShiftOownsignalinputfrcmcruisecon
W h e nc r u i s ec o n t r o il s u s e d :p u l s e s
Drives EVAP purge controlsolonoid valve.
S O 2 S H T (CS E C O N D A R V HEATEDOXYGENSENSOR HEATERCONTROL) SCS(SERVICE CHECXSIGNAL)
Drivessacondaryheatedoxygen sensor
W i t h e n g i n sr u n n i n ge, n g i n ec o o l a n tb, e l o w1 5 4 ' F (68'C)rbatteryvoltage W i t h e n g i n er u n n i n ge, n g i n ec o o l a n ta, b o v e1 5 4 " F {6a'C}rduty conl.olled With ignitionswitch ON (ll): baneryvoltage W i t h f u l l yw a r m e du p e n g i n er u n n i n gd: u t y
Detects seNics check conneclor signal (he signalcausinga DTC indicatjon)
w i t h r h el e r m i n a cl o n n e c t e d :v0 W i t ht h e r e r m i n a l d i s c o n n e c t e d r a b5ovu to r
D 4 I N D( D 4 I N D I C A T O R ) + 3 D I N D( D I N D I C A T O R T I
DrivesD4*3.Dr'indicaior light.
W , r h0 4 ' , O " i n d r c a t ol ri g h tt u r n e dO \ b a t t e r ,
F L R( F U E LP U M PR E L A Y )
Drivssfusl pump relay.
0 V f o r i w o s e c o n d sa f t e r r u ' n i n 9 i g n ' l i o n s w i l c h ON lll), then banery voltage
ACC(I/C CLUTCHRELAY}
Drivesl,/C clurch rclay.
INDICA. MIL (MALFUNCTION TORLIGHT) EPEED N E P( E N G I N S PULSE)
Driv€sMlL.
W i t hc o m p r e s s oOr N r 0V With compressorOFF:batteryvoltage W i t h M l L t u r n e dO N : 0 V With MIL turned OFF:batteryvoltage : ulses W i t hs n g i n er u n n i n 9 p
FANC{RADIATOR FANCON TROL)
Drivesr6diatorfan rslay. S e n d sa n d r e c e i v €ssc a nt o o l s i g n a l . Detectssecondaryh€at€doxygensensor
20
GRN
21
8LU/t/EL
K-LINE
23
WHT/RED
SHO2S(SECONDARY HEATED SENSOR2i OXYGENSENSOR.
21
BLU/WHT GBN
2f
BLU/BEO
2A'\
WHT/NED
29
Signal
W i t h D 4 * 3D , * . i n d i c a t olri g h tt u r n e dO F F r 0V
16
26
'12V.
LT GRN
Outputsenginespsed pulse.
With throttlefully openedfrom idle wilh fully w a l m e du p e n g i n ea: b o v e0 . 6V with rhrottlequicklyclosed:below 0-4V Whh staner switch ON (lll): batlery voltage With srarterswitch OFF:0 V
SWITCHSIG, STS (STARTER NAL}
Dotoctssrarterswitch signal.
PSPSW{P/SPsESSUFE SWITCHSIGNAL) ACS (Ir'C SWTCH SIGNAL}
DetecrsPSPswitch signal.
At idle with steeing wh€el in stBighl aheadposition:0 V At idls with nee ng wheel al full lockr banory voltage
D€tectsly'C switch signal.
With Ay'Cswitch ON:0 V With l/C swil€h OFF:about 5 V
SLU {INTERLOCK CONTROL UNIT) P T A N K( F U E LT A N KP R E S ' S U R ES E N S O R ) E L( E L D }
Orives interlock control unil.
With ignilion switch ON (ll)and brakepedal depressed: battery vohage
Detoctsfueltank pressuresensorsignal.
W i t h a g n i t i o ns w i t c h O N ( l l ) a n d f u e l f i l l c a p opensd; about 2.5 v
DetectsELDsignal.
W i r hp a a i n gr i g h t s t u m eodn a t i d l e : a b o u2t. 5- 3 . 5V W i t h l o w b e a mh e a d l i g h ttsu m e do n a t i d l e : a b o u t1 . 5 - 2 . 5 V
BKSW(BRAKESWTTCH)
Dst€cts brake switch signal.
W i r h b r a k e p e d a l r e l e a s e d : 0V With brake pedal depressed: battery vollage
GBN/FED GRN/WHT
W i t h r a d a a t of ar n r u n n i n g : 0V With radaatorfanstopped:batteryvollage With ignition switch ON (ll): p'rlses
13: '98 modsl 15: USA
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(cont'd)
11-71
Troubleshooting '98 - 00 Models Engine/Powertrain ControlModuleTerminalArrangement(cont'd) B {25PI ECM/PCMCONNECTOR
ECM/PCMCONNECTORB I25PI Ierminal Wire color numb€t 1
YEUBLK BLK RED BLU YEL
Wiresideof femaleterminals
NOTE:Standardbafteryvoltageis l2
Terminsl name
Description
IGPl(POWER SOURCE) Powersourcefor the ECM/PClvl with ignitionswitchON (ll):batteryvoltage controlcircuit. with ignitionswitchOFF:0V RR O U N D } Ground for the ECM/PClvlcontrol Lessthan 1.0V at all times P G 1( P O W EG circuit.
l N J 2( N o .2 F U E LI N J E C - DrivesNo. 2 Iuel injector.
roR)
9
YEUBLK
10
BLK
PG2(POWER GROUND} Ground for the ECM/PCMcontrol
'
BRN
l N J l ( N o . 1 F U E LI N J E C TOR)
crrcurt. DrivesNo. l tuel injector.
RED
PNK
19*.
20
BRN/BLK
With ignition switch ON (ll): battery voltage With engine running: pulses With ignition switch ON (ll):duty controlled
A,/Tclutchpressurecontrol solenoidvalvepowersupply positiveterminal Drives OVER-DRIVE OFF indicatorlight.
LG1(LOGIC GROUND)
control Lessthan 1.0V at all times Groundfor the ECM/PCM circuit. Powersourcefor the ECM/PCM Batteryvoltage at all times controlcircuit. PowersourcefortheDTCmemory.
BRN/BLK
LG2(LOGIC GROUND)
23
BLVBLU
IACV{IDLEAIR CON. TROLVALVE)
11-72
With engine running:duty controlled
LS+(A,,IT CLUTCHPRES SURECONTROL SOLENOIDVALVE+ SIDE) ODIND(OVER-DRIVE OFFINDICATOR}
22
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With ignition switch ON (lll: baftery voltage With ignition switch OFF:0 V '1.0 Lessthan V at all times
Sendsignition pulse.
VBU (VOLTAGE BACK WHT/BLU U P )
*2t MlT *3: '98 model "4: '99 - 00 models
With ignition switch ON (ll):duty controlled
rcM {rGNrTroN coN-
YEUGRN TROL MODULE)
17*1
With engine running:duty controlled
l N J 31 N o .3 F U E LI N J E C - DrivesNo. 3Iuel jnjector. TOR) l N J 4{ N o . 4 F U E LI N J E C - DrivesNo. 4 fuel injector. TOR)
LS- (A"/TCLUTCHPRES. A,/Tclutchpressurecontrol SURECONTROL SOLE, solenoidvalvepowersupply _ SIDE) NOIDVALVE negative terminal. IGP2IPOWERSOURCE) Powersourcefor the ECN,I/PCM controlcircuit.
WHT
8*1
Signal
Ground for the ECN4/PCM control ctrcutt, DrivesIAC valve.
With OVER-DRIVE OFFindicatorlight turned ON: 0 V OFFindicatorlight With OVER-DRIVE turned OFF:battery voltage
Lessthan 1.0V at all times With engine running: duty controlled
ECM/PCMCONNECTOFC (31PI
C (31P) ECM/PCMCONNECTOR
Wire sideo{ femaleterminal€
Termidal
NOTE:Standardbatteryvoltageis 12V. D.3cription
8LI(WHT
Signal
HEATED POzSHTC{PRIII4ABY OXYGENSENSORHEATER CONTROL)
Drivssprim6ry h$ted oxygsn sensor
Wilh ignition switch ON (ll): baneryvoltsge With ftrllywarmsd up €ngine runnang:duty
CON, ALTC(ALTERNATOR TROL)
Sondsalternalorcontrol signsl.
With fully wafmod up €ngine rnningrban€ry voltago Du ng driving with small elsctricallo6d:0 v
2"
WHT/GBN
3'1
FED/8LU
K S( K N O C K SENSOR)
DstectsKS signal.
With engine knockang:pulses
5
WHT/RED
FRSIGALTF(ALTERNATOR NAL}
DetectsalternatorFRsignal.
W t h f u l l y w a r m e du p € n g i n er u n n i n g : 0V - b a t t e r y voltag€{d€pendingon slsctricalload)
1
GRN,4trHT
R8 0 U N D } S G 1( S E N S O 6
Groundfor l/tAP sensor.
L€ssthan 1.0v 6t all times
CKPP(CKPSENSOFP SIDE)
Dat€clsCKPs6nsor.
W i t h € n g i n €r u n n i n gpr u l s € s
9
CKPI.,I| {CKPSENSOFM SIDE)
Groundfor CKPs€nsor.
15
PHO2S{PRIMARYHEATED SENSOR1) OXYGENSENSOR,
Detoctspfimary he6t6doxygenssnsor {sonso1 r )signal.
with ihfottls fully openedfrom idle with fully, walm6d up engins:above0.6 V With throttloquicklyclossd:below 0.4 v
D6tectsMAP s€nsorsign6l.
W i t h i g n i t i o ns w i t c hO N ( l l ) : a b o u3t V A t i d l s :a b o u l1 . 0V { d s p s n d i n o g n e n g i n es p e e d )
VCCl {SENSORVOLTAGE)
Power soufce to MAP s€nsor.
With ignition switch ON (ll): about 5 V With ignition switch OFF:0V W i t h e n g i n ef u n n i n g P : ulses
8
BLU
17
RED/GRN
MAP (MANIFOLDABSOLUTE P R E S S U RSEE N S O R )
18
GRN/BLK
B NOUNDi S G 2( S E N S O G
19
YEUBED
Lsssthan 1.0V at all tim€s
20
GRN
TDCP{TDCSENSORP SIDE)
DerecisTDCsensor.
2l
RED
TDCM ITDCSENSORM SID€)
Groundfor TDCsensor.
22
BLU/RED
PSIDE) C K F P( C K FS E N S O R
DstsctsCKFs€nsor.
With sngins running: pulsss
23
BLU/WHT
VSS (VEHICLE SPEEDSEN-
vss signal. Dstscrs
25
RED//EL
IAT (INTAKEAIR TEMPERA' T U R ES E N S O B )
DetactsIAT sensorsignal.
W i t h i g n i t i o ns w i t c hO N ( l l ) a n df r o n tw h e e l s rotaringrcyclss0 v- 6bout 5 V or ban€ryvoltage With igniiion switch ON (ll):about 0.1 - 4.8 V (d€p€ndingon iniate air t€mp€raturc)
26
REO/WHT
ECT{ENCINECOOLANT TEMPERATURE SENSOR)
oetsctsECTsensorsignal.
With ignition switch ON (ll): about 0.1 4.8 V {dopondingon 6ngin€coolanllemper6tu16)
27
RED/BLK
TPS (THROTTLE POSITION SENSOR)
DotectsTP sensorsignrl.
with rhrottls fully op€n: aboui 4.8 v with throtrl6fullyclosed: about 0.5 v
2A
YEUBLU
VCC2lSENSOR VOLTAG€}
Provid€ss€nsorvoltage.
With ignilion switch ON (ll):about 5 V Whh ignitionswitch OFF:0 V
29
YEL
CYPPICYPSENSO8P SIDE) CYPM(CYPSENSORM SIDE)
DsrsctsCYPsensor.
With €ngins runningrpulsss
Groundfor CYPsansor.
30
BLK
soR)
WHT/RED CKFM{CKFSENSORM SIDE) 11.AfT 13. '94 model '2:M/T 14:'99- 0omodsls .5: USA 31
6.ound lof CKFssnsorsignal.
(cont'd)
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11-73
Troubleshooting Powertrain Control Module Terminal Arrangement -'98
- 00 Models (cont'dl
ECM/PCMCONNECTOR D {16P}
PCM CONNECTORD (16P)
Wire sideof lemaleterminals
NOTE:Standardbatteryvoltageis 12V. D€s4ription Oriv€slock'up conrrolsolenoidvalve A.
With lock-upON: b6tteryvoltags W i t h l o c k - u pO F F : 0V
S H B( S H I F T CONTROL SOLENOIO VALVEB)
Drivesshift controlsolenoid valve B.
In 1st,2nd position,in lst and 2nd gear anD4, D3 (D)11position:batteryvohag€ In P, R, N position,in 3rd geaf in D1, D3 (D)*. position,in 4th gear in D4 (D)*rpositionr0V
GRN/BLK
LC 8 (LOCK,UP CONTROL SOLENOIDVALVEB}
Driveslock up controlsolenoidvalve B.
With full lock-up:8atteryvoitage With half lock'uprdutycontrolled
BLK/YEL
VBSOL(BATTERY VOLTAGE F O RS O L E N O IV DA L V E }
Pow€rsourceof solenoidvalvs.
With ignition switch ON (ll): batteryvoltage With ignition switch OFF|0 V
ATPR{AI GEAEPOSITION SWITCH)
DelsclsA/T gear posrtionswirch srgnal.
SHA (SHIFTCONTROL SOLENOIDVALVEA)
Drivesshift conrrolsolenoidvalvp A.
In 2nd, R position,an2nd and 3rd ge6r in D4, D3 (D)r' posilion:batleryvoltage In 1st gear in 04, 03 {D)}. position,in 4th gear in D 4 ( D ) * .p o s i t i o ni,n P , N p o s i t i o n : 0V
ATPD3(AT GEARPOSITION
DetectsA,/Tg€ar poshionswirchsign6l.
I n D 3 p o s i t i o n : 0V h any other posiiion:ban€ryvoltage
YEL
GBN,M/HT
2+1
Sign!l
LCA {LOCK,UPCONTBOL SOLENOIDVALVEA)
BLU,ryEL
PNK
In any other positjon:battsryvoltage
swrTcH) O D S W( O V E R . D B I V SE W I T C H ) DetectsOVEF-DRIVE swirch sagnal.
PNK
9''
YEL
10.,
BLU RED
With Ovor Drivs OFF(O/DOFFindicatorlight t u r n e dO N ) :0 V Wilh Ovsr Drivs ON (O/DOFFindicrto.lasht turned OFF):about 5 V
ATPDI}3,O}I {AT GEAR POStTtONSWTTCH) NC (COUNIERSHAFT SPEED SENSOR)
Dot€ctsA/T g€ar positionswirch signal.
I n D 4 r 3O , * . p o s i t i o n : 0V In any other posilion:batteryvoltage
Detsctscounl€rshaftspeedsensor
With ignition switch ON (ll), and ffonr wheels
N M I I V A I N S H A FSTP E E D SENSOB)
Detectsmainshaftspeedsensorsign6ls.
W i l h e n g i n er u n n i n gp: u l s e s
N M S G{ M A I N S H A F T S P E E D Groundfor mainshaftspeedsensorSENSOB GBOUND) '13*1
LT GRN
8LU BRN
15.' t6'' i1:A/T '2: M/T
GRN *3:'98 model *4:'99 00 models
11-74
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ATPNP(AT GEARPOSITION
DelectsA,/Tgear positionswitch signat.
swtTcH) ATP2(AT GEARPOSFION
DstectsA,/Tgear positionswitch signal.
swrTcH) ATP1{AT GEARPOSITION
h any othsr position:batteryvoltsgs DetsctsA/T gear positionswitch signal.
swrTcH) N C S G{ C O U N T E R S H A F T SPEED SENSOR GROUND}
I n p a r ko r n € u t r a l : 0V h any other posilion:about 5 V
In any other position:htteryvoltage Grouodfor counterchaftsp€eds€nsor.
DiagnosticTrouble Code (DTCIChart DTC (MlLindication*l
Detection ltem
ProbableCause
Pago
P0107
(3)
ManifoldAbsolute Pressu.eCircuit Low Input
Openor short in MAP sensorcircuit MAP sensor ECMiPCM
't'l-90
P0108
{3)
ManifoldAbsolute PressureCircuit H i g hI n p u t
Open in MAP sensorcircuit MAP sensor ECM/PCM
11-92
P 0 11 1 * 3
(10)
IntakeAir TemperatureCircuit Range/Performance Problem
P0112
(10)
lntakeAir TemperatureCircuit Low Input
Short in IAT sensorcircuit IAT sensor ECM/PCM
11-96
P0113
(10)
lntakeAir TemperatureCircuit H i g hl n p u t
Open in IATsensorcircuit IAT sensor ECM/PCM
'I 1-97
P0116
(86)
EngineCoolant TemperatureCircuit Range/Performance Problem
ECTsensor Coolingsystem
P0117
(6)
EngineCoolant TemperatureCircuit Low Input
P0118
(6)
EngineCoolant TemperatureCircuit H i g hI n p u t
Shortin ECTsensorcircuit ECTsensor ECM/PCM Openin ECTsensorcircujt ECTsensor ECM/PCM
P0122
\11
ThrottlePosition Circuit Low Input
Openor short in TP sensorcircuit TP sensor ECM/PCM
11-103
P0123
l7l
ThroftlePosition Circuit H i g hI n p u t
Openin TPsensorcircuit TPsensor ECM/PCM
11-107
PrimaryHeatedOxygenSensor Circuit Low Voltage (Sensor1)
P0131
(1)
P0132
(1)
PrimaryHeatedOrygen Sensor CircuitHighVoltage (Sensor1)
P0133
(61)
Primary HeatedOxygen Sensor Slow Response (Sensor1)
(41)
PrimaryHeatedOxygenSensor Heater CircuitMalfunction {Sensor1)
P0135
. IATsensor 11-95
Short in PrimaryHO2S{Sensor1) circuit PrimaryHO2S(Sensor1) Fuelsupplysystem ECM/PCM Openin PrimaryHO2S(Sensor1) circuit PrimaryHO25(Sensor1) ECM/PCM . PrimaryHO2S(Sensor1) . Exhaustsystem . Openor short in PrimaryHO2S(Sensor 'l) heatercircuit . ECM/PCM
11-99
11 - 1 0 0
11-101
11-110
' 1 11 1 3
11 'I16
11-12'l
*: TheseDTCSwill be indicatedby the blinkingof the MalfunctionIndicatorLamp (MlL)with the SCSserviceconnector connected. **: The E (E)*u indicatortightand the MalfunctionIndicatorLamp(MlL)may come on simultaneously. *1' AIT *3 '97 model +5;'99 - 00 models *2: MlT *4:'98 model {cont'd)
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11-75
Troubleshooting DiagnosticTrouble Code (DTCIChart (cont'd) DTC
Detectionhem
lMlL indicationl P0137
(63)
Secondary Heated Oxygen Sensor Circuit Low Voltage { S e n s o r2 )
P0138
(63)
S e c o n d a r yH e a t e dO x y g e nS e n s o r C i r c u i tH i g h V o l t a g e
P0139
{63)
SecondaryHeatedOxygenSensor
Probable Caus. Shon in Secondary HO2S(Sensor2) circuat Secondary HO2S(Sensor 2) ECM/PCM Openin Secondary HO2S(Sensor 2)circuit HO2S(Sensor2) Secondary EC|\il/PCM HO2S(Sensor 2) Secondary
Page 'n-1t7
1 11 1 8
11-120
lSensor2i P0141
P0r71
(65)
Second6ry Heated Oxygen Sensor Heater C i r c u i tM a l f u n c t i o n ( S e n s o r2 )
Openorshonin Secondary HO2S(Sensor 2) heatercircuit EC|V/PCtu
System Too Lean
Fuel supply system P r i m a r yH O z S( S e n s o r1 )
(45)
Contaminated fuel
't2l
11
1 1124
E x h a u s tl e a k a g e System Too Rich P0112
(45)
Fuelsupplvsystem PrimaryHO2S(Sensor 1) 11124
Contaminated fuel Random Mistire and
Po3ol P0302 P0303 P0304
ltr \ 112| 173i \74t
P0301 P0302 P0303 P0304
/71 \ 112| 173| \74l
P0325*5
{23)
P033s
{4}
P0336 P0420
P0441*3
I A Cv a l v e C o n t a m i n a t e df u e l L a c ko f f u e l
11-126
-
C y l i n d e r1 C y l i n d e r2 C y l i n d e r3 - C y l i n d e r4 Misfire Detected
F u e li n j e c t o r Fuel injector circuit lgnition system
Knock Sensor {KS) Circuit Malfunction
Open or shon in Knock Sensor (KS) circuit K n o c kS e n s o r( K S ) ECM/PCt\4
11-130
Crankshaft Position SensorCircuit
Crankshaft Position Sensor Crankshaft PositaonSensor circuit ECl\,l/PCl\,'!
11-131
(4)
Crankshaft Position Sensor Range/Performance
Crankshaft Position Sensor Timing belt skipped teeth
11,131
{67)
Catalyst System Efficiency Below Threshold
Three Way Catalytic convener Secondary HO2S {Sensor 2)
Evaporative Emission ControlSystem Insulficient Purge Flow
EVAP Purge Control Solenoid valve EVAP Purge Control Solenoid valve circuit Throttle gody (purge port) Tubing PCM
'It 205
F u e l T a n kP r e s s u r eS e n s o rC i r c u i t Bange/Performance
FuelTank PressureSensor ECM/PCM
t't-208
(91i
Fuel Tank PressureSensor Circlit Low Input
{91)
F u e l T a n kP r e s s u r eS e n s o rC i r c u i t HighInput
OpsnorShortin FuelTankPressure Sensorcircuit FuelTankPressureSensor ECM/PCt\4 Openin FuelTankPressureSensorcircuit FuelTankPressure Sensor ECt /PCt\.1
(92)
P0451*5
P0453*r.5
lgnition system Fuel supply system
't't 127
't1-200
11-209
11-211
*: TheseDTCSwill be indicatedby the blinkingo{ the MalfunctionIndicatorLamp (MlL)with the SCSserviceconnector connected. **: The E (El*s indicatorlight and the MalfunctionIndicatorLamp{MlL)may come on simultaneously, *1; A/T *3: '97 model *5: '99 - 00 models *2: MlT *4: '98 model
11-76
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DTC (MlLindicationl
Dotection ltom
P0500
t17)*,
VehicleSpeed SensorCircuit Malfunction
P0501
l17J*1
VehicleSpeed SensorCircuit Malfunction
P0505
(14)
P0700 P0715 PO720 P0730 P0740 P0753 P0758
ldle Control System Malfunction Automatic Transaxle
ProbableCause VehicleSpeedSensor VehicleSpeedSensorcircuit ECtVI VehicleSpeedSensor VehicleSpeedSensorcircuit PCM IACvalve ThrottleBody Fastidlethermovalve*1
Page 11 - 1 3 5
11-135 ' ]1 150
Section l4
P1106
(13)
P1107
(13)
P1108
(13)
P1121
(7)
P1122
(7)
P112a
(5)
P1129
Barometric Pressure Circuit Range/Performance Problem Barometric Pressure Circuit LowInPut Barometric Pressure Circuit HighInpur
(Barosensor) ECM/PCM 11-137
. ECM/PCM {Barosensor) 11-137
ECM/PCM {Barosensor) 11,137
Throttle Position Lower Than Expected
. TPsensor
ThrottlePosition H i g h eTr h a n Expected ManifoldAbsolute PressureLowerThan Expected
' TP sensor
(5)
ManifoldAbsolute PressureHiqherThan Expected
' MAPsensor
P1297
(20)
Electrical Load DetectorCircuit Low Input
ElectricalLoadDetector ElectricalLoadDetectorcircuit ECM/PCM
11 -1 3 8
P1298
(20)
Electrical Load Detector Circuit HighInput
ElectricalLoad Detector ElectricalLoad Detectorcircuit ECM/PCM
11-140
Random lvlisfire
lgnitionsystem Fuelsupplysystem MAPsensor IACvalve fuel Contaminated Lackoffuel
11-126
P1300'3 P0301 P0302 P0303 P0304
7l 72 13 14
11-109
11-'109
. MAPsensor 11-94
1l-94
*: TheseDTCSwill be indicatedby the blinkingof the MalfunctionIndicatorLamp {MlL}with the SCSserviceconnector connected. **:The E (E])+sindicatorlight and the MalfunctionIndicatorLamp(MlL)may come on simultaneously. *1:A,./T "3: '97 model +5:'99 - 00 models *2: M/T *4:'98 model
{cont'd)
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11-77
Troubleshooting DiagnosticTroubleCode(DTCIGhart(cont'd) DTC {MlLindication}
Detection ltem
ProbableCause
154)
Crankshaft Speed Fluctuation Sensor Intermittent Interruption
. CKFsensor
P1336 P1337
i54)
Crankshaft Speed FluctuationSensor No Signal
P1359
(8)
CKFsensor CKFsensorcircuit ECM,FCM ' CKP/TDC/CYP sensorcircuit
P1361
(8)
P1362
(8)
P1381
(9)
P1382
(9)
CrankshaftPosition/TooDead CenterSensorrcylinder Position ConnectorDisconnection Top DeadCenter SensorIntermittent Interruption Top Dead Center SensorNo Signal
CylinderPositionSensor Intermittent Interruption Cylinder PositionSensor No Signal Evaporative Emission ControlSystemLeakDetected (FuelTank System)
P1456n.*
{90}
Evaporative Emission ControlSystemLeakDetected (EVAPControlCanister Svstem) Pr457n.s
{90)
P1508
(14)
ldleAir Control ValveCircuit Failure
Pr607
(-)
EngineControlModule,Powertrain ControlModule InternalCircuit FailureA
Pagc 11-142
11-142
11-146
11-131
TDCsensor TDCsensorcircuit ECM/PCM . CYPsensor CYPsensor CYPsensorcircuit ECM/PCM F u e l f i lcl a p Vacuumconnection Fueltank Fueltankprossure sensor EVAPbypasssolenoidvalve EVAPtwo way valve EVAPcontrolcanistervent shut valve EVAPcontrolcanister EVAPpurgecontrolsolenoid valve Vacuumconnection EVAPcontrolcanister Fueltankpressure sensor EVAPbypasssolenoidvalve EVAPtwo way valve EVAPcontrolcanister ventshutvalve Fueltank EVAPpurgecontrolsolenoid valve IACvalve IACvalvecircuit ECM/PCM . ECM,FCM
11-131
11-131 11-131
11-213
11-219
11-152
11-147
P1705 Automatic P1706 Transaxle P1753 Section'14 P1758 P1768 r: TheseDTCSwill be indicatedby the blinkingoJ the MalfunctionIndicatorLamp (MlL)with the SCSserviceconnector connected. **: The Di (E)*5 indicatorlight and the MalfunctiontndicatorLamp (MlL)may come on simultaneously. *1: A[f *3;'97 model *5: '99 - 00 models *21M/f *4: '98 model
11-7 8
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How to ReadFlowcharts A flowchartis designedto be usedfrom startto final repair.lt's likea map showingyou the shortestdistance.But beware: lf you go off the "map" anywherebut a "stop" symbol,you can easilyget lost.
brARn tw"t t.-OotO FcTloNl @ fS-OPl (boldtype)
Describes the conditionsor situationto starta troubleshooting flowchart. Asksyou to do something;performa test,set up a conditionetc. Asksyou aboutthe resultof an action,then sendsyou in the appropriatetroubleshooting direction. The end of a seriesof actionsand decisions,describesa final repairactionand sometimesdirectsyou to an earlierpart of the flowchartto confirmyour repair.
NOTE: . The term "lntermittentFailure"is used in thesecharts.lt simply meansa systemmay have had a failure,but it checks out OK at this time. lf the MalfunctionIndicatorLamp (MlL)on the dash does not come on, checkfor poor connections or loosewires at all connectorsrelatedto the circuitthat you are troubleshooting(seeillustrationbelow). . Most of the troubleshootingflowchartshave you resetthe EngineControlModule (EcM)/Powertrain ControlModule (PCM)and try to duplicatethe DiagnosticTroubleCode(DTC).lf the problemis intermittentand you can't duplicatethe code,do not continuethoughthe flowchart.To do so will only resultin confusionand, possibly,a needlesslyreplaced ECM/PCM, o "Open" and "Short" are common electricalterms.An open is a breakin a wire or at a connection.A short is an accidental connectionof a wire to ground or to anotherwire. ln simple electronics,this usuallymeanssomethingwon't work at all. In complexelectronics(likeECM'S/PCM'S), this can sometimesmeansomethingworks,but not the way it's suooosedto.
LOOSE
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11-79
PGM-FISystem SystemDescription INPUTS CKP/TDC/CYP Sensor CKFSensor MAP Sensor ECTSensor IAT Sensor TP Sensor PrimaryHO2S SecondaryH02S
vss
KS*5 BAROSensor ELD*6 StarterSignal ALT FRSignal Air ConditioningSignal Ay'TGearPositionSignal*1 BafteryVoltage(lGN.1) BrakeSwitchSignal PSPSwitchSignal *5 FuelTankPressuae Sensor*4.
ENGINECONTROL MODULE(ECM)/ POWERTRAIN MODULE(PCM) CONTROL
|iuel 1"j""- Th,rhg""d Drrafr";-l
OUTPUTS FuelInjectors PGM-FlMain Relay(FuelPump) MIL IACValve Ay'CCompressorClutchRelay RadiatorFanRelay CondenserFanRelay ALT
tcM Et*-.nt"tdt"cont.orl
to,r*,c;;trffi;] . l.----.---:. Lrgnrnon|lmrngLonrrorI
B*k',p Fr""il] Ecir/PcM m;"t-ll-r*'io*l
Countershaft SpeedSensor*1 MainshaftSpeedSensor*r OVER-DRIVE SwitchSignal*s
EVAPPurgeControlSolenoid Valve PrimaryHO2SHeater SecondaryH02S Heater EVAPBypassSolenoidValve*a*5 EVAPControlCanisterVent Shut DLC Lock-upControlSolenoidValve*l Shift ControlSolenoidValve*1 Ay'TClutch PressureControl SolenoidValve*1 D4 IndicatorLight'1*3,*a D IndicatorLight,l *5 OVER-DRIVE OFFIndicator Lighl*t *: * 1 :A / T '2: M/f
{ 3 : ' 9 7m o d e l +4:'98 model *5: '99 - 00 models "6: USA
PGM-FlSystem The PGM-Flsystemon this model is a sequentialmultiportfuel injectionsystem. Fuel iniecior Timing and Duration The ECM/PCMcontainsmemoriesfor the basicdischargedurationsat variousenginespeedsand manifoldpressure.The basicdischargeduration,after being read out from the memory,is further modifiedby signalssentfrom varioussensors to obtainthe final dischargeduration. ldle Air Control ldle Air ControlValve(lACValve) When the engineis cold,the Ay'Ccompressoris on, the transmissionis in gear,the brakepedalis depressed, the P/Sload is high,or the alternatoris charging,the ECM/PCM controlscurrentto the IACValveto maintainthe correctidle speed. lgnition Timing Control o The ECM/PCMcontains memoriesfor basic ionition timing at various engine speedsand manifold air flow rates. lgnitiontiming is alsoadjustedfor enginecoolanttemperature. . A knockcontrolsystemwas adoptedwhich setsthe idealignitiontiming for the octaneratingof the gasolineused.*s Other Control Funstions 1. StartingControl Whenthe engineis started.the ECM/PCMprovidesa rich mixtureby increasingfuel injectorduration. 2. FuelPumpControl . When the ignition switch is initiallyturned on (ll). the ECMiPCMsuppli€sground to the PGM-FImain relay that suppliescurrentto the fuel pump for two secondsto pressurize the fuel system. . When the engineis running,the ECM/PCMsuppliesground to the PGM-FImain relaythat suppliescurrentto the fuel oumo. . When the engineis not runningand the ignitionis on, the ECM/PCMcuts groundto the PGM-FImain relaywhich cuts currentto the fuel pump.
11 - 8 0
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5.
Fuel Cut-off Control . Duringdeceleration with the throttlevalveclosed,currentto the fuel injectorsiscutoffto improvefueleconomyat speedsover 970 rpm ('97- 98 models),920 rpm ('99- 00 modelsl. . Fuelcut-offactionalso takes placewhen enginespeedexceeds6,500rpm ('97 - 98 models),6900rpm ('99 - 00 models),regardlessof the positionof the throttlevalve,to protectthe enginefrom over-rewing. With Ay'Tmodel.the PCMcutsthe fuel at enginespeedsover 5,000rpm when the vehicleis not moving.*' 4,./CComoressorClutch Relav When the ECM/PCMreceivesa demandfor coolingfrom the air conditioningsystem,it delaysthe compressorfrom beingenergized, and enrichesthe mixtureto assurea smoothtransitionto the Ay'Cmode. Evaporative Emission(EVAP)PurgeControlSolenoidValve Whenthe enginecoolanttemperatureis above 154"F(68'C),the ECM/PCMcontrolsthe EVAPpurgecontrolsolenoid valvewhich controlsvacuumto the EVAPpurgecontrolcanister, Alternator Control The systemcontrolsthe voltagegeneratedat the alternatorin accordancewith the electricalload and driving mode. which reducesthe engineloadto improvethe fuel economy.
PCMFail-safe/Back-upFunctions 1. Fail-safe Function When an abnormalityoccursin a signalfrom a sensor,the ECM/PCMignoresthat signal and assumesa pre-pre grammedvaluefor that sensorthat allowsthe engineto continueto run. 2. Back-upFunction When an abnormalityoccursin the ECM/PCMitself,the fuel injectorsare controlledby a back-upcircuitindependent of the systemin orderto permitminimaldriving. 3. Self-diagnosis FunctionIMalfunctionIndicatorLamp (MlL)l When an abnormalityoccursin a signalfrom a sensor,the ECM/PCMsuppliesgroundfor the MIL and storesthe DTC in erasablememory.When the ignition is initiallyturned on {ll),the ECM/PCMsuppliesground for the MIL for two secondsto checkthe MIL bulb condition. 4. Two Trio DetectionMethod To preventfalseindications, fuel metering-related. idle control the Two Trip DetectionMethodis usedfor the HO2S*1, system,ECTsensorand EVAPcontrol systemself-diagnostic functions.When an abnormalityoccurs,the ECM/PCM storesit in its memory.When the same abnormalityrecursafter the ignitionswitch is turned OFFand ON (ll) again, the ECM/PCMinforms the driver by lighting the MlL. However,to ease troubleshooting,this function is cancelled when you jump the servicecheckconnector,The MIL will then blink immediatelywhen an abnormalityoccurs. 5. Two (or Three)DrivingCycleDetectionMethod{'97 model) A "DrivingCycle"consistsof startingthe engine,beginningclosedloop operation,and stoppingthe engine.lf misfiring that increasesemissions or EVAPcontrol system malfunction is detected during two consecutivedriving cycles. or TWC deteriorationis detectedduringthreeconsecutivedrivingcycles,the ECM/PCMturnsthe MIL on. However,to easetroubleshooting, this functionis cancelledwhen you jump the servicecheckconnector.The MIL will then blink immediatelywhen an abnormalityoccurs. *1: '97 - 98 models *2: '99 - 00 models
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PGM-FISystem Powertrain Control Module {PCM}-'97 The Malfunction lndicator LamD (MlL) nev6r comes on {evenlor two seconds) after ignition is turned on (lll, or it's on dimly and flickers.
Model
NOTE:lf this symptomis intermiftent, checkfor a loosefuse No.25 METER(7.5A) in the underdashf{rse/relay box, a poor connectionat PCMterminalA18, or an intermittent openin the GRN/ORN wire betweenthe PCM(A18)and the gaugeassembly.
Turnthe ignitionswitchON {ll}. ls the chargingsystemlighton? -
Rep.ir short or opon in tho wire batween No. 25 METER (7.5Alfuso and gauge a$€mbty. R6pl.c€No. 25 METER17.5Al fus€.
PCM OON ECTORA {32P} PGl IBLKI
Try to stan the engine.
Doesthe enginestart?
Chocktor.n open in th6 wire3 {PG1,PG2linesl: 1. Turn the ignitionswitchON (ll). 2. Measurevoltage between body ground and PCM connectorterminalsA10 and A23 individually. Check for an op€n in the wir6 or bulb (MlL lin€l: 1. Turn the ignitionswitchOFF. 2. Connectthe PCM connector terminalA18 to body ground with a iumperwire. 3. Turnthe ignitionswitchON {ll).
ls thorel€ssthan 1.0V?
Substituto . known-good PCM and r€check.ll symptom/indication goss away, rcplacathe original PCM.
l s t h e M I Lo n ? -
Substitut6 a known-good PCM and rocheck.ll 3ymptom/indication goes away, replacethe o.igin.l PCM.
11-42
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Wire side of female terminals
n€peir open in tho wirelsl hwoon PCM and Glol (loc!t.d at thc tha.mo3tat houling thrt htd moro th.n 1.0V.
A {32PI PCMCONNECTOR
R6pai. open in th. wilei belwoon rcM lAl8l dnd g.uge a3rombly. Roolac€the MIL bulb. Wire sideot temaleterminals
The Malfunciion lndicator Lamo {MlL) stavs on o. comes on aftel two seconds,
Check the Oiegnosiic Trouble Code(DTC): 1 . C o n n e cat n O B D l l s c a nt o o l or HondaPGMTester. 2. Turnthe ignitionswitchON 1lli. 3. Read the DTC with the scan tool or HondaPGII Tester.
Are any DTCIs)indicated?
Ch6cklh6 DTCby MIL indication: 1. Turnthe ignitionswitchOFF. 2. Connectthe SCSserviceconn e c t o rt o t h e s e r v i c ec h e c k connector. 3. Turnthe ignitionswitchON (ll).
NOTE: . Whenthereis no Diagnostic TroubleCode(DTC)stored,the MIL will stay on if the SCS serviceconnectoris connected andthe ignitionswitchis on. . lf this svmotomis intermittent, checkfor: - A looseFl E/M(15Aifuse in the underdashtuse/relay box - A looseNo. 13 FUELPUMP{15A) fuse in the under-dash fuse/relay box - An intermittentshort in the wire betweenthe PCM(C7)and the servicecheckcon-
An intermittentshortin the wire betweenthe PCM(A18)and the gaugeassembly An intermittentshon in the wire betlveenthe PCM(D4)and the MAP sensor An intermiftentshortin the wire betweenthe PCM{D10)and the TP sensor. PGM-Flmain relay. 'See the OBD ll scantool or HondaPGM Testeruser'smanualslor specilicoperating instructions,
Go to troubleshootingprocedures (s€€page11501. NOTE:An openor shortin the wire betweenthe PCM(C8)and the DLCwill keepthe with the PCM.You shouldioterpret scantool or HondaPGMTesterlrom communicating this as no DTCSare indicated.
Doesthe MIL indicateany DTc?
-
Repair opon or short in wi.6 between the PCM (C8) and Data Link Connector. Go to troubloshooting procedur€s {3eepage 11-601. PCMCONNECTOR c l3lPl scs .BRNI
Try to startthe engine.
Doesthe enginestart?
C h e c kt o r a s h o r t i n t h e w i r e {SCSline): 1. Turn the ignition switch OFF a n d t u r n t h e i g n i t i o ns w i t c h oN flt). 2. Measurevoltagebetweenthe P C M c o n n e c t o rt e r m i n a lC 7 and body ground.
ls thereapprox.5 V?
(To page1'l-84)
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lTo page11 84)
Wire sid6of f€maleterminalg
Repairshort to body ground in the wire between PCM lCTl and servicecheck connector.
(cont'dl
11-83
PowertrainControlModule (PCM)-'97
Model (cont'dl
( F r o mp a g e 1 1 8 3 )
Checkfor a short in the wire (MlL line): 1. Turnthe ignitionswitchOFF. 2. Disconnect the PCMconnector A {32P). 3. Turnthe ignitionswitchON (ll).
lsthe MILON?
Repairshort to body ground in the wire between the PCM {418} and MlL.
Substitute a known-good PCM and recheck. lf symptom/indication goes away. replace the original PCM.
InspectFl E/M (15 A) fuse in the undeFhoodfuse/relaybox. -
Reoair shod in the wire between Fl E/M {15 A} fuse and PGM-FImain relav. ReplaceFIE/M 115A)fuse.
InspectNo. 13 FUELPUMP(15Ai fuse in the underdashfuse/relay
CheckloJ a short in a sensor: 1. Turnthe ignit;onswitchON (ll). 2. Disconnectthe 3P connector of eachsensorone at time: . MAPsensor
( T op a g e1 1 - 8 5 )
1 1 -8 4
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-
Repair short in lh€ wire bolween No. 13 FUEL PUMP 115A) Iuse and PGM-FImain
-
ReplaceNo. 13 FUELPUMP 115A) fuse.
(Frompage 11-84)
Does the MIL go off.,
Reolacethe Sensor that caused the lighl lo go out.
Check for a short in the wires lvCC linesl: 1. Turnthe ignitionswitchoFF. 2. Disconnectthe PCM connec tor D (16P). 3. Checkfor continuitybetween bodygroundand PCMconnec tor terminalsD4 and Dl0 indi vidually.
D (16PI PCMCONNECTOR VCCl NEL/RED}
Wiresideof femaleterminals Repair shorl lo body ground in the wile between the PCM {D4}and the MAP sensor. Repairshort to body ground in th€ wire between the PCM lol0l and the TPsensor.
PCMCONNECTOR A (32PI
Check tor an open in the wires llGPline3l: 1 . D i s c o n n e ctth e f u e l i n j e c t o r connectorsand IAC valve con 2. Turnthe ignitionswitchON (lli. 3 . [ , 4 e a s u r ev o l t a g e b e t w e e n b o d y g r o u n d a n d P C Mc o n ' nectorterminalsA'11and A24 individually.
-
Checkfor an open in the wires {LGlinesl: 1. Turnthe ignitionswitchOFF. 2, Reconnect all sensorconnectors, 3. Reconnectthe PCMconnector D (16P). 4. Turnthe ignitionswitchON (ll). 5 , M e a s ur e v o l t a g e b e t w e e n b o d y g r o u n d a n d P C Mc o n nectorterminalsAg a^d 422 individually.
l s t h e r e l e s st h a n 1 . 0 V ?
R e p a i ro p e n i n t h e w i r e ( s l boiween the PCM 1A11,A24) and the PGM-Flmain relav. Ch€ck lor poor connections or loose wires at ihe PGM-FI main relay. Tesi lhe PGM-FImain relav {seep.g6 1l-1871.
Wire side of lemale terminals
R6pair open in the wire{sl between the PCM {A9. A22l and G101 {located at the thetmostat housing)that had morethan 1.0V.
Substituto a known-good PCM and rech€ck.It symptom/indication goos away, replacethe original PCM.
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11 - 8 5
PGM-FISystem Engine Module/PowertrainControlModule(ECM/PCM) '98 - 00Gontrol Models Tho Maltunction Indicator Lamo (MlL) n6Yor como3 on leven lor two laconds) rft6r tho ignhion is turnod ON {lll.
Turnth6 ignitionswitchON (ll).
NOTE: . lf this symptom is intermittent,checktor: - A looseFl E/M{15A) fuse in the under-hood fuse/relay box - A looseNo. 25 METER{7.5A) fusein the under-dash fuse/relay box - A looseNo. 13FUELPUMP(15Alfuse in the underdashfuse/rolay box - An intermiftentshort in the wire betweenthe ECM/PCM (A18)and the gaugeassem-
(C19)and the MAPsensor An int€rmiftent shortin the wire betweenthe ECM/PCM An intermiftentshort in the wire betweenrhe ECM/PCM(C28),the TP sensor,the EGRvalvelift sensorand/or{ueltank Dressure sensor A laulty PGM-FImain relay
-
ls the low oil pressurelighton? -
Repair lhort or opcn in tho wire between the No. 25 METER17.5Al fu3e snd the gaugeassembly. Repl.co the No. 25 METER 17.5Al fus€. ECM/PCMCONNECTOR A (32P}
Try to start the engine. Chockfor an opsn in th€ wiro or bulb {MlL line,: 1. Turnthe ignitionswitchOFF. 2. Connectthe ECM/PCMconnectorterminal A18 to body groundwith a iumperwire. 3. Turn the ignitionswitch ON (ll).
Wiresideof femaleterminals
ls th6 MIL on?
Turnthe ignitionswitchOFF. Inspectthe Fl E/M 115A) tuse in the undeFhoodfuse/relay box.
Substitute a known-good ECM/ PCM and rochock. lf rymptom/ indication goes eway, replace tho o gind ECM/PCM.
-
-
Repair short in the wire between lhe Fl E/M (15 Al f u s G a n d t h e P G M - F lm . i n .slay. R o p l s c et h € F l E / M ( 1 5 A l fu3€.
I n s p e c t h e N o . 1 3 F U E LP U M P (15A) fuse in the under-dash fuse/relaybox. -
-
(Topage11-871
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Repair short in th6 wire between tho No. 13 FUEL P U M P 1 1 5A ) l u s e a n d t h e PGM-FImain .elay. R e D l a c et h o N o . 1 3 F U E L PUMP115Al tuse.
Rep.ir open in the wi.os botween the ECM/FCM lA18l and the gaugo rasombly. Roplecethe MIL bulb.
(Frompage11-86) ECM/FCMCONNECTOR A {25PI IGPl (YEL/BLK)
Ch€ck tor rn opon in tha wiioa (lGPlino.): 1. Disconnectthefuel inj€ctorand IACvalveconnectors. 2. Turn the ignitionswitchON {ll}. 3. Measurevoltage between body ground and ECM/PCM conn€ctorterminals B'l and 89 individually.
r
8
10
20
vXv)iiP2 rELlBLK)
't3
11
17
23
21
Wire sideof lemaleterminals -
ls there batteryvoltage?
2 I 19
-
-
Repaii opon in th6 wirc{3l betw.6n tho ECM/PCM (B1. B g l l n d t h o P G M - F Im a i n roby. Chock for poor connactions or loo3€ wiJo3 at the PGM-FI main ralry. T.st the PGM-FImtin r.lay (soop.ge 11-1871.
Chack for an opon in tho wire3 {PG,LG lino3l: 1 . R e c o n n e ctth e l u e l i n i e c t o r and IACvalveconnectors. 2. Measurevoltage between body ground and ECM/PCM connectorterminals82, 810, 820 and 822 individually.
lstherelessthan1.0V?
Chock for a shon in the wira3 {VCCI, VCC2lin..l: Measurevoltage betweenbody ground and ECM/PCN4 connector terminalsC19and C28individuallv.
ls thereapprox.5V?
B.pair open in the wiroltl b.twocn tho ECM/PCM .nd G101 lloc.t6d rt th. thormoiat houingl that had mo.e than 1.0 V. ECM/PCMCONNECTOR C {3'IP} |
Chock lor a short in r s€nsor: While measuring voltage betwoen body ground and ECM/ P C M c o n n e c t o rt e r m i n a l s C 1 9 and C28 individually,disconnecl the 3P connector ol each sensor one at time:
2 i 3
7
s /
E
't6 1 7 1 8 1 9 20 21\22 26 27 2el E 30 31
vcc2
kt
(YEL/BLUI
vccl
(YEL/RED)
Wire sideof lemaleterminals
. TP sensor . Fueltankpressuresensor
ls there approx. 5 V? Sub3lhuio . known-good ECM/ PCM .nd rcch6ck. lf tymptom/ indic.tion go.3 away, rapl.ce th. original ECM/PCM.
Rooairahort in tho wire b€twoen tho MAP sen3or.TP sensor, Fuel tank DreaaureSonsor and the ECM/PCMtC19,C28).
R e p l e c et h e r o n s o r t h t t h a d approx. 5 V.
lcont'd)
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11-47
PGM-FISystem EngineControlModule/Poweftrain ControlModule(ECM/PCM)
'98 - 00 Models (cont'dl The Malfunction lndicator Lamo lMlll 3lays on or comes on after two 3econds.
Check the Dirgnostic Troublo Cod€ (DTCI: '1. Connecta scantool or Honda PGMTester. 2. Turnthe ignitionswitchON (ll). 3. Readthe DTC with the scan tool or HondaPGMTester.
NOTE: . When there is no DiagnosticTrouble Code IDTC)stored,the MIL will stay on iI the SCS serviceconnectoris connectedand the ignitionswitch is ON (ll). . lf this symptom is intermittent,checkfor: - An intermittentshort in the wire betweenthe ECM/PCM(A10)and the servicecheck connoctor - An intermittentshort in the wire between the ECM/PCM(At8l and the gauge assemDty . See the OgD ll scantool or HondaPGMTesteruser'smanualsfor specificoperating rnstructions.
Go to troublGhooting procadura. (3€c prg€ l lS0l
check tho DTc by MIL indication: 1. Turnthe ignitionswitchOFF. 2. Connectthe SCS serviceconnector to the service check connector, 3. Turnthe ignitionswitchON (ll).
Doesthe MIL indicateany DTC?
Ropair op.n ol Bhort in wiro b.twe.n thc ECM/FCtrl (A21) and D.i. Link Connoctor. Go to troublo3hootlng proc€dur6. lt o pag. 11.6lrl
Try to start the engine.
Doesthe enginestan?
Sub3titute r known"good ECM/ PCM .nd roch.ck. lt .ymptom/ indic.tion gooa awsy, repl.co the origin.l ECM/PCM. ECM/FCMCONNECTOFA {32P)
Check tor a 3hort in the wire ISCSlinel: 1. Turn the ignition switch OFF and turn the ignition switch
o N{ ) .
2- Measurevoltage between body groundand the ECM/ PCi, conneclorterminalA10.
Ropria ahort to body ground in tho wi.c Mwe.n tho ECM/PCM lA10l and aarvic. check connsctor.
lTo page1l-89)
11-88
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Wire sideof femslet6rminals
(Frompage11-88)
Checktor a short in the wire (MlL linel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECM/PCMcon nectorA (32P). 3. Turnthe ignitionswitchON (lli. Repairshort to body ground in the wire b€twe.n the ECM/PCM lA18) and tho MlL. Substituto a known-good ECM/ PCM .nd recheck. lf symptom/ indication goo3 .way, replace th€ original ECM/PCM.
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1-89
PGM-FISystem ManifoldAbsolutePressure(MAPISensor The scan tool indicatesDiagnosticTrouble Code (DTC)POl07:A low input (high vacuum) problem in the ManifoldAbsolutePressure(MAP)sensor, The MAP sensorconvensmanifoldabsolutepressureinto electricalsignalsand inputsthe ECM/pCM.
OUTPUI VOLTAGE
tvl3.s 3.0 2.5 2.O 1.5 1.0 0.5
o
r o - 1 5 ^ 1 o 25 30 lin.H9) GAUGE .5 READIT{G 100 200 300 a00 5oo 6fi, 7d) lmmHgl
Th6 MIL has b€en reoorted on. DTCP0107is 3tored.
Problomverification: 1. Turn the ignitionswitchON lll). 2. Checkthe lvlAPwith the scan root.
ls approx.101kPa(760mmHg, 30 in.Hg),2.9 V indicated?
lrtormittem tailu.e, lystam b OK at thb timo. Checktor poor connoctions or loosa wird at C131 (MAP rensor) and rt the ECM/ PCM.
Check for an op6n in wi.o IVCC1 linel: 1. Turn the ignitionswitchOFF. 2. Disconnectthe MAP sensor connector, 3. Turn the ignitionswitch ON {ll}. 4. Measurevoltage between the MAP sensorconnectorNo. 1 termanal and No. 2 terminal.
ls thereapprox.5 V?
(Topage11-91)
11-90
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MAP SENSOR3P CONNECTOR IC131I
vccl
(YEL/RED}
Roprir op€n in the wir6 bstween tho ECM/PCM(D4,C19*l and the MAP sensor.
Wiro side ol temale terminals
{Frompage11-90)
Chocktor .n open or short in the MAP 3€n30r: C h e c kt h e M A P w i t h t h e s c a n tool.
ls approx.2 kPa(15mmHg, V or lessindi0.6in.Hg),0.1 cated?
(C131I MAP SENSOR3P CONNECTOR
Chock for a lhort in the wire (MAPlinol: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e c tt h e E C M / P C M connectorD (16P),(C131P))*. 3. Checkfor continuitybetween the MAP sensorconnectorNo.3 terminaland body ground.
R€p.ir 3hort in the wire bstwcen tho ECM/PCM(D3,C17') rnd tho MAP 3rnsoi.
Wire sideof lgmaleterminals
Sub3lilut. . known-good ECM/ PCM and rocheck. lf normal MAP k indic.tcd, r.pl.co thc originrl ECM/PCM.
(cont'd)
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11 - 9 1
PGM-FISystem Manifold Absolute Pressure(MAP)Sensor (cont'd) The scan tool indicatesDiagnosticTrouble Code (DTC)P0108:A high voltage (low vacuum) problem in the [tn,t |jg nn-] ManifoldAbsolutePressure(MAP) sensor. The MIL has boen reportedon. DTCm108 is slored. Problemveritication: 1 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutral)until the radiatorfan comeson, then letit idle. 2. Checkthe MAP with the scan tool. ls 101kPa{760mmHg,30in.Hg), 2.9V or higherindicated?
Intermittent tailuro, system i3 OK at this time. Checktor ooor connections or loose wires at C131 IMAPs6nsor)snd the ECM/rcM. MAP SENSOR3P CONNECTOR IC131I
Check Ior an open in the MAP sensor: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e M A P s e n s o r 3P connector. 3. lnstall a jumper wire between the MAP sensor3P connector terminals No.3 and No.2. 4. Turnthe ignitionswitchON {ll). 5. Checkthe MAP with the scan tool.
tcRN/wHrll
IIRED/GRN|
Wire side of female terminals ls 10'lkPa(760mmHg,30in.Hg), 2.9V or higherindicated?
vccl IYEL/RED}
Check for an open in wire (SGl liDel: 1. Removethe jumperwire. 2. Measurevoltagebetweenthe MAP sensor 3P connectorterminalsNo. 1 and No-2. ls thereapprox.5 V? YES
R6p.ir open in the wire betwoen the ECM/PCM(D12,CTrl and the MAP sensor.
Check for an open in the wire (MAPline): 1. Turnthe ignitionswitchOFF. 2. lnstall a iumper wire on the PCMconnectorsbetweenD3 and D12. 3. Turnthe ignitionswitchON (ll). 4. Checkthe MAP wirh the scan tool. ls 101kPa1760mmHg,30 in.Hg), 2.9V or higherindicated?
D I16PI PCMCONNECTOR JUMPERWIRE
Ropair opon in the wire between the PCM {D3, .nd the MAP son3('t.
sGl IGRN/WHTI Wire side of lemale termin6ls
(To page11,93) ': '98- 00 models
1 1-92
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(Frompage11-92)
I Check for an open in the wire {MAPlinel: 1. Turnthe ignitionswitchOFF. 2 . I n s t a l la j u m P e rw i r e o n t h e ECM/PCMconnectorsbetlveen C7andC17. 3. Turnthe ignitionswitchON (ll) 4. Checkthe MAP with the scan tool. ls 101kPa(760mmHg,30in.Hg), 2.9V or higherindicated?
Bopairop€n in the wi.es between the ECM/PCM(c1?l and the MAP 5en30t.
Substitute a known'good ECM/ PCMand recheck.lf normal MAP k indicated, replace the o.iginal ECM/PCM,
(cont'd)
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11-93
PGM-FISystem ManifoldAbsolutePressure(MAP)Sensor(cont'dl The scan tool indicatesDiagnosticTroubleCode (DTC)P1128:ManifoldAbsolutepressure(MAp) lower than exoected. -
The MIL has be6n r€portedon. DTCPl128 is stored.
Problomverification: 1. Turnthe ignitionswitchON1lli. 2. Checkthe MAP with the scan tool,
ls 54.1kPa(406mmHg,16.0in.Hg), 1.61V or higherindicated?
I to.mittent failure, 3ydom i! OK al thbtimc,
The scan tool indicatesDiagnosticTroubleCode (DTC)P'l129:ManifoldAbsolutePressure(MAP)higherthan expected. -
The MIL has boenreportodon. DTCPl129 is stored.
Problemveritication: 1 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load lin Parkor neutral)until t h e r a d i a t o rf a n c o m e s o n , then Iet it idle. 2. Checkthe MAP with the scan tool,
ls 43.3kPa(325mmHg,12.8in.Hg), '1.32 V or lessindicated?
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11 -9 4
Intarmittani fuilure, systom i3 OK at this time.
l
IntakeAir Temperature(lAT)Sensor problemin The scantool indicatesDiagnosticTroublecode (DTC)P0111:A ranoe/performance
1P0111 | ('97model)the lntakeAir TemDerature(lAT)Sensorcircuit.
of the thermistordecreasesas the intake The resistance The IAT Sensoris a temperaturedependantresistor(thermistor). air temDeratureincreasesas shown below -
The MIL has beenreportedon. DTCP0111is stored. Or lrom ProbableCauseList.
RESISTANCE IKOI
Problemvetification: 1. Turnthe ignitionswitchOFF. the IAT sensor2P 2. Disconnect connector, 3. Removethe IATsensor. 4. Reconnectthe IAT sensor2P connector, 5. Leavethe IATsensoretposed to ambienttemPerature. 6 . T u r n t h e i g n i t i o ns w i t c hO N
. 3' aa ro. r?a arl ,.t r.fl 20 0 to ao ao aa ioo t2otocl
INTAKEAIB TEMPERATURE
flr).
7. check the IAT with the scan tool-
R€placethe IAT son3or.
Checkthe IAT sensor output: 1. Warm the IAT sensor with a hair dryer. 2. Checkthe IAT with the scan tool.
Did the IATrise2.0'F(1.0'C) or morefrom the ambient temperature?
Intermittent f.ilure, aY3temis OK ai this tim6.
Replacethe IAT sensor.
(cont'd)
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11 - 9 5
PGM-FISystem IntakeAir Temperature(lAT)Sensor(cont'dl The scantool indicatesDiagnosticTroublecode (DTC)P0112:A low voltage(hightemperature)problem in the IntakeAir Temperature0AT)sensorcircuit. The IAT Sensoris a temperaturedependantresistor(thermistor). The resistance of tho thermistordecreasesas the intake air temperatureincreasesas shown below. -
RESISTANCE IKO)
The MIL has been reDonedon. OTCm112 is stored, Or from ProbableCaus€List.
Problemvsrification: 1. Turnthe ignitionswitchON flt). 2. Checkthe IAT with the scan tool. -. 32 aa rorr 1?a 2ra 2aa f.el -m 0 20 rto ao i0 too l2ofcl
INTAKEAIR TEMPERATUR€
ls 302'F (150'C)or higher (or H - L i m i ti n H o n d a m o d e o f PGMTesterior 0 V indicated? ls the correctambienttemperatureindicated,,?
Beplocetho IAT sensor. It the engineis warm,it will b€ higher than ambienttemperature.
Check for a short in the IAT sensot: 1. Disconnect the IAT sensor2p
Intermittent failure, system i3 OK at this time. Ch6ckfor poor connectiona o. loose wires rt C133 {lAT s€nsorl and rt th6 ECM/pCtr4.
2. Checkthe IAT with the scan tool.
ls 302"F{150"C)or higher{or H - L i m i ti n H o n d am o d e o f PGMTester)or 0 V indicated?
Raplacethe lAT aensor. IAT SENSOR2P CONNCCTOR (C'33I
Ch€ckfor a short in the wir6 llAt linel: 1. Turn the ignitionswitchOFF. 2. Disconnectthe ECM/PCMconnector{D (16P}, C (31P)'). 3. Checkfor continuitybetween the IATsensor2P connectorter minalNo.2andbodyground.
i
'
)
2
A 9)
) /
tAr (RED/YEU
-L
Wi16sideof femsleterminals Repairshort in the wi.o botween th6 ECM/rcM {D8,C25*l and th6 IAT 3ensor. Substitute a known-good ECM/ PCM and recheck. lf normel IAT is indicaled, replace the original ECM/PCM, *: '98- 00 models
11 - 9 6
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The scantool indicatesDiagnosticTroubleCode(DTC)P0113:A high voltage(low temperature)problemin the IntakeAir Temperature(lAT)sensorcircuit.
The MIL has beenreportedon. OTCP0113is stored.
Problemv€rification: 1. Turnthe ignitionswitchON (ll). 2. Checkthe IAT with the scan tool,
ls -4'F (-20"C)or less(or L Limit in Hondamode of PGMTester)or 5 V indicated?
Intermiftent failure, syatem is OK at this time. Ch.ck for Door connections or loose wires at c133 llAT s6nsorland at the ECM/ PCM.
sG2 {GRN/BIIO
Checklor an open in the IAT sensor: 1. Disconnectthe IAT sensor2P connector, 2. Connectthe IATsensor2P con n e c t o r t e r m i n a l sN o . 1 a n d No.2 with a ,umperwire. 3. Checkthe intakeair tempera' ture with the scantool.
ls -4'F (-20"C)or less(or L-Limit in HondamodeoI PGMTester)or 5 V indicated?
ICl33I IAT SENSOR2P CONNECTOR
JUMPENWNE IAT IRED/YELI Wire side ol female terminals
Replacethe IAT sensor.
YES
_!!7rqd9ll_____FCM CONNECTOR O IT6PI
Checklor en opan in the wires llAT, SG2 lines): 1. Turnthe ignitionswitchOFF. 2. ConnectPCM connectorterm i n a l sD 8 a n d D 1 1w i t h a 3. Turnthe ignitionswitchON lll). 4. Checkthe IAT with the scan tool.
IAT IRED/YEL)
sG2 IGRN/BLK}
JUMPER w|BE ls -4"F {-20"C)or Iess(or Llimit in Hondamodeot PGMTester)or 5 V indicated?
Rgpairopen in the wires b€tween the PcM (D8. D11) and rhe IAT 3en30r,
Wiresideof female terminals
l
(cont'd) (Topage11-98)
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11-97
PGM-FISystem IntakeAir Temperature(lATl Sensor(cont'd) (Frompage11,97)
ECM/PCMCINNECTORC t3lPl
Checkfor an open in the wires {lAT,SG2lines): 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCMconnector terminalsC18and C25with a jumperwire. 3. Turnthe ignitionswitchON (ll). 4. Checkthe IAT with the scan tool. ls -4'F 1-20"C)or less(or L limit in Hondamodeof PGMTesterior 5 V indicated?
2 ./
23
5 7 I I 16 1 7 1 8 19 20 21 22
4 Wp,
IAT{RED/YELI
29 c) 31 sG2{GRN/BLK)
JUMPERWIRE Wire sideof fernaleterminals Repsir op€n in the wirca batween the ECM/PCM1C18,C25l and the IAT s€nsor.
I
Substitute a known-good ECM/ PCM rnd recheck, lf normal IAT is indicated, leplaco the originsl ECM/PCM.
'l 11 - 9 8
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(ECTISensor EngineGoolantTemperature problem in the Engine The scan tool indicatesDiagnosticTrouble Code (DTC)P0116:A range/performance CoolantTemperature(ECT)Sensorcircuit. as the engine of the thermistordecreases The resistance The ECTSensoris a temperaturedependantresistor(thermistor). coolanttemperatureincreasesas shown below RESISTANCE tk0l
- 4 3 2 6 8 r 0 a r a 0 1 7 62 1 22 a E{ ' r ) -2O O 20 ito tO .o ! t2O I c)
THERMISTON
ENGINE COOLANT TEMPERATURE
NOTE:lf DTC P0117and/or P0118are stored at the same time as DTC P0116,troubleshootthose DTCSfirst, then troubleshootDTCP0116. PossibleCause a ECTsensordeterioration . Malfunctionin the thermostatand coolingsystem Troubleshooting Flowchart -
The MIL has be€nroportedon. DTCP01'16is stored.
Probl6mverification: 1 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000 rpm with no load (in Parkor neutral)until t h e r a d i a t o rf a n c o m e s o n , then let it idle. 2. With the scan tool, checkthe ECT.
ls 176- 200'F(80- 93"C)or 0.4-0.TVindicated?
Intermittent failure, sYstemb OK at this tim6. Check lhe thermostat and the cooling 5y3tom.
Check the thermostat and the cooling system. It th€y are OK, reolacethe ECTseNor.
(cont'd)
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11 - 9 9
PGM-FISystem EngineCoolantTemperature(ECTISensor{cont'd) :[F011' -
The.scantool indicatesDiagnosticTroubleCode(DTC)P0117:A low voltage(hightemperature)problemin the EngineCoolantTemperature(ECT)sensorcircuit.
The MIL has been rooortodon. DTCml17 is sto.od.
Problemverification: 1. Turn the ignitionswitchON {ll). 2. Checkthe ECTwith the scan tool,
ls 302"F(150'C)or higher(or H Limitin Hondamodeot PGMTester)or 0 V indicated?
Intermittont f.ilure, sysiom is OK at thk time. Checkfor poor connections or loo3e wire3 at C1lil (ECT sensorl and et the ECM/ PCM.
Checkfor a Bhort in the ECTsen301:
'1. Disconnect the ECTsensor2P connefior, 2. Checkthe ECTwith the scan tool.
ls 302"F(150"C)orhigher(or H-Limitin Hondamodeof PGMTester)or 0 V indicated?
ECTSENSOR2P CONNECTOR {C114I
C h e c kf o r r s h o r l i n t h e w i r s (EgTlinel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECM/PCMconnectorD (16P),(C(31P)*1. 3. Checktor continuitybetween the ECTsensor2Pconnectorter minalNo.1 and bodyground. Wire sideof femaleterminals ls therecontinuity?
Substitute a known-good ECM/ PCM and recheck.It normal ECT i! indicatod, replaco the oiiginal ECM/PCM. *:'98 - 00 models
1-1
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Repairshort in the wir€ between the ECM/FCM(D2,C26rl ,nd th6 ECTsenaor.
The scantool indicatesDiagnosticTroubleCode{DTC)P0118:A high voltage{low temperature)problemin the EngineCoolantTemperature(ECT)sensorcircuit. The MIL has be€nreportedon. DTCP01'18is stor€d.
Problemverification: 1. Turnthe ignitionswitchON {ll). 2. Checkthe EcT with the scan tool-
ls -4"F (-20'C)or less(or L-Limit in Hondamodeot PGMTester)or 5 V indicated?
Intermiftent tailu.€,3ystem is OK at this time, Checl foJ poor conn€ction3 or loose wires et C1'14 (ECT ren3or) and at the ECM/ PCM.
ECTSENSOR2P CONNECTOB(C11ill
Checkfor an open in the ECTsen-
ECT (ncD/wlrT)
1. Disconnect the ECTsensor2P connector. 2 . C o n n e c tt h e E C Ts e n s o r2 P connectorterminalsNo. 1 and No.2 with a jumperwire. 3. Checkthe ECTwith the scan tool.
JUi,IPEBWNE
sG2 (GRN/8LKI
Wirc side of lemale terminals
ls -4'F (-20'C) or less (or L'Limit in Hondamodeof PGMTester)or 5 V indicated?
('97model) D {T6PI PCMCONNECTOR JUMPERWIRE
ECT IREDAAIHT)
Checkfor an open in the wiies {ECT,SG2 lines): 1. Turnthe ignitionswitchOFF. 2. ConnectPCM connectorter m i n a l sD 2 a n d D 1 1 w i t h a iumperwire. 3. Turnthe ignitionswitchON {ll}. 4. Checkthe ECTwith the scan tool,
ls -4"F (-20'C)or less(or L-Limit in Hondamodeof PGMTesterior 5 V indicated?
IGRN/BLX}
Wire sideoI femaleterminals
Repairopen in th6 wire! botwe€n the PCM lD2, D'l1l and the ECT 3€n30t.
(To page11-102)
(cont'd)
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11 - 1 0 1
PGM-FISystem EngineGoolantTemperature(ECTISensor(cont'dl ( F r o mp a g e1 1 1 0 1 )
Chacklor an open in the wires (ECT,SG2 lines): 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCMconnector terminalsC18 and C26with a
ECM/PCMOONNECTOR C 13lPI 1
3. Turnthe ignitionswitchON (ll). 4. Checkthe ECTwith the scan tool.
7 I 9 't8 '19 ,/ 16 1 7 20 n
ECTIRED/WHTI
sG2(GRN/BLK)
JUMPERWIRE Wiresideof temaleterminals
ls -4"F (-20"C)or less(or L-Limit in Hondamodeof PGMTesterlor 5 V indicated?
Substitute a known-good ECM/ PCM and rech.ck. lf normal ECT is indicrted, replace ths originsl ECM/PCM.
11-102
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Ralpairopen in tho wir6s b6twe€n tho ECM/PCM1C18,c26l 6nd tho ECTsensor.
ThrottlePosition(TPlSensor The scan tool indicatesDiagnosticTroubleCode (DTC)P0122:A low input (voltage)problem in the Throttle Position(TP)sensorcircuit. lt is connoctedto the throttlevalve shaft.As the throttle positionchanges,the throftle The TP Sensoris a potentiometer. positionsensorvariesthe voltagesignalto the ECM/PCM. '97
BRUSH HOI,I'ER
mod6l: -
The MIL h.3 been reoorted on. OTC m122 b 3tored.
OUTPUT VOLTAGE IVI 5 4
Problemvorificalion: 1 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutralluntil t h e r a d i a t o rf a n c o m e s o n , then turn the ignition switch OFF. 2. Turn the ignitionswitchON (ll). 3 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool.
3 2 1 0
THROITLE OPCNIiIG FUTI IHROTTI"E
TP SENSOR3P CONNECTOR {Cl3OI ls there approx. 10%when the throttle is fully closedand approx.90%when the throttle is fully opened?
Intormittent feilu?e, 3y3tem is OK at thb iime. Checktor poor connodiona or loose wiros at C130 tTPloNorl .nd rt th€ PCM.
Check tor an open in the wire {vOC2linel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe TP sensor3P connector, 3. Turnthe ignitionswitchON lll). il. Measure voltage between the TP sensor3P connectorterminalsNo.1 andNo.3.
vcc2 IYEL/BLUI
Wi.6 6ide ot fgmaleterminsls
D I16PI PCMCONNECTOR
ls thereapprox.5V?
Checkto. an open in wir6 {VCC2 linel: Measurevoltage between PCM connector terminals010 and D11. Ch6ckto. an opon or shon in TP sonaol: 1. Turnthe ignitionswitchOFF. 2, At the sensor side, measure r e s i s t a n c eb e t w e e nt h e T P sensor3P connectorterminals No. 1 and No. 2 with the throttle fullyclosed.
ls thereapprox.5 V?
(GRN/BLX)
Wiresideof femaleterminals Repairopen in the wirc between PCM{D10}and TP 3ensor.
Sub3tituto . known-good PCM and rechock. It proscribed voltag. b now availablo.rcplacoth6 originsl PCM,
( T op a g e1 1 - 1 0 4 ) Terminalsideof maleterminals
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(cont'd)
11 - 1 0 3
PGM-FISystem ThrottlePosition(TP)Sensor(cont'd) (Frompage11 103) TP SENSOR3P CONNECTOR ls thereapprox.0.5- 0.9kO?
Chockfor an open or short in the TP sensor: Measureresistancebetweenthe T P s e n s o r3 P c o n n e c t otre r m i n n a l sN o . 2 a n d N o . 3 w i t h t h e throttlet!lly closed. Terminalsideof maleterminals ls thereapprox.4.5kO? PCMCONNECTOR D I16PI Check to. an open in the PCM (TPSlinell 1 . R e c o n n e ct th e T P s e n s o r3 P connector. 2. Turnthe ignitionswitchON (ll). 3. Measurevoltage between PCMconnectorD (16P)termin a l sD 1a n dD 1 l .
TPS IREO/ BLK)
SG2 (GRN/BLKI
Wiresideol femaleterminals ls thereapprox.0.5V whenthe throftle is fully closedand approx.4.5V when the throttle is fullyopened?
Substitute a known-good PCM and recheck. It orescribod voltage is now available,roplacothe o.iginal PCM.
Repairshort in the wire bstween the PCMlDl)snd the TP ssnso..
11-104
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I
'98 - 00 model3: The MIL has boon reDortod on. DTCm122 b rtorod.
P.oblom veiification: 1. Start the engine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until t h e r a d i a t o rt a n c o m e s o n , then turn the ignition switch OFF. 2. Turnthe ignitionswitchON lll). 3 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool. TP SENSOR3P CONNECTOR {C130} ls thereapprox.10%whenthe throttle is fully closedand approx.90%when the throttle is fully opened?
Intarmittent failure. system is OK at thia time. Checkfor poor conn€ctions or loolo wires rt C130 ITPs.nsorl and.t the ECM/FCM.
Checkfor an opon or short in tho wire {VCC2linel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe TP sensor3P connedor, 3. Turn the ignitionswitchON (ll). 4 . M e a s !r e v o l t a g e b e t w e e n the TP s€nsor3P connectorterminalsNo. 1 andNo.3.
vcc2
sG2 IGRN/BLKI
IYEUBLUI
Wire side oI Iemale lerminals
C (31P} ECM/PCMCONNECTOR
sG2IGRN/BLKI 1
3
a ,l -
18 sl./|
5
ls thereapprox.5 V?
/ 1 6 17
gJ lzgi3osrI T ^ vccz {YEL/8LUl
23 Checklor an opon in wiro IVCC2 linel: Measurevoltage betweenECM/ rcM connectorterminalsC'18and
zzl lrs]zolzr
25
27)
Wire sid6of temaleterminals
c2a. Chockfor en op€n or Bhort in TP 3an30r: 1. Turnthe ignitionswitchOFF. 2. At the sensor side, measure r e s i s t a n c eb e t w e e nt h e T P sensor3P conneclorterminals No. 1 and No. 2 with the throttle fullyclosed.
(To page11-106)
ls lher€approx.5 V?
B.psir opon in the wire b€{woon tho ECM/PCM {C281and th6 TP 3en!xtt.
Subslitute e known-good ECM/ PCM .nd r.chock. lf pro3cribed voltrge iB now rYrilablo, replaca th. originll ECM/PCM. Terminalsideof maletorminals
(cont'd)
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11 - 1 0 5
PGM-FISystem ThrottlePosition(TPlSensor(cont'dl (Fromp6ge11-105) TP SENSOR3P CONNECTOR ls there approx. 0.5 - 0.9 kO?
Chockfor rn op€n or 3hort in tho TP sonsor Measure resistancebetween the TP sensor 3P connectorterminals No. 2 and No. 3 with the throttle fully closed. Terminalside of mal6 terminals ls th€re approx. 4.5 k0?
ECM/PCMCONNECTOR C {31P}
Check lor an open in the ECM/ PCM ITPSlinel: 1. Reconnect the TP sensorcon' nector. 2. Turn the ignitionswitchON {ll). 3. Measurevoltage between ECM/PCMconnectorC (31P) terminalsC18and C27.
3
I
7 l
la
I
1 6 17 t 8 1 9 l m
23
27 t l
TPS IRED/BLK)
l 2 e30 31
Lle (GRN/BLKI {9}
Wire sideol temaletorminals ls thgre6pprox.0.5V when the throttle is Iully closedand approx.4.5V when the throttle is lully opened?
Raoai. ahort in th€ wira lrltw.an the ECM/PCM (C181lnd th€ TP 3€n3rot.
11 - 1 0 6
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Subrtituto . known-good ECM/ PCM rnd rocheok. lI pro.cribed voltaga ia now rvailablc, rcpl.ce th. o.igln.l ECM/PCM.
The scantool indicatesDiagnosticTroubleCode(DTC)P0123:A high voltageproblemin the ThrottlePosition (TP)sensorcircuit. The MIL hlr br€n r.9ort.d on. DTCP0123ir stored.
Pioblom vorificltion: 1 . S t a r t t h e o n g i n 6 .H o l d t h € ongine at 3,000rpm with no load {in Parkor neutral)until t h 6 r a d i a t o rf a n c o m e s o n . then turn the ignition switch OFF, 2. Turn the ignitionswitchON (ll). 3 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool.
ls therespprox. 1oyowhen tho throttle is Iully closedand approx.90%when the throttle is tully open€d?
Intarmittant tailuro, ryrtern b OK at this timo. Chocklor poor connections or loo3o wir€3 at C130 ITP 3orcorl .nd at tho ECM/FCM.
TP SENSOR3P @]{NECTOR IC13O}
sG2 (GnN/Br.Xl Choct toJ an opcn in th6 TP s6n3t']: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe TP sensor3P connectol, 3. Turn the ignitionswitchON (ll). 4. At the wir6 harnossside, measuro voltage betweonthg TP sensor 3P connectort€rminals No. 1 and No.3.
vocr tYEt/8LU)
Wiro side of fom.le terminals
ls thereapprox.5V?
('97model) PCMCON'{ECTOFD I16PI Chack for an oDan in tha wira (SG2linel: M6asu16voltage b6tween PCM conn€ctorterminalsDl0 and D'!1.
{GBIT/BLKI ls there approx. 5 V?
R.pai. opcn in tha wira botwcon tho PcM {o111rnd the TP 3en3('t,
Wire side ot femaleterhinals
(Topage11-108)
(cont'd)
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11-107
PGM-FISystem ThrottlePosition(TP)Sensor(cont'dl (Frompage11-107)
ECM/PCMCONNECTOR C {31PI
Check lor an open in the wirc (SG2line): Measurevoltage betweenECM/ PCMconnectorC (31P)terminals C18and C28.
ls thereapprox.5 V?
Ropairopen in th€ wire betweon rhe ECM/PCM(Cl81.nd the TP 56nSOl,
Substitute a known-good ECM/ PCM and rocheck.lf pre3cribed voltago is now avaibble, replace tho origin.l ECM/PCM,
11 - 1 0 8
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Wire sideof temaleterminals
Pl121 lThescantool indicatesDiagnosticTroubleCode{DTC)Pl121;ThrottlePosition(TP)lowerthanexpected. -
The MIL has been reportedon. DTCPl121 is stored,
Problemveritication: 1. Turnthe ignitionswitchON (ll). 2 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool.
ls 14.1%(12.97.)* or higher indicatedwhen the throttleis fullyopened?
Intormittent failur6, systom is OK at this lime.
I Pl122 | The scantool indicatesDiagnosticTroubleCode(DTC)P1122:ThrottlePosition(TP)higherthanexpected. -
The MIL has b€enreoortedon. OTCP1122is dored.
Problemverification: 1. Turnthe ignitionswitchON lll). 2 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool.
(16.9%)'or less ls'17.670 indicatedwhen the throftle is lully closed?
IntermitteDt tailu.o, system is OK at thb time.
*:'99 - 00 models
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1-109
PGM-FISystem PrimaryHeatedOxygenSensor(PrimaryHO2S)(Sensor1) In operation, The HeatedOxygenSensors(HO2S)detectthe oxygencontentin the exhaustgas and signalthe ECM/PCM. the ECM/PCMreceivesthe signalsfrom the sensorand variesthe durationduring which fuel is iniected.To stabilizethe sensor'soutput,the sensorhasan internalheater.The PrimaryHO2S(Sensor1) is installedin exhaustpipeA.
s€NsoR
HO2S:
TERMINALS
VOLTAGEIVI
ztRcoNtA EI.IMENT
HEATER HEATEB TERMINALS
RICH- AIR. . LEAN FUEL NATO
The scan tool indicatesDiagnosticTroubleCode (DTC)P0131:A low voltage problem in the PrimaryHeated OxygenSensor(HO2S){Sensor1} circuit, 37 - 98 models: The MIL has been reoorted on. DTC P0131 is stoied.
Problemverification: 1. Do the ECM/PCMResetProceoure. 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 load (in Parkor neutral)until the radiatorfan comeson. Test-drivewith the A/T in E position(M/T in 4th gear) Check the Primary HO2S {Sensor1} output voltagewith the scantool during acceleration usingwide openthrottle. Intermittent f.ilure, system is OK at this time. Check fo. poor connections or loose wirer at C111 (Primary HO2S,SeGor 1) and at rh€ ECM/FCM. Checkthe fuel pressure(seepage 11-178).
Repairthe fuel supply system.
{ T op a g e1 1 ' 1 1 1 }
1 1 - 11 0
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{ F r o mp a g e1 1 - 1 1 0 }
Checktor a shorl in the HO2S: 1. Turnthe ignitionswitchOFF. the PrimaryHO2S 2. Disconnect (Sensor'1i 4Pconnector. 3. Startthe engineand let it idle. 4. Check the Primary HO2S (Sensor1)outputvoltagewith the scantool.
Doesit stay at 0.1 V or less?
Replacethe HO2S{Sensor1). (Cl111 PRIMARYHO2Sls.n.or 'l I 4P CONNECTOR
Check for a short in the wir€ (PH02Slinel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECM/PCMconnector(D (16P),C (31P)*). 3. Checktor continuitybetween the PrimaryHO2S{Sensor1) 4 P c o n n e c t o tre r m i n a lN o . 1 and body ground.
PHO2S ---'t rwHTr T-T-l T-1 1 2l
6 t lr___J_J r rl Y
L
Wire sideof temaleterminals Repairshort in tho wire botwesn the ECM/PCMlD7, C16*) .nd th6 Prim.ry HO2S(S€nsor11.
Substituto a known-good ECM/ PCM and recheck. ll 3ympiom/ indicationgoes away. raplaceth. origin.l ECM/PCM.
(cont'd)
www.emanualpro.com
11-111
PGM-FISystem PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1l (cont'd) '99 - 00 models: -
The MIL has bsen reported on. DTCP0131ir storod.
Problemve fication: 1. Do the ECM/PCMReset Procedure, 2. Start the engine. Hold the engine at 3,000rpm with no load {in Parkor neutral)until lhe radiatortan comeson. 3. Check the Primary HO2S (Sensor1) oltput voltage with the scantool during acceleration usingwide op€nthrottle. Doesthe voltage stay at 0.5 V or less?
Inl.rmittant failura, 3yrtam i! OK at thb tim.. Ch.ck tor poor connectiona oa looaa wlraa al C111 {Pri|n.ry HO2S,Son3or 1l .nd .t tho ECM/FCM,
Checktho fuel pressure(seepago 1r,178).
R.p.ir th. fu€l lupply ry!t.m.
Chocklor a short in tho HO2S: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe Primary HO2S (Sensor1) 4Pconnector. 3. St6rtthe engineand lot it idle. 4. Check the Primary HO2S (Sensor1) output voltage with the scantool,
Does it stay 6t 0.5 V or less?
Chock for a short in tho wirc (PHO2Slino): 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECM/PCMconnectorC (31P). 3. Check tor continlity between the PrimaryHO2S{Sensor'l} 4P connectorterminal No. I and body ground.
Rephc. th6 HO2S(S.n3or 11.
PRIMARYHO2S(Son.or 1l aP CONNECTOR |C111)
PHO2S T--1 rwHTr f-T---] --1 1 2l I
t---
1
t6)lslrl v L__r__J
_L
Wire sideol femaleterminals Ragah rhort in tha wira balwoan t h . E C M / P C M{ C l 6 1 r n d t h c Prirn.ry HO2S(S.n3or 11. Substltut6 a known-good ECM/ PCM and recheck. lf rymptom/ indicrtion 00os away, raplaco thc original ECM/PCM.
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11-112
The scan tool indicatesDiagnosticTroubleCode (DTC)P0132:A high voltage problemin the PrimaryHeated OxygenSensor{PrimaryHO2S)(Sensor1) circuit. '97 - 98 models:
Problemverification: 1. Do the ECM/PCMResotPro, ceoute, 2. Start the engine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until the radiatorfan comeson. 3. Test-drive with the Ay'Tin E position(M/Tin 4th gear). 4. Check the Primary H02S {Sensor1}outputvoltagewith the scantool duringdeceleration using completelyclosed throttle. Does the voltage stay at 1.0 V
Intormittent l.ilure, 3ystem ia OK at thb timo. Chcck fo. poor connections01 looso wi.es at C111 {Prim!ry HO2S, Sensor 1} and ECM/PCM.
Checkfor an open in th6 Primary H()2S: 1. Turnthe ignitionswitchOFF. 2. Disconnect the PrimaryHO2S (Sensor1)connector3 . C o n n e c tt h e P r i m a r yH O 2 5 lSensor1) 4P connector termin a l sN o . 1 a n d N o . 2 w i t h a jumperwire. 4. Turnthe ignitionswitchON (ll). 5. Check the Primary HO2S (Sensor1) output voltagewith the scantool,
sG2
PHO2S IWHTI
IGRN/ BLK}
Wire sideot femaleterminals
ls there1.0V or more?
{'97 model}
Ch€ck for an opon in the wires (PHO2S,SG2linesl: 1. Turnthe ignitionswitchOFF. 2. ConnectPCM connectorterm i n a l sD 7 a n d D l 1 w i t h a
PCMCONNECTOR D {16PI JUMPERWIRE PHO2SIWHTI
SG2 IGRN/BLK}
3. Turnthe ignitionswitchON (ll). 4. Check the Primary HO2S {Sensor1) output voltagewith the scantool. ls there1.0V or more?
{ T op a g e1 1 - 1 1 4 )
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Roprir opon in the wire betweon tho PCM {D7 01 D11l and the Primsry HO2S{S6nsor1).
Wire sideof temaleterminals
I (cont'dl
11-113
PGM-FISystem PrimaryHeatedOxygenSensorlPrimaryHO2S){Sensor1} {cont'dl ( F r o mp a g e ' 1 1 - l 1 3 )
Ch.ck for an open in the wire (PHO2Slinel: 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCMconnector terminalsC16and C18with a
ECM/PCMCONNECTOR C {31PI
3. Turnthe ignitionswitchON {ll). 4. Checkthe Primarly H02S (Sensor1) outputvoltagewith the scantool. ls there1,0V or more?
Substitute a known-good ECM/ PCM and rach€ck.lt 3ymptom/ indication goos away, replace the origin.l ECM/PCM.
11-114
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R€p.ir open in the wire bqtw€en t h e E C M / P C M ( C 1 6 1a n d t h € PrimaryHO2S(Sen.or'l).
'99 - 00 modols: Th6 Mll has b€on reDortodon. DTCml32 is itorod.
Problemvorification: '1. Do the ECi!4/PCM ResetPro cedure, Start the ongine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until the radiatorfan comeson. Check the Primary HO2S lSensor1) outputvoltagewith the scan tool during decelelation using completelyclosed throftle.
Doos the voitage stay at 1.5 V or more?
Int.rmitt .fi tailuro, syltom b OK at thit tima. Checkfor poor connactiona oi loo3a wirar !t Cltl (Primrry HO2S,S.nror 1) .nd .t th. ECM/FCM.
PRIMARYHOzS (S6n!or 1l aP CoNNECTORlcltl)
Pt()2s IWHTI
Checkfor an opsn in the Prlmary HO2S: 1. Turnthe ignitionswitchOFF. 2. Disconnect the PrimaryHO2S (Sensor1)connector. 3 . C o n n e c tt h e P r i m a r yH O 2 S (Sensor1) 4P connectort6rmin a l sN o . 1 a n d N o . 2 w i t h a iumperwire. 4. Turn the ignitionswitchON (ll). 5, Check the Primsry H02S (Sensor1) output voltagewith the scantool,
sG2 {GRN/ BTJ(I
Wire side of tem6leterminsls
lsthere 1.5V or more?
Check for an op6n in th6 wiro {PHO2Sline): 1. Turntho ignitionswitchOFF. 2. Connect ECM/PCMconnector terminalsC16 and C18with a iumperwire. 3. Turnthe ignitionswitchON lll). 4. Check the Primary HO2S (Sensor1) outputvoltagewith the scantool.
ECM/PCMCONNECTOR C (31P} 2 23
7 8 9 't8 1912A 0 22 / 1 6 17 E 29 g) 31
PHO2S{WHTI ls there1.5V or more?
Ropair opon in thc wire bc{w.cn t h e E C M / P C M{ C l 6 } . n d t h e PrimaryHO2S{S€nror 1}.
sG2IGRN/BLKI
JUMPERWIRE Wire sideol temalet6rmin6ls
Substituto a known-good ECM/ PCM snd rochock.lf 3ymptom/ indicetion go€a awry, roplaca tho origin.l ECM/PCM. www.emanualpro.com
(cont'd)
1 1- 11 5
PGM-FISystem Primary Heated Oxygen Sensor (PrimaryHO2S)lSensor 1) (cont'd) scantool indicatesDiagnosticTroubleCode(DTC)P0133:A slow responseproblemin the PrimaryHeated tFO133 \ lhe : Oxysen Sensor (Primarv HO2S\ (Sensor 1) circuit. Description By controllingthe airlfuelratiowith a PrimaryHO2S(Sensor1) and a SecondaryHO2S(Sensor2), the deteriorationof the PrimaryHO2S(Sensor1) can be evaluatedby its feedbackperiod.When the feedbackperiodof the HO2Sexceedsa cer tain valueduringstabledrivingconditions,the sensorwill be judgedas deteriorated. When deteriorationhas beendetectedduringtwo consecutive trips,the MIL comeson and DTCP0133will be stored. NOTE: lf DTCP0131,P0132and/or P0135are storedat the same time as DTCP0133.troubleshootthose DTCSfirst, then troubleshootDTCP0133. PossibleCause . PrimaryHO2S(Sensor1) Deterioration . PrimaryHO2SHeater(Sensor1) Deterioration . Exhaustsystemleakage Troubleshooting Flowchart -
The MIL has b6€n reoortedon. DTCP0133is stored.
ProblemVerilication: '1. Do the ECM/PCMResetPro cedure. 2. Connectthe scantool. 3. Start the engine.Hold the engine at 3,000rpm with no load lin Parkor neutraliuntil the radiatorfan comeson. 4. Connectthe SCSservicecon nector. 5. Test-driveunderthe following condations, 55 mph (89 km/h) steady speed - M in @ position(E posi tion and Over DriveON)*, (M/Tin sth gear) - Until readinesscode comes
Intermittent failure, system is OK at this time. Checktor poor connectionsor loose wires at C111 (Primary HO2S,Sensor 1) and al the ECM/PCM. Replacethe Primary HO2S {Sensor 11.
1 1 - 11 6
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SecondaryHeatedOxygenSensor(SecondaryHO2S)(Sensor2) The scantool indicatesDiagnosticTroublecode (DTC)P0137:A low voltageproblemin the secondaryHeated OxygenSensor(SecondaryHO2S)(Sensor2) circuit. The MIL hrs been reported on. DTC P0137 is stored.
Problemveritication: 1. Do the ECM/PCMResetPro' cedure. 2 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm wilh no load (in Parkor neutral)untal the radiator{an comeson, 3 . C h e c kt h e S e c o n d a r yH 0 2 S l S e n s o r2 ) o u t p u tv o l t a g ea t 3,000rpm with the scantool.
Doesthe voltage stay at 0.3 V or less?
lnlermittent failure, 3ystem i5 OK at this time. Checktor Poor con' noction3 or loose wires at C127 {locatod on ECM/PCM bracket}, C721 (Secondary HO2S, Sensor 2l and at the ECM/PCM.
Checkfor a short in the Secondary HO2S: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e c tt h e S e c o n d a r y HO2SlSensor2) 4Pconnector. 3. Startthe engine. 4 . C h e c kt h e S e c o n d a r yH O 2 5 (Sensor2) outputwith the scan tool.
HO2Sls.nlor 2) SECONDARY 4P CONNECTOBlC721l C h e c kl o r a s h o r t i n t h e w i r e (SHO2Slinel: 1. Turnthe ignitionswitchOFF. 2 . D i s c on n e c t t h e E C M / P C M connector{D (16P},A (32P}'). 3. Check for continuity between the SecondaryHO2S(Sensor 2i 4PconnectorterminalNo. 1 and bodyground.
Wire sideof lemaleterminals Reoairshort in the wire b€twoen rhe ECM/PCM|D14, 423*l and the SecondaryHO2S{Sensor2).
Substitute a known-good ECM/ PCM and rocheck.lf symptom/ indication goes away, replace the original ECM/PCM.
(cont'd)
*: '98 - 00 modeis www.emanualpro.com
11-117
PGM-FISystem SecondaryHeatedOxygenSensor(SecondaryHO2SI(Sensor2l (cont'dl The scantool indicatesDiagnosticTroubleCode(DTC)P0138:A high voltageproblemin the SecondaryHeated OxygenSensor(SecondaryHO2S)(Sensor2) circuit. The MIL hra b€on Eported on, OTCm138 b stor.d.
PJoblcmv6dtic.tion: 1. Do the ECM/PCMResotProcedure, 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 load (in Parkor neutral)trntil the radiatorlan comeson. Check the Secondary HO2S (Sensor2) outpl.rtvoltage at 3,000rpm with the scantool.
Doesthe voltage stay at 0.6 V or more?
Int.rmitto tailurc, syst.m b OK rt ihi! timo. Chack fo. poo. oonnoctioni or looaa wiiaa at C127 lloc.ted on EcM/PcM br.cket), C721 (Second!ry llO2S, Sonlol 2).nd at th. ECM/PCM.
Chockfor an opon in the Socondary HO2S: 1. Turn the ignitionswitchOFF. 2 . D i s c o n n e c tt h e S e c o n d a r y HO2S(Sensor2) 4P connector. 3. Connectthe SocondaryHO2S (Sensor2) 4P connectorterminalsNo. 1 and No. 2 with a
SECONDABYHO2S (Sonror 2) 1P CONNECTORrC721l
sHo2s {WHT/REDI
4. Turn the ignitionswitchON {ll}. 5 . C h e c kt h e S e c o n d a r yH O 2 S {Sensor2) output voltagewith the scantool.
sH()2sG IGFN/WHTI
Wire side of female terminals
ls there0.6V or more?
('97model) Ch6ck for an open in thg wiro3 (SH()2S,SG2 line3l: 1. Turnthe ignitionswitchOFF. 2. ConnectrcM connectorterminals 014 and D13 with a J!mper wite. 3. Turnthe ignitionswitchON (ll). 4 . C h e c kt h e S € c o n d a r yH O 2 S ( S € n s o r2 ) o u t p u t v o l t a g e with the scantool.
lsthere0.6V or more?
{ T op a g e1 1 - 1 1 9 ) www.emanualpro.com
1 1 - 11 8
PCMCOI{NECTOR D {16PI
sHo2sG (RED/YELI JUMPERWIRE
Rapair op6n in tho wir. b€{woan tho PcM lDla or Dl3l .nd tho S.condlry HO2S{Senlor 21.
Wirc sideol lemaleterminals
( F r o mp a g e1 1 - 1 1 8 )
('98- 00 models) ECM/PCMCONNECTORS A l32Pl Check for an open in tha wire ISH()2Slinel: 1. Turnth€ ignitionswitchOFF. 2. ConnectECM/PCMconnector terminalsA23 and C18with a iumperware. 3. Turnthe ignitionswitchON (ll). 4. Checkthe Secondary HO2S (Sensor2) output voltage with the scantool.
ls there 0.6 V or more? L _._._ _
_
SHO2SW}iT/RED)| JUMpERW;RE
Repairopon in tho wire botwaen t h e E C M / P C Ml A 2 3 l a n d t h e Second.ry HO2S(Sonsot21.
Wire sideof fomaleterminals I
Substitute a known.good ECM/ PCM .nd recheck. It symptom/ indication goes rway, replace the origin.l ECM/PCM.
(cont'd)
www.emanualpro.com
1 1 - 11 9
PGM-FISystem SecondaryHeatedOxygenSensor(secondaryHO2SI(sensor2l (cont,d) -lTol3al -
The scantool indicatesDiagnostic TroubleCode(DTC)P0139:A slow responseprobtemin the SecondaryHeated UxygenSensor(HO2S)(Sensor2l circuit.
The MIL has b€en reoortedon. DTCP0139is storad.
Probl€mve.itication: 1. Do the ECM/PCMResetPro cedure, S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutral)until the radiatorfan comeson. C h e c kt h e S e c o n d a r yH O 2 S (Sonsor2) output at 3,000rpm with the scantool.
Doesthe voltagestaywithin 0.3- 0.6V for two minutes?
1 1 -1 2 0
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lntehittont failure, 3ystem is OK at this time. Chock for poor connections o. loose wi.es at C127 (located on ECM/PCM brack€t), C721{SecondaryHO2S,Sensor2l and at the EcM/PcM.
HeatedOxygenSensor(HO2S|Heater scantool indicatosDiagnosticTroubleCode Fol3slThe {PrimarvHO2S)(Sensor1) Heatercircuit. indicatesDiagnosticTrouble Code F o 1 1 t The l scantoolHO2S) (Secondary (Sensor2) Heatercircuit. -
(DTC)P0135:A problemin the PrimaryHeatedOxygenSensor
(DTC)P0141:A problem in the SecondaryHeatedOxygen Sensor
Th6 MIL h.. bocn roponod on. DTC P0135,and/oi mlal are stored.
Probl.m verification: 1. Do the ECM/PCMResotProcedure, 2. Startthe engine.
Int.rrnittaii frilurc, awtom ir OK at thi3 time. Chocklor poor conn.ctiona or loosa wiro3 !t C111 lPrim.ry HO2S, Sen3o. 11.C12? llocatcd on ECM/PCM br.ck.t), C721 lsocond.ry Ho2s, s.n3or 2r and at tho ECM/PCM.
Ch.ck ior an opon or shoYt in the HO2S: 1. Turnthe ignitionswitchOFF. 2. Disconnoctthe Ho2s (Primary or Secondary*)(Sensor1 or Sensor2)4P conneclor. 3 . A t t h e H O 2 Ss i d e , m e a s u r e resistancebetween the HO2S 4P connectorterminalsNo. 3 a n dN o . 4 .
PBIMARYHO2Sls.n.or ll 4P CONNECTOR(CI 11I, SECONDARY HO2Sls.n.o.2l aP CONNECTOR lc721l.
Terminalsideof malet€rminals
ls there10- 40 0?
C h e c kf o r c o n t i n u i t y b e t w e e n body ground and the HO2S 4P c o n n e c t o rt e r m i n a l sN o . 3 a n d No. 4 individually. PRIMARYHO2Slson.o. 1l aP CONNECTOR{Cl 11}, SECONDARY HO2Sls.nror 214P CONNECTOR
tcr21l. Checktor an op6n or 3hort in the wires IPO2SHTC, SO2SHTC' linel: 1. Turnthe ignitionswhchON {ll). 2. Moasurevoltage between the HO2S4P connectorterminals N o . 3a n dN o . 4 .
('97model:To page'11-122) ('98- 00 models:To page11-'123)
so2sHTc tBLK/WHn.
PO2SHTC (BLK/ WHTI tGl IBLKAAIHTI'
Wire sid€ of lemale terminals
('97model:To page'11-122) 1'98- 00 modelslTo page11-123)
(cont'd)
*: P0141 www.emanualpro.com
11-121
PGM-FISystem HeatedOxygenSensorIHO2S)Heater(cont'd) {'97model) PRIMARYHO2S(S.nsor 1) ap CONNECTOR {cl111
Chockfor en open or lhort in the wire (lG1 line): M e a s u r ev o l t a g e b e t w e e nt h e HO2S4P connectorterminalNo. 3 ( s e c o n d a r yN: o . 4 ) a n d b o d y ground,
| 1 1 2|
|.i-l 1 3. l
'ot X(9 tErK/ Reprir op6n or 3hort in thc wirc betwo.n th€ No. 15 ALTERNATOR SP SENSOR(7.5 Al fu!. rnd tho HO2S(Primary.Socond.ry*).
Ch€ck for an open in the wire (PO2SHTC, SO2SHTC.lin€): 1. Turnthe ignitionswitchOFF. 2. Reconnectthe HO2S4P con-
-L
Wiresideof femaleterminals
SECONDARY HO2S ISENSOR214P CONNECTOR
lcr21l,
3. Disconnectthe PCM connector A (32P). 4. Turnthe ignitionswitchON (ll). 5 . M e a s u r ev o l t a g e b e t w e e n PCM connectort€rminals46 andA10(A5andA10)*.
ls thero0.1V or less?
YELI
IGl IBLK/WHTI
Bepair opon in the wiro botwoon the PcM (A6. A5lr and tho Ho2s {Prim.ry, Socond!ryr}.
Wire sideol femaleterminals
Substitute a lnown-good PCM and recheck. lt 3ymptom/indication goes away, .oplacothe original PCM.
( F r o mp a g el 1 - 1 2 1 )
Wire sideof femaleterminals Check fo. a ahort in the wire SO2SHTC.lins): IPO2SHTC, 1. Turn the ignirionswitchOFF. 2 . D i s c o n n e c tt h e P C M c o n nector A {32P). 3. Checklor continuily between the PCM connectorterminal 46 (A5)*and body ground.
So2HTCIALK/WHTI*PO2SHTCIBLK/WHTI
Bopair short in the wire lrotwsen tho PC{r4{A6, A5rl and the HO2S lPiimary, S€condary.l. Substitute a known-good PCM and .echgck. lf 3ymptom/indication go€s awry. repl.cethe original PCM.
11-1 2 2
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('98- 00 models)
HO2S{S.n3or 1l aPCONNECTOR PRIMARY lc111l Check for an open in the witoa (lGP,lGl'lino): Mgasurevoitage betweenthe primary HO2S4P connectorterminal No. 3 (secondaryHO2S:No. 4) and body ground.
1 1 2 l
r--T -
lL-.IJ------J 3 t . l
Bepair opan or short in tho wilo bdtween th6 nlo. 15 ALTERNATOR SP SENSOR17.5Al fu$ .nd th6 HO2S{Primrry, S€condtrytl.
Wiresideof femaleterminals HO2S SECONDARY {SENSOR2} 4P CONNECTOR (c7211'
Chock lor sn opon in the wires SO2SHTC'lincl: IPO2SHTC, 1. Turnthe ignitionswitchOFF. 2. Reconnectthe HO2S4P connector. 3. Disconnectthe ECM/PCMconnector C (31P)(ECM/PCMconneaor A (32P))*. 4. Turnthe ignitionswitchON (ll). 5. Moasurevoltage between ECM/PCMconnectorterminals 82 andCl (82andA8)*. ls there0.1V or less?
lcl /5' tErK/ g, YELI I
IGl IBLK/WHT}
Wire sideof femaleterminals Repsir opsn in tha wire between tho ECM/PCM(C1, A8.) .nd the HO2SlPrimsry,Socond.ry*}.
ECM/FCMCONNECTORS PGl (BLK}
Sub.titute a known-good ECM/ PCM and rocheck. lf iymptom/ indicrtion goes away, repbce the original ECM/PCM.
lFrom page11-12'!)
Chock lor a short in the wi.es (PO2SHTC, SO2SHTC'linol: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe EcM/PcM connector C {31P)lECM/PCMconnectorA (32P))*. 3. Check for continuity between ECM/PCMconnectorterminal Cl (A8)*and bodyground. ls therecontinuity?
Roolir 3hort in th. wiro betwoon the ECM/PCMlC1, A8'l and the HO2S(Primary,S6condary*).
Sub3tituie s known-good ECM/ PCM and rech6ck. It symptom/ indicaiion goes away. lgplaco th6 origin.l ECM/PCM. : P0'14'l
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Wire sideof lemaleterminals
11-123
PGM-FISystem Fuel Supply System [POliil
The"""ntool indicatesDiagnosticTroubteCode(DTC)p0'171:Thefuet systemistoo lean.
[Fo17ZJ rh""""ntool
indicatesDiagnosticTroubtecode {DTc)p0172:Thefuelsvstemistoorich.
Description By monitoringthe LongTerm Fuelrrim, long term malfunctionsin the fuel systemwill be detected. lf a malfunctionhas beendetectedduringtwo consecutive trips,the MIL will come on and DTc p0171and/orpol72 will be stored. NOTE: lf someof the DTCSlistedbeloware storedatthesametimeas DTCP017'land/orp0172,troubleshootthose DTcs first,then troubleshootDTCP0171and/orPO1i2. P0107,P0108,P1128,P'1129: MAP Sensor P0135:PrimaryHO2S(Sensor1)Heater P0137,P0138:SecondaryHO2S{Sensor2) P0141:SecondaryH02S (Sensor2) Heater P0441*r:EVAPSystemlnsufficientPurgeFtow P1456*,,P'l457*?i EVAPSystem Insufficientpurge Ftow
* 1 : ' 9 7m o d e l *2: '98 - 00 models
PossibleCause DTCP0171 too lean
FuelPumpinsufficientflow/pressure FuelFeedLineclogged.leaking FuelPressureRegulatorstuckopen FuelFilterclogged FuelInjectorclogged,air leakage Gasolinedoesn'tmeet Owner'sManualspec. PrimaryHO2S(Sensor1) deteriorated ValveClearance Exhaustleak
DTCP0172
FuelPressureRegulatorclogged,stuckclosed FuelReturnPipeclogged FuelInjectorleaking Gasolinedoesn'tmeetOwner'sManualspec. PrimaryH02S (Sensor1) deteriorated EVAPPurgeControlSolenoidValveleaking,stuckopened ValveClearance
flch
11 -1 2 4
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TroubleshootingFlowchart -
The MIL has beenrePortedon DTC P0171 andlot P0172 are stored,
ls the lLrelpressuretoo high Checklhe Primaty HO2S: 1 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkot neutral)until the radiatorfan comeson 2 . C h e c kt h e P r i m a r yH O 2 S ( S e n s o r1 ) o u t P u tw i t h t h e scantool.
Doesit stayat lessthan0.3V or morethan 0.6V?
Checkfor a sticking or leaking EVAPpurge control solenoid vacu With a vacuumpump,aPPIY u m t o t h e E V A PP u r g ec o n t r o l s o l e n o i dv a l v e f r o m t h e i n t a k e manifoldside.
Doesit holdvacuum?
Checkth6 valve clearanc€sand adjust il necessary. It the valv€ clearancesare OK, replace the fuel iniectors.
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Checklh€ fuel pumP. fuel faed pipe. fuel fiher, and luel Prossurc .eguhior.
Checkthe lu6l pressuroregulator and tusl relum PiPe.
PGM-FISystem RandomMisfire lF()gool",tftod-'
The scantool indicatesDiagnosticTroubleCode (DTC) pO3O4; Random misfire.
andsome orlpiogolthroughTo3otiP0300*,,P1300*1and someof po30t-
Descriotion Misfiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaft speedfluctuation(cKF)sensor which is attachedto the crankshaft. lfmisfiring strongenoughto damagethe catalystis detected,the MIL will blinkduring the time of its occurrence, and DTc P0300*' P1300*1 , and some of DTCsP03olthrough P0304will be stored.Then,after misfirehasceased, the MtL will come on, lf misfiringthat increasesemissionsis detectedduring two consecutivedriving cycles,the MIL will come on, and DTc and some of DTCSp0301through p0304wi be stored. NOTE:lf some of the DTCSlistedbeloware storedat the sametime as a misfireDTc, troubleshootthose DTcsfirst. then troubleshootthe misfireDTC. P0106,P]128,P1'129; MAp sensor P0171.P0172;Fuetmetering P0505:ldle Control Svstem P1336,P1337;CKFsensor P1361,P1362:TDCsensor Pl381.Pl382:CYPsensor *1:,97 model P1508:IACvalve *2: '98 - 00 models PossibloCaus€ . Fuelpump insufficientfuel pressure,amountofflow . Fuelline clogging.blockage,leakage . Fuelfilter clogging a Fuelpressureregulatorstuckopen . Distributormalfunction . lgnitioncoil wire open,leakage . lgnitioncontrolmodulemalfunction . Valvescarbondeposit a Compressionlow a Fueldoes not meetOwner'sManualspec.,lackoffuel Troubleshooting By test-driving,determinethe conditionsduring which misfireoccurs.Depending on these conditions,test in the order describedin the table below.
\ [
Possible cause -.... ;;;;-
Condition Only low rpm and load
Crankshaft speedfluctuation sensor
Fuel pressure
Distributorand lgnitionwires
tcM
section6
11-178
section 23
section 23
,6)
Valve Clearance section 6
o
Only accelerating
o
o
o
Only high rpm and load
o
@
,a'
@
o
@
o
@
Not specification
G\
NOTE:lf misfiredoesn'trecur,some possiblecausesare fuel that doesn'tmeet owner'smanual spec,lackof fuel, carbon deposits on spark plu9, etc.
11-1 2 6
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MisfireDetectedin OneCylinder Ipffi1]
ThescantootindicatesDiagnosticTroubleCode(DTC)P0301:Cylinder1 misfiredetected.
lF03O2l 16".""n toot indicatesDiagnosticTroubleCode(DTC)P0302;Cylinder2 misfiredetected. I P0303 | fne scantool indicatesDiagnosticTroubleCode(DTC)P0303:Cylinder3misfiredetected. Cylinder4 misfiredetected lF0il04l 16" ""un tool indicatesDiagnosticTroubleCode(DTC)PO3O4: Description (CKF)sensor Misfiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaftspeedfluctuation which is attachedto the crankshaft. and DTC lf misiiringstrongenoughto damagethe catalystis detected,the MIL will blinkduringthe time of its occurrence. on. MIL will come the has ceased, misfire after the Then, will be stored. P0304 and/or P0303 P0301,P0302, DTc lf misfiringthat increasesemissionsis detectedduring two consecutivedriving cycles.the MIL will come on, and P0301,P0302,P0303and/orP0304will be stored. first,then NOTE:lJ some of the DTcs listedbelow are storedat the sametime as a misfireDTc, troubleshootthose DTcs troubleshootthe misfireDTC. P0107,P0108,P'n2a,P1129tMAP sensor 'l P0112tFuel suPP|Ysystem Po'17 , P0441:EVAPinsufficientPurgeflow P1336,P1337:CKFsensor P1359,Pl361,P1362:TDCsensor Pl381,P1382:CYPsensor PossibleCause . Fuelinjectorclogging,fuel leakage,air leakage . Fuelinjectorcircuitopen or shorted . Sparkplug carbondeposits,fouling,malfunction . lgnitionwires open,leaking . Distributormalfunction . Compressionlow . Valveclearanceout of specification
(cont'd)
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11-127
PGM-FISystem MisfireDetestedin OneCylinder(cont'dl Troubl93hootingFlowchart -
Th. MILh!3 b6onr.portod on. DTCm30r, P0302,m303. or P0304is indicated.
Ch.ck tho fuol inicctor tunction: Startthe engino,and listenfor I clickingsoundat the fuol injector in the probl€mcylinder.
The illustration shows '97 - 98 models,'9900 models are similar. Checkfor an open or short in the harnessbetweenthe ECM/PCM and the luel injector.
Boprir opan or 3hort in tha wlre.
-
Problom vorification: 1. Atter chackingthe lre€zedata, do the ECM/PCMReset Procedure. 2. Exchange the sparkplug from the problemcylinderwith one ol anothercylinder. 3. Connectthe SCS service connector. 4. Tost-drivethe vohicleseveral times in the rangool the freeze data.
(Topage'11-129)
1 1 -1 2 8
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Roplacoth. tuel inioctor. Substitut. . known-good E C M / P C M. n d r o c h o c k .I t 3ym ptom/ indicati on go.3 a w . y , r e p l a c et h e o l i g i n a l ECM/PCM.
NOTE: .lf there is no freezedata ol misfiring, just clearthe DTC. .lf there is no freezedata ot misfiring, test drives under various conditions are necessary,
( F r o mp a g e1 1 - 1 2 8 )
ls DTCP0301,P0302,P0303, or P0304indicated?
ooesthe misfireoccurin the othercylinder?
Check lor fuel iniector maltunct|on: 1 . E x c h a n g et h e f u e l i n j e c t o r f r o m t h e p r o b l e mc y l i n d e r with one from anothercylinder. 2. Letthe engineidlefor two min utes. 3. Test'drivethe vehicleseveral times in the rangeof the freeze data,
ls DTCP0301,P0302,P0303, or P0304indicated?
Doesthe misfireoccurin the othercylinder?
lntormittent misfire due lo spark plug fouling, etc. (no mislire at this tim€).
Replacethe faulty spark Plug.
NOTE:lf there is no freezedata of mis firing, test drives under variouscondi_ tionsare necessary.
lntermittent misfiro due lo bad contrct in the fuel iniector connector {no misfire at this time).
Replacelhe faulty luel inlector.
Checkfollowing items - Valvo clearance - Cvlinderl€ak-down - Compression - Crsnkshaft Speed Fluctuation ICKF)sensol
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11-129
PGM-FISystem KnockSensor{KSl ('99- 00 models)The scantool indicatesDiagnosticTroubloCode(DTC)P0325:A malfunctionin the circuitof the KnockSensor(KS). -
The MIL has been rooortedon. DTCm325 is storod.
Problemverification: 1. Do the ECM/PCir,ResetPro cedure, 2 . 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 load (in Parkor neutral)until t h e r a d i a t o rt a n c o m e s o n , then let it idle. 3 . H o l d t h e e n g i n e a t 3 , 0 0 04,000 rpm for at least 60 seconds, Intermittent lailu.e, 3ystom is OK at thi3 tim. (te3t drive m.y be nacalLrYr. Chock to. poor connsctions ol loora wiros rt C137 lknock aon.o. (KS))and ar the ECM/FCM. Ch€ck tor a short in the wir6 {KS linel: 1. Turnthe ignitionswitchOFF. 2, Disconnectthe knock sensor lP connector. 3. Checklor continuitybetween E C M / P C Mc o n n e c t o rt e r m i nalsC3and body ground.
ECM/PCMCONNECTOR C 131P}
Replil rhort in the n irg b6{wocn tho ECM/PCMlc:ll and the knock s€ngr1. Check fo..n open in the wire {KSline): C h e c kf o r c o n t i n u i t y b e t w e e n ECM/PCMconnector terminal C3 and knocksensorconnectorter, m i n a lN o .1 .
Wiresideof femaleterminals
KS 1P CONNECTOR IC13?'
KS IRED/BLU) Wire side ol female termtnals
ls therecont;nuity?
B.pair opon in the wirc lrotween lho ECM/PCMlctl and thc knock acnsor.
Substitutea known-goodknock sensorand recheck.
NOTE: Torquethe knocks6nsorto 31 N.m (3.2kgl.m, 23 lbf.ft).
ls DTCP0325indicated?
Bcpl.ce the originalknock 3€nsor,
ECM/PCMCONNECTOR
KS c (31P) (BED/BLU)
Wire sideot femaleterminals
Substituto a known-good ECM/ PCM and .echeck. lf 3ymptom/ indication goes away, replace the original ECM/PCM.
11 - 1 3 0
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Sensor Position(CKP/TDC/CYPI CrankshaftPosition/TopDeadGenter/Gylinder scantool indicatesDiagnosticTroubleCode tro-rslThe sensorcircuit,
(DTC)P0335;A malfunctionin the CrankshaftPosition(CKP)
problemin the Crankshaft The scantool indicatesDiagnosticTroubleCode(DTC)P0336:A range/performance
1Tffi61 Position{CKP)sensorcircuit. The
tool indicatesDiagnosticTroubleCode {DTC)P1361:Intermittentinterruptionin the Top DeadCenter
scan tF136t(TDC) sensorcircuit. The scan fPfa6r-1 ci.cuit.
tool indicatesDiagnosticTroubleCode (DTC)P1362:No signalin the Top DeadCenter(TDC)sensor
tool indicatesDiagnosticTroubleCode(DTC)P1381:Intermittentinterruptionin the CylinderPosition
The scan tF138tl(CYP) sensorcircuit.
The scantoot indicatesDiagnosticTroubleCode {DTC)P1382:No signalin the CylinderPosition(CYP}sensor
I-Pi382lcircuit.
Description The CKPSensordeterminestiming for fuel injectionand ignitionof eachcylinderand also detectsenginespeed.The TDC Sensordeterminesignitiontiming at start-up{cranking)and when crankangle is abnormal.The CYPSensordetectsthe Sensoris built into the distribupositionof No. 't cylinderfor sequentialfuel injectionto eachcylinder.The CKP/TDC/CYP ror. NOTE:lf DTCP1359is storedatthesametimeas DTCP0335,P0336,Pl361,P1362,P1381and/orP1382,troubleshootDTC P1359first,then troubleshootthose DTCS.
'97 model: -
The MIL has be€n reportedon. DTC P0335, P0336, P136' 1, P1362,Pl341 and/oi P1382are stored.
lOP DISTRIBUTOR CoNNECTOR(Cl211 TDCPIGRNI
CYPPIYELI
Problemverific.tion: 1. Do the PCMResetProcedure. 2. Startthe engine. ls DTCP0335,P0336,P1361,P1362, P1381and/orP1382indicated?
Ch.ck for an open in tho CKP/ TDC/CYPsensor: 1. Turn the ignitionswitchOFF. the distributor10P 2. Disconnect connector. 3. Measureresistancebetween the terminalsof the indicated sensor(seetable). ls there 350 - 700 o?
Intermittent lailure, 3yd6m i3 OK at thb tims. Chcck tor poor connections ol looso wire3 si C12'l ldistributor) .nd .t the PCM.
CYPM(BLKI TIrcMIREOI
Terminalsideof maleterminals S E N S O E DTC
Replacetho distributor ignition housing {sea3ection41.
SENSOB
WIRE PCM E R M I N A I COLOR
P0335 P0336
l
CKP
c2
8
c12
TDC
P1361 P1352
9
P' I381 P1342
3 't0
CYP
8LU
2
GRN
c13 c4 c14
RED YEL BLK
{cont'd) (To page11-132)
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11-131
PGM-FISystem Grankshaft Position/Top DeadCenter/Cylinder Position(CKP/TDC/CYPI (cont'd) Sensor DISTRIBUTOR 10PCONNECTOR tCl2l)
{ F r o mp a g e 1 ' 1 - 1 3 1 )
CKP P IBLUI
TDCP {GRNI
Check for a short in the CKP/ TDC/CYPsensor: C h e c kf o r c o n t i n u i t yt o b o d y ground on both terminalsof the indicatedsensorindividually(see t a b l eo n p a g e1 l 1 3 1 ) .
ls therecontinuity?
R€plac€the distributor ignition housing {seesection4}.
Ch€ckfo. an open in the wires lines): {CKP/TDC/CYP '1. Reconnect the distributor10P connector. 2. DisconnectPCMconnectorC (31P). 3. Measureresistancebetween the terminalsof the indicated sensoron the PCMconnector o n p a g e1 l 1 3 1 ) . lseetable
ls there350- 7000?
Terminalsideof maleterminals
Repairopen in the indicated sensor wires {se6 table on page 11131).
PCMCONNECTORS C I31P) CKPP TDCP CYPP IBLU) IGRNI IYEL}
Check tor a short in the wires linesll {CKP/TDC/CYP C h e c kf o r c o n t i n u i t y b e t w e e n body groundand PCMconnector terminalsC2,C3and/orC4 individ-
ls therecontinuity?
Substitute a known-good PCM, and recheck.lf symptom/indication goes away, r€placelhe original PCM.
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R€Dairshort in the indicatodsensor wires lsee table on page 1113rI.
{WHT)
IREDI IBLK) Wiresideof female terminals
CKPP
TDCP
CYPP
'98 model: 1OP DISTRIBUTOR CoNNECTOR(C121) TDCP(GRN) CYPP(YEL}
'98 - 00 models:
'99 - 00 modelr: 8P DISTRIBUTOR coNNECTOR{C121) TDCP (GNN} CYPP IYEL}
The MIL ha3beenreoortedon. DTC P0335. P0336, P1361, P1362.P1381andlor P13V are stor€d, Problemverification: 1. Do the ECM/PCMResetPro cedure. 2. Startthe engine.
TDCM(REDI CYPMIBLKI Terminalsideof maleterminals Intermittant tailure, svstom is OK at this time. Check for poor connections or loose wirgs al C121 {distributo.l .nd at the ECM/ PCM.
ls DTCP0$5, m$6, Pl361,P1362, P1381and/orPl382 indicated?
Check for an open in th6 CKP/ TDC/CYPsensor: 1. Turnthe ignitionswitchOFF. 2. Disconnect the distributor10P (8P)*connector. 3, Measureresistancebetween the terminalsof the indicated sensor{seetable).
CYPM IBLKI
TDCM (RED} sideof maleterminals Terminal S E N S O R DTC
SENSOR ECM/PCM WIRE ERMINAT I E R M I N A I COLOR ):'99mode
P0335 P0336
8 (6)
c8 c9
BLU
CKP
P1361 Pl362
2 (3)
c20
GBN
TDC
9 (7)
c21
RED
3 (4)
c29
YEL
1 0{ 8 )
c30
BLK
CYP
P]381 P]382
1 t2)
Rephce the distributor ignition houaing l3e93oction4).
ls there350 7000? '98
modeli
TDCP {GRNI
Check for a short in the CKP/ TDC/CYPs€nsor: C h e c kf o r c o n t i n u i t yt o b o d y ground on both terminalsof the indicatedsensorindividually(see table).
Replacotho distributor ignition housing lsee soction tll.
Check for an op€n in th6 wires linesl: ICKP/TDC/CYP 1. Reconnect the distributor10P (8P)*connector. 2. Disconnect ECM/PCM connector C (31P). 3. Measureresistancebetween the terminalsof the indicated sensoron the ECM/PCMcon nector(seetable).
ls there350 700O?
C {31P) ECM/PCMCONNECTOFS
CKP P {BLU)
Repairopen in the indicated sensor wires lsee t.ble). ':'99 - 00 models
TOCP IGRNI CYPP (YEL)
(Topage11-134) femaleterminals
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CKPM IWHT)
M
(RED) CYPM (BLKI
(cont'd)
11 - 1 3 3
PGM-FISystem GrankshaftPosition/TopDeadCenter/CylinderPosition(CKP/TDC/CYPI Sensor{cont'd} (Frompage11 133) C {3IPI ECM/PCMCONNECTOR
Chock lor r 3hon in tho wirer lin6): ICKP/TDC/CYP C h e c kf o r c o n t i n u i t y b e t w e e n body groundand ECM/PCMconnectorterminalsC8, C20 and/or C29individually.
Rep.ir lhort in ths indicatedsonaor wiroa 136otable on prge 11133). Substituto r known-good ECM/ PCM, and .6chock. tf 3ymptom/ indication goe3 swey, replrce tho original ECM/PCM.
11 -1 3 4
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Wire sideof femaleterminals
Vehicle Speed Sensor (VSSI |posoll-' lPosoo-]-'.
The scantool indicatesDiagnosticTroubleCode{DTC}P0500*' orP0501*r:A range/perfor* I ; A/T mancein the VehicleSpeedSensor(VSS)circuit. *2i Mfi
'97 modol: FCM CONNECTORS
The MIL hes boen roported on. DTCm501 is 3tor€d.
A t32Pl LG1
(BRN/BLK) Problomverificetion: 1. Test'drivethe vohicle. 2. Checkthe vehiclespeedwith the scantool,
ls the correctspeedindicated?
Chockfor an open in tho PiCM: 1. Turnthe ignitionswitchOFF. 2. Block the rear wheels and set the parkingbrake. 3. Jack up the lront of the vehicle and support it with salety stands. 4. Turn the ignitionswitchON (ll). 5. Elockthe right front wheel and slowly rotate the left tront wheel by hand. 6. Measurevoltage between PCMconnectorterminalsC18 and A9. Doesthevoltagepulse0 V and 5 V or batteryvoltage?
lntormittent tailure, rystom b OK at thia timo. Chocktor poor connection3 or 10o3owires rt C129 lvss) .nd rr rhe Pcfr4,
N O T E :D o n o t u s e t h e e n g i n et o t u r n t h o front wheels with th6 rear wheels on the ground. The 4WD system will engage and the vehiclewill suddenlvIurchforward. Wire side ot femaleterminals
Substitulc a known-good PCM and .och6ck. It symptom/indicd. tion go.a away, .cplacotho originel FCM. LGl
{BRN/BLKI Checkfor a .hort in the PCM: L Turnthe ignitionswitchOFF. 2 . D i s c o n n e c tt h e P C M c o n ' nectorC (31P). 3. Turnthe ignitionswitchON (ll). 4 . E l o c kt h e r i g h t f r o n t w h e e l and slowly rotate the left front 5. MeasurevohagebetweenPCM connectorterminalsC18 and A9. Doesthevoltagepulse0 V and 5 V or batteryvoltage?
-
-
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Substituto e known-good PCM and rochock. f rymptom/indication goos rwry, roplsc. tho originalFCM.
Repair short in the wire between the PCM lC18l, cruise control unit, speodometer, and VSS, Repair opon in the wire between the PCM {C181.nd
rhevss. f wire is OK. tost lho VSS l3oo soction 231.
(cont'd)
11-135
PGM-FISystem VehicleSpeedSensor(VSSI{cont'd} '98 - 00 models: -
ECM/PCMCONNECTORS
The MIL ha3 beenreDonedon. DTC P0500" or P0501*1i3 3torod.
B t25Pl
Probl6mverification: 1. Test-drive the vehicle. 2. Checkthe vehiclespeedwith the scantool,
ls the correctspeed indicated?
Checkfor rn open in the ECM/ PCM: l Turnthe ignitionswitchOFF. 2. Elockthe rearwheelsand set the parkingbrake. 3. Jack up the front oI the vehicle and support it with satety stands. 4. Turn the ignitionswitchON {ll}. 5. Blockthe right front whoel and slowly rotate the lett front
Intermittont failu.e, svstem is OK at thk time. Check for poor connection! or loose wiros at C129 lvss) .nd ar the EcM/PcM.
NOTE(4WD):Do not use the engineto turn the front wheelswith the rearwheelson the ground. The 4WD system will engage and the vehiclewill suddenlylurchforward.
Wiresideof femaleterminals
6. Measurevoltage between E C M / P C Mc o n n e c t o rt e r m i nals820 and C23. Doesthe voltage pulse between 0 V and 5 V or battery voltage?
Substitute a known-good ECM/ PCM and rochock. ll symptom/ indicetion 9063 away, .oplace th€ origin.l ECM/PCM.
B (25P)
Check for a short in the ECM/ PCMI 1. Turn the ignitionswitchOFF. 2 . D i s c o n n e c tE C M / P C Mc o n nectorC 131P). 3. Turn the ignitionswilch ON {ll). 4 . B l o c kt h e r i g h t f r o n t w h e e l and slowly rotatethe left front 5. MoasurevoltagebetweenECM/ PCMconnectorterminals820 and C23.
Doesthe voltage pulse betlveen 0 V and 5 V or battery voltage?
-
R.pair short in the wiro betwe€n the ECM/PCMlC23) .nd tho VSS. Roprir open in th6 wire botweon the ECM/PCMlc23l and th6 vss. It wirc is OK, te3t ihe VSS (!€e soetion23).
*2:Mft
11 - 1 3 6
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Sub.titute a known-good ECM/ PCM and rschock. It rymptom/ indication goos .w.y. replece rhe original ECM/PCM.
BarometricPressure(BARO)Sensor problemin the Barometric The scantool indicatesDiagnosticTroubleCode(DTC)P1106:A range/performsnce Pressure{BARO)Sensorcircuit. The MIL has been reDortedon. OTCPl106b slored.
Problemve.ification: 1. Oo the ECM/PCMreset pro' ceoure. 2. Start the engine.Hold the engine at 3,000rpm with no load (;n Parkor neutral)until the radiatorlan comeson, then letit idle. 3. Connectthe SCSserviceconnector, 4. Test'drivewith the A/T in E position,M/T in 4th gear. 5. AccelerateIor five seconds usingwide openthrottle.
ls DTCP1106indicated?
Intermittent fsilure, sy3tom i5 OK at this time.
Substitute a known-good ECM/ PCM .nd recheck.It symptom/ indication goes away, replacethe origioal ECM/PCM.
fTiloz l The scantool indicatesDiagnosticTroubleCode(DTC)P1107:A low voltageproblemin the Barosensorcircuit. The scan tool indicatesDiagnosticTrouble Code tP11o8l circuit. -
(DTC)Pl108: A high voltage problem in the Baro sensor
The MIL h.3 b€en roport€don. OTCPl10?or Pl108i3 stored.
Problomveritic.lion: L Do the ECM/PCMResetProcedure. 2. Turnthe ignitionswitchON (lli.
ls DTCP1107or P1108indicated?
Sub3tituto a known-good ECM/ PCM and rcch6ck. ll symptom/ indication 9oo3 away. .oplaco rho o.igin.l ECM/PCM.
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Intarmittoni failure, lystom b OK at thb time.
PGM-FISystem ElestricalLoadDetector(ELDI(USAModell The scan tool indic€tesDiagnosticTrouble Code (DTC)P1297:A low voltage problem in the ElectricalLoad Detector(ELD)circuit. '97 model:
Problemvsriticltion: 1. Do the PCMFesetProcedure. 2. Startthe engine. 3. Turn on the headlights.
ls DTCP1297indicated?
Intormittent lailuic, 3vstom k OK at thk time. Ch.ck tor poor connections or loose wiro3 at C127 (loc.ted on PCM b.sckot), C354 {ELO,.nd at tho FCM. ELD3P CONNECTOR {C354I
Ch.ck for 3hort in lho ELD: Measurevoltage between body groundand the ELD3P connector t e r m i n aNl o . 3 .
--+l 1 L 2 l 3 l lerO) tcnrulaeot
Y
ls thereapprox.4.5V?
Wire sideot femaleterminals
PCMCONNECTOR D I16P)
Checkfor a short in tho wire IEL linel: 1. Turnthe ignitionswitchOFF. 2. DisconnectPCM connector D (16P). 3. Checkfor continuitybetween body ground and PCMconnec tor terminalD16.
Wire sideof femaleterminals Rcpair 3hort in tho $rire botwo€n the PcM lDl6l and tho ELD.
Substituto a known-good PCM and rocheck. lf 3ymptom/indic.tion goos !w!y, repl.ce the original PCM.
11 - 1 3 8
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98 - 00 mod6l3: -
OTCPl1€7 is 3tored.
Problcm vcrificrtion: 1. Do the ECM/PCMResetProcedure, 2. Startthe engine. 3. Turn on the headlights.
ls DTCP1297indicated?
Intcrmittent tailuro, ryrtom ir OK !t thi3 timo. Ch.ck tor poor connectiont or looao wire! at CXl54 IELD)rnd at rh6 ECM/PCM,
Chockfor 3hort in tho ELD: Measurevoltage between body groundand the ELD3P connector terminalNo.3.
ELD3PCONNECTOR ICAs4I
-I
f 2_ l l 3, l
l---r'. &)
T
iGRN/RED)
Wire sideof temaleterminals
ls there approx. 4.5 V?
ECM/PCMCONNECTOR A I32P) Chcck lor a 3horl in tho wiio (EL linol: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e c tE C M / P C Mc o n nectorA (32P). 3. Check for continuity between body ground and ECM/PCM conn€ctort€rminalA30. Wire sid6of femaleterminals Ropairshon in thc wira botwocn tho PcM (A301rnd rho ELD.
Sub.tituto a known.good ECM/ PCM .nd rocheck. ll lymptom/ indication gocs .w!y. replsce th6 o.iginal ECM/PCM,
(cont'd)
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1 1- 1 3 9
PGM-FISystem ElectricalLoadDetestor(ELDI(USAModel)(cont'dl The scan tool indicatesDiagnosticTrouble Code {DTC)Pl298; A high voltage problem in the ElectricalLoad Detector(ELD)circuit. 97 modsl:
ELD3P CONNECTOR {C35,'I Problamverification: 1. Do the PCMResetProcedure. 2. Startthe engine. 3. Turn on the headlights. Intermittent tailuro, systcm is OK .t this time. Chack for ooor connoction! or looro wire3 at C127 {locaied on PCM brackot), C35{ {ELDIand .t tho PCM. Chack for an opan in tho wile llGl linol: 1 . T u r n t h g i g n i t i o na n d h e a d lightsOFF. 2. Disconnectthe ELD3P connector. 3. Turn the ignitionswitchON {ll). 4. M6asurevoltage b€tw€en body ground and the ELD 3P connoctorterminalNo. 1.
WiresidooI lemaleterminals
rlzlrl --T_ow /6\ IBLKI
Y Repail op€n in th. wire b€tws€n t h o N o . 1 5 A L T E R N A T O RS P S E N S O R1 7 . 5 A ) t u s e i n t h e under-dlrh fuso/r.lay box and th6 ELD.
EL {GRN/NEDI
Chock lol !n open in the wire IGND linel: '1. Turn the ignition switch and headlights OFF. 2. Disconnectthe ELD 3P con neqor, 3. Check for continuity between body ground and the ELD3P connectorterminalNo.2. Ropairopon in th6 wi.e betweon th. ELDconnectorrnd GiO2,
Wire sideof lemaleterminals PCMCONNECTORS
Ch.ck lo. an open in th€ wiro (EL line): Checkfor continuity between the ELD3P connectorterminalNo. 3 and PCMconnectorterminal016. ls therecontinuityT
R6pafuop6n in tho wire between the PCM{D161sndth6 ELD. Subltituto . known-good PCM and rachock, f symptom/indic.tion goes awry, ropl.ce the origin.l PCM.
Chock for . malfunction in the ELD: 1 . R e c o n n e ctth e E L D 3 P c o n neclor, 2. Start the engineand allow it to idle. 3. While measuring voltage betweenPCM connectorter m i n a l s0 1 6 a n d A 9 . t u r n t h e headlights on (low).
Doesthe voltagedrop?
Wire sideof lemaleterminals
1 1 -1 4 0
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38 - 00 modeb:
Problemverification: 1. Do the ECM/PCMResetPro ceoure. 2. Stanthe engine. 3- Turn on the headlights. ls DTCP1298indicated?
Check lor an open in the wire (lG1line): ' 1 . T u r n t h e i g n i t i o na n d h e a d lightsOFF. 2. Disconnectthe ELD3P connector. 3. Turnthe ignitionswitchON (ll). 4 , M e a s ur e v o l t a g e b e t w e e n body ground and the ELD3P '1. connectorterminalNo.
ELO3PCONNECTOR {c35/rl
Intermittent feilure, sysl.m is OK at this time. Checkfor ooor connections or loose wires at C354 (ELDIand at the ECM/PCM.
Wire sideot temaleterminals
ELD3P CONNECTOR {C35,lt
Reprir open or short in th6 wire botweon the No. 15 ALTERNATOR SP SENSOR{7.5 Al fuse in the under-drah fuse/relay box and the ELD.
Wiresideof femaleterminals
Check tor an opon in tho wire {GNDline}: 1. Turn the ignition switch and headlights OFF. 2. Disconnectthe ELD 3P con nector. 3. Check for continuity between body ground and the ELD 3P connectorterminalNo.2, Repairopon in the wire between the ELDconneclor and GilO2.
Ched(fo. an op€n in the wir€ (ELlinel: Checkfor continuity between the ELD3P connectorterminalNo. 3 and ECM/PCMconnectorterminalA30.
EL IGRN/RED} Wire sideof female termrnars Repairop€n in tha wile botwecn the EcM/PCM lA30l .nd rhe ELD.
ECM/PCMCONNECTORS A l32P)
Checkfor s malfunction in lhe ELD: 1 . R e c o n n e ctth e E L D 3 P c o n nector. 2. Start the engine and allow it to idle. 3 . W h i l e m e a s u r i n gv o l t a g e between ECM/PCMconnector terminalsA30 and 820, turn the headlightson (low).
Wire sideof femaleterminals Substiiute a known-good ECM/ PCM and recheck. It symptom/ indication goos away, replace the original ECM/PCM. www.emanualpro.com
11-141
PGM-FISystem GrankshaftSpeedFluctuation(CKF)Sensor Tj":""l.tool indicatesDiagnosticTroubleCode(DTCIP1336:Intermittentinterruptioninthe Crankshaft Speed fF13361l : Fluctuation(CKF)sensorcircuit. The scan tool indicatesDiagnosticTrouble Code (DTC)P1337:No signal in the CrankshaftSpeedFluctuation(CKF) sensorcircuit. Description The diagnosticsystemhas a pulserrotor on the crankshaftand a pulsepick-upsensoron the engineblock.The ECM/PCM monitorsthe crankshaftspeedfluctuationbasedon the CKFsensorsignal,and judgesthat an enginemisfireoccurredif the fluctuationgoes beyonda predetermined limit.
37 mod.l: -
Tho MIL ha3been reportedon. DTC P1336and/or P1337are stored.
Problemverificrtion: 1. Do the PCMResetProcedure. 2. Startthe engine.
CKFSENSOR
Intermittent {ailure,systom is OK .l thia timo. Ch6ck tor poor connections or loose wir$ at Clorl ICKFsonsorl .nd at tho PCM. Chocktor an opon in th6 CKF.en' 30r: 1. Turn the ignitionswitchOFF. 2. Disconnect the CKFsensor2P connector, 3, Measure the resistance b e t w e e nt h e C K Fs e n s o r2 P connectorterminalsNo. 'l and No.2.
ls there1.6-3.2 kO?
CKFSENSOR2P CONNECTOR IClO4I T:] l-r'r Lll l' 1' z' L' l CKFP I lcKFM talu/aeotfdJ twxrneor
\-7
Checkfo. a short in the CKF3ensot: C h e c kf o r c o n t i n u i t y b e t w e e n body groundand the CKFsensor 2P connectorterminalsNo. 1 and No.2 individually.
(Topage11-113)
1 1 -1 4 2
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Terminal side of male terminals
{ F r o mp a g e1 1 - 1 4 2 ) PCMCONNECTOR C 13lPI Chock to. an open in the wires (CKFlin06l: 1. Reconnect the CKFsensor2P connector, 2. D;sconnectthe PCM connect o rC ( 3 1 P ) . 3. Measureresistancebetween PCM connectorterminalsC1 a n dC l 1 . Wire sideof lemaleterminals ls there1.6- 3.2k0?
Ropair open in the wire betwoon tho PCM lcl, Cl1l and th6 CKF !6naor. CKFP IELU/REDI
Chock tor a short in the wires (CKFlino3): C h e c kf o r c o n t i n u i t y b e t w e e n body ground and PCMconnector terminalCl.
Rcoair short in thc wire b€tween the PCM{Cl I and the CKF.en!o..
Subsiituto r known-good PCM and r6chock. lf symptom/indication goe3away, roplacothe origin.l rcM.
(cont'd)
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11-143
PGM-FISystem GrankshaftSpeedFluetuation(CKFISensor(cont'dl .98 - 00 modols: -
The MIL has boon reportedon. DTC P1336and/or P1337are stored.
ProblGmverification: 1. Do the ECM/PCMResetProcedure, 2. Stanthe engine. Inte.mittant failuro, 3y*om b OK at thb tima. Chack lor ooor connections or looso wirea at C10a { C K Fs e n s o r la n d . t t h e E C M / PCM, Chgckforun open in tho CKFsonsori 1. Turnthe ignitionswitchOFF. 2. Disconnectthe CKFsensor 2P connector. 3. Measure the resistance between the CKF sensor 2P connectorterminalsNo. 1 and No.2.
IClO'I CKFSENSOR2P CONNECTOR r-:-i-_l
tr_-
|
l, 1, -2 l' l CKFP
ICKFM
I
tsLuneotTOl wlrrneo) \7
lsthere1.6- 3.2kO?
Terminalsideof maleterminals Checkfor a short in the CKFsenC h e c kl o r c o n t i n u i t y b e t w e e n body groundand the CKFsensor 2P connectorterminalsNo. 1 and No.2 individually.
r:l
t !E l .KFPXA"*." \:f talurneor
(Topage11'1451
11-144
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rwxvneor
C (31P) ECM/PCMCONNECTOR CKFP IBLU/REDI
Check for an open in the wires ICKFlinca): 1. Feconnectthe CKFsensor2P connector. 2. DisconnectECM/PCMconnect o rC ( 3 1 P ) . 3. Measureresistancebetween E C M / P C Mc o n n e c t o rt e r m i ' nalsC22and C31.
ls there1.6- 3.2kO?
f
1 2
,/ 2s
7 8 1 6 1 7 1 6 't9 20 21 22 26 27 28 29 3() 3 l
__l (oI -l T
M CKFM (WHT/BEOI Wi16sideof l6maleterminals Repairopon in the wir6 botwoon the ECM/PCM1C22,glll lnd th6 CKFs6n3or.
( F r o mp a g e1 1 - 1 4 4 ) C (31PI ECM/PCMCONNECTOR CKFP {BLU/RED)
Check for a shorl in the wires (CKFlines): C h e c kl o r c o n t i n u i t y b e t w e e n body ground and ECM/PCMcon nectorterminalC22.
ls therecontinuity?
Repairshort in tho wire between the ECM/PCM{C221and rh. CKF
Wire sideof femaleterminals
Substitute a known-good ECM/ PCM and recheck. lf svmptom/ indication goes away. replace the original ECM/PCM.
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11-145
PGM-FISystem Sensor CrankshaftPosition/TopDeadCenter/CylinderPosition(CKP/TDC/CYP) The scantool indicatesDiagnosticTroubleCode (DTC)P 1 3 5 9A: problemin the CrankshaftPosition/TopDead sensor circuit. Center/CvlinderPosition tCKP/TDC/CYP) -
The MIL has been reoortedon. DTCP1359is stored.
Problemverific.tion: 1. Do the ECM/PCM ResetProcedure. 2. Startthe engine.lf the engine won't start, crank it continuouslyforat least15seconds.
ls DTCP1359indicated?
C h e c kf o r p o o r c o n n e c t i o n so r loosewires betweenthe distribu' tor andthe EcM/PcM.
Substitute a known-good ECM/ PCM, and recheck. ll symplom/ indication goes away, replacethe original ECM/PCM.
1 1 -1 4 6
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Intermitteni lailure, system is OK. Check for ooor connectionsor loos€ wires al C121 {distributor} and at the ECM/PCM.
ECM/PCMInternalCircuit lFi6oil -
Th" """n tool indicatesDiagnosticTroubleCode{DTC)P1607:An ECM/PCMInternalCircuitProblem.
The MIL has been reoortedon. DTCPlmT is slor6d.
Problomveritication: 1. Do the ECM/PCMResetPro 2. Turnthe ignitionswitchON (ll). 3, Waitthreeseconds,
ls DTCP1607indicated?
Sub3tiiut€ a known-good ECM/ PCM and recheck.lf symptom/ indicationgoes away, replacethe originalECM/rcM.
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11-147
PGM-FISystem HO2SReplacement 1.
Disconnect the HO2S4P connector,and removethe HO2S.
PRIMARYH02S:
PRIMARYHO2S 4P CONNECTOR
02 SENSOR WRENCH
PRIMARY HO2S 44 N.m {4.5kgt m,33lbf.ftl
SECONDARY HO2S:
SECONDARY HO2S 4,0N.m (4.5 kg{.ft, 33 lbtftl
2.
Installthe HO2Sin reverseorderof removal.
11-1 4 8
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ldle Control System SystemDescription The idle speedof the engjneis controlledby the ldle Air Control(lAC)Valve' The valvechangesthe amount of air bypassinginto the intakemanifoldin responseto electriccurrentcontrolledby the Whenthe lAc valve is activated,the valveopensto maintainthe properidle speed. ECM/PCM. YEL/ BLK
FromPGM'FI TMAIN RELAY
VARIOUS SENSORS
IAC VALVE INTAKEMANIFOLD
After the enginestarts,the IACvalve opensfor a certaintime. The amountof air is increasedto raisethe idle speed about 150- 300 rpm. when the cootanttemperaturets row, the lAc valve is openedto obtain the proper fast idle speed The amount o{ bvoassedair is thus controlledin relationto the enginecoolanttemperature and the scantool does not indicateDiagnosticTroubleCode(DTC)P0505 When the idle speedis out o{ specification items: or P1508,checkthe following . Adjustthe idle speed(seepage11-169,170) . A i r c o n d i t i o n i nsgi g n a (l s e e p a g e l l - 1 5 5 1 . A L TF Rs i g n a (l s e ep a g e1 l - 1 5 9 ) . Starterswitchsignal(seepage11-16'1) . A,/Tgear positionsignal(seesection14) . P S Ps w i t c hs i g n a (l s e e p a g e l l - 1 6 2 ) . Brakeswitchsignal(seepage11-165) . F a s ti d l e t h e r m o v a l v (es e ep a g e ' 1 11 6 8 ) . Hosesand connecttons . IACvalveand its mountingO-rings 4.
lf the aboveitemsare normat,suDslitutea known-goodIACvalveand readjustthe idle speed{seepage 11-169,170) lf the idle speedstill cannot be adjustedto specification(and the scantool does not indicateDTC P0505or Pl508) after IAC valve reolacement,substitutea known-goodECM/PCMand recheck lf symptom goes away' replacethe originalECM/PCM.
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11-149
ldle Control System ldle ControlSystem I P0505 | The scantool indicatesDiagnosticT.oubleCode(DTCIPO5O5: ldlecontrolsvstemmattunction. NOTE:lf DTCP1508is storedat the sametime as DTCP0505,troubleshootDTCP1508first.then troubleshootDTCp0505. PossiblsCause . IACvalvemechanicalmalfunction . Throttlebody cloggedport,improperadlustment . Intakemanifoldgasketleakaging . Intakeair hoselooseleakaging . Vacuumhose leakaging a ECTsensorincorrectoutput . ThrottlePositionsensorincorrectoutput TroubleshootingFlowchart The MIL has been reDortedon. DTCP0505is sto.ed.
Problemverificationi 1. Start the engine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until the radiatorIan comeson, then let it idle. 2. With the scan tool, checkthe lollowingitems. - Throttleposition should be approx. 10%with the throttle {ully closed. - E n g i n ec o o l a n tt e m p e r a ture shorJldbe 194- 205'F (90- 96"C). lf they are not within the spec.,repairthe faultysensor circuit. 3 C h e c kt h e e n g i n e s p e e d a t idle with no-loadconditions: headlights,blower fan. rear defogger,radiatorlan, and air conditionerare not operaling,
ls it 750{730)*i 50 rpm?
Inte.mittent failure. syltem is OK at this time.
ls il 700(680)'rpm or less?
l:'99 - 00 models
{ T op a g e1 1 - 1 5 1 )
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( T op a g e1 ' l - 1 5 1 )
(Frompage11-150)
Checkthe IAC valve: the 2P connectorfrom Disconnect the IACvalve.
Doesthe enginespeeddroP or the enginestall?
Adiust the (basel idl€ speed lsee page11-169,1t0).Itihe ba3eidle speed cannot be adiust€d, clean the Dorts in the throttle body.
UPPER
{ F r o mp a g e1 1 - 1 5 0 }
Checkthe tast idle lhermo valve: 1. Turnthe ignitionswitchOFF. 2 . R e m o v et h e i n t a k ea i r d u c t from the throttle body. 3. Startthe engineand let it idle. 4. Put your finger on the lower pon in the throttlebody.
THERMOVALVE (A/Tonlyl Doesthe enginespeeddrop?
Checkenginecool.nt leveland for air in the cooling sy3lem. lf OK, reolacethe f.st idle thermo valve.
Putyour Iingeron the uPPerPort in the throttlebody.
Doesthe enginespeeddroP?
Adjust the idle spoed lsee Page 11-169.1701.lf the adiustment does not correct lhe problem, r.olace the IAC valve.
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Check for vacuum leaks, make sure the throttle valve is com' pletely clo3ed.and repair as nec-
ldle Control System ldle Air ControlllAC)Valve The scan tool indicatesDiagnosticTrouble Code (DTC)Pl508: A probtem in the ldle Air ControtflAC)varve circuit. The IACValvechangesthe amountof air bypassingthe throttlebody in responseto a currentsignalfrom the ECM/PCMin orderto maintainthe properidle speed. From AIR To INTAKE CLEANER MANIFOLD
37 model; The MIL has beon .eport€d on. OIC Pl508 is sto.ed.
Problemveiification: 1. Do the PCMResetProcedure. 2. Startthe engine,and warm it up to normal operatingtemperature.
ls DTCPl508indicated?
Inte.mittent failure, systcm b OK at thi3 time. Checktor poo. connections or loose wircs at C132 (lAC v.lvel and at the PCM. IAC VALVE2P CONNECTOR {C132}
Check lor an open in the wir6 {lGPl lins}: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe IAC valve 2P connector. 3. Turn the ignitionswitchON {ll). 4. Measurevoltagebetweenbody ground and the IAC valve 2P connectorterminal No.2.
,f\
#
rcp' IYEL/BI.(I
I- 2df -) 1
Y Wir€ side of female terminals
Repairopen in the wire trctwoon tha IAC v!lv6 and the PGM-Fl main relly. PCMCONNECTOR A I32PI Chockfor an opan o. short in tho wi.e (lACv linel: 1. Turn the ignition switch OFF and reconnectthe IAC valve 2P connector. 2. Disconnectthe PCMconneclor A (32P). 3. Turn the ignitionswitchON {ll). 4 , M e a s u r ev o l t a g e b e t w e e n body ground and PCM connectorterminalA12.
{ T op a g e1 l - 1 5 3 )
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tacv IBLK/ BLU) Wire sideof femaleterminals
( F r o mp a g e1 1 - 1 5 2 )
ls therebafteryvoltage?
Bepair op€n or short in the wire betweon th€ PCM {A121and the IAC vrlve.
Checkthe IAC valve function: Momentarilyconnect PCM con' n e c t o rt e r m i n a l sA 1 2 a n d A 1 0 with a iumoerwire severaltimes, Wire sideof femaleterminals Doesthe IACvalveclick?
Substitute . known-good PCM and r€check, lt 3ymptom/indication goes away, replacothe origi_ nalPCM,
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1-153
ldle Air Control(lAC)Valve{cont'd} '98 - 00 models: The MIL has boen r.ported on. DIC Pl 508 b 3tored.
Problemveritication: L Do the ECM/PCMResetProcedure. 2. Startthe engine,and warm it up to normal operatingtemperature.
ls DTCP1508indicated?
Int€rmittent failure, systom is OK al lhis timo. Check lor poor connections or looro wirca at C132 (lAc vrlvel and .t rho EcM/PcM. IAC VALVE2P CONNECTOR {C132I
Chock tor an open in the wir6 llGPl linel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe IAC valve 2P connector, 3. Turnthe ignitionswitchON (ll). 4. Measurevoltagebetweenbody ground and the IAC valve 2P connectorterminaI No, 2.
rcpt
F\
*l tYELrBLxl I2/'-
-
rf) Y
Wire side ot fem.le terminals Repairopon in the wira botwoon the IAC valve and tho PGM-FI main aalay. B (25PI ECM/PCMCONNECTOR
Checktor an open or short in the wire (IACVlinel: 1. Turn the ignition switch OFF and reconnectthe IAC valve 2P connector. 2 . D i s c o n n e c tE C M / P C Mc o n nectorB {25P). 3. Turn the ignitionswitchON {ll}. 4. Measurevoltage between body ground and ECM/PCM connectorterminal823.
9 19
2 'to
5 1l
21 22
20
8
13
t7
23
tAcv (BLK/BLUI
v
Wiresideof femaletorminals ls there batteryvoltage?
Checkthe IAC valve func,tion: Momentarilyconnect ECM/PCM connectorterminals823 and 82 with a jumperwire severaltimes.
Ropair open or short in thg wire between tho ECM/FCMlB23l and the IACvalve.
PG1 {BLKI 1
2 |
t 3 4 5
9 1 0 1 1 13 19 20 | 121)22
8 17
tAcv (BLK/ BLU)
Does the IACvalve click?
Subslitute . known-good ECM/ PCM .nd rechock.lf symptom/ indication goes aw.y, replac. th€ original ECM/PCM. www.emanualpro.com
JUMPERWIRE
Air ConditioningSignal This signalsthe EcM/PcMwhen there is a demandfor coolingfrom the air conditioningsystem. '97 modol:
Chock for a shorl in thc wiro (ACSlinol: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe A/C pressure switch2Pconneclor. 3. Turnthe ignitionswitchON (ll). , 1 . [ I e a s ur e v o l t a g e b e t w e e n PCM connectorterminalsC5 andA9.
Wiresideof lemaleterminals
C (31PI PCMCONNECTOR ACS IBLU/RED) Check for . .hon in the wire IAGS linel: 1. Turnthe ignitionswitchOFF. 2. DisconnectPCM connectorC (31P). 3. Check for continuity between body ground and PCM connectortorminalC5. Wiresideof femaleterminals
Reoaii short in tho wire b€twoen rh6 PCM (Csl and the A/C pres3urc 3witch.
Check tor an opon in the wite (ACClino): 1. TLrrnthe ignitionswitchOFF. 2. Roconnectthe A/C pressure switch2Pconnector. 3. Turn the ignitionswitchON (ll). 4 . M o m e n t ar i l y c o n n e c t P C M c o n n e c t o tr e r m i n a l sA 9 a n d 417 with a iumper wire sev' eraltimes,
(To page11-156)
-
-
Subcdtrte a known{ood PCM and recheck. lf pr6actibed voltage is now av{ilable, roplace the origind PCM, Soethe eir conditionorin3p€clion lsee soction221.
A (:TIPI PCMCONNECTOR JUMPERWIRE
Wire sideoI Iemaleterminals
(cont'd)
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1 1 - 15 5
ldle GontrolSystem Air ConditioningSignal(cont'dl (Frompage11-'155)
Ch6ck for an open in th€ wire (ACClinel: Momentarilyconnectthe underhood fuse/relaybox 9P connector t e r m i n a lN o . 5 t o b o d y g r o u n d with a jumperwire severaltimes.
ls therea cl;ckingnoisefrom the 4!/Ccompressorclutch?
ls therea clickingnoisefrom the 4!/Ccompressorclutch?
UNOER.HOOD FUSE/RELAY BOX 9P CONNECTOR tqt52) 1
2
3
5
6
I
JUMPER WIRE
I
ACC IBLK/REDI IBLK/R Wire sideof female termrnats
See air condiiioner inspection {seesection221.
Repai. op6n in the wire betwoen the PcM (A17) and tho A/C clutch relay. PCMCONNECTORS
A t32Pl
C t3rp)
Checkthe A/C operation: 1. Startthe engine. 2. Turnthe blowerswitchON. 3. Turn the A"/Cswitch ON.
Wire sideol lemaleterminals
Doesthe A,/Coperate?
Check for an open in the wire (ACSline): Measurevoltage between PCM connectorterminalsAg and C5.
Air conditioningsignal is OK. ls therelessthan 1.0V?
-
-
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Subqtitute a known-good FCM .nd r€ch6ck.lt 3ymptom/indication goes awav, replece the originalrcM. Soe th€ eir conditioner in3pection (s6€aec.tion22).
Repair open in the wire between the PCMlCSland the A/C awitch.
'98 - 00 models:
ECM/PCMCONNECTORS A {32P1
Check for a shott in the wire {ACSlinel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe A/C Pressure switch2Pconnector. 3. Turnthe ignitionswitchON (ll) 4. Measurevoltage between E C M / P C Mc o n n e c t o rt e r m l nalsA27 and 820.
A (32PI ECM/PCMCONNECTOR
ls there batteryvoltage?
Checktor . short in the wire IACS linel: 1. Turnthe ignitionswitchOFF. 2. DisconnectECM/PCMconnector A (32P). 3. Checkfor continuitybetween body ground and ECM/PCM connectorterminalA27.
Wiresideof femaleterminals
ls therecontinuitv?
R.oak short in the wile between rhe ECM/PCM(A271and the A/C Dressureswitch.
ECM/PCMCONNECTORS Check for an open in the wire (ACCline): '1. Turnthe ignitionswitchOFF. 2. Reconnectthe A/C Pressure switch2Pconneclor. 3. Turn the ignitionswitchON (ll). 4 . M o m e n t a r i l yc o n n e c tE C M / PCMconnectorterminalsA17 a n d 8 2 0 w i t h a j u m P e rw i r e severalllmes,
{To page11 158)
Sub6titute a known{ood ECM/ rcM and recheck. lf pte6cribed voltage i3 now available,re' pl.ce the origioalECM/rcM. Seeih6 air conditionerinspection (s6esection221.
A (32P1
ACC(BLK/REOI
(BRN/BLKI JUMPERWIRE LG1
{cont'd)
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11-157
ldle ControlSystem Air Gonditioning Signal(cont'd) (Frompage'11,157)
ls therea clickingnoiselrom the y'y'Ccompressorclutch?
Check Ior dn opon in the wiro IACClinel: Momentarilyconnectthe underhood fuse/relaybox 9P connector t e r m i n a lN o . 5 t o b o d y g r o u n d with a jumperwire severaltimes.
ls therea clickingnoisefrom tho A,/Ccomprossorclutch?
Repai. open in th6 wiro lr€twlan the ECM/PCMlAl7l .nd tho A/C clutch rolay.
UNDER-HOOD FUSE/RELAY BOX9PCONNECTOR {G'52I
5
JUMPER WIRE
2
3 a
5
8
9
(BLK/R ACC(BLK/RED' Wire side otfemale ot terminals
Sae rir conditional in3paction lroa saction 221.
ECM/PCMCONNECTORS
Check tho op.ration of tho A/C: 1. Stan the engine. 2. Turnthe blowerswitchON. 3. Turn the Ay'Cswitch ON.
Doesthe !y'C operate?
ChGGkfor an open in the wi.e IACS linel: Measurevoltage betweonECM/ P C M c o n n e c t o rt e r m i n a l sA 2 7 and 820.
Wiresid€of femaletorminals
Air conditioning 3ignal i3 OK. ls voltagelessthan 1.0V?
Sub6lftna a known{ood ECM/ PCM and rechock. lf symptom/indicetion goes away. roplacethe originalECM/rcM. See the ah conditionor inspoction {3e€section 22},
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Rap.ir opon in the wir6 bdtunaan rh. Ecil/FcM lA27l rnd rh. A/c rwitch.
Alternator(ALT)FRSignal This signalsthe ECM/PCMwhen the Alternator(ALTIis charging. PCMGONNECTORS
,97 modet: Inspectionot ALT FRSignal. C h e c kl o r a s h o r t i n t h e w i r e {ALT F line}: 1. Disconnectthe 4P 13Pi*con nectorfrom the ALT. 2. Turnthe ignitionswitchON (ll) 3, Measurevoltage between PCMconnectorterminalsC17 and A9.
ls thereapprox.5 V?
Checkth€ ope.ation of the ALT: 1. Turnthe ignitionswitchOFF 2. Reconnectthe ALT 4P {3Pi* connectorto the ALT. 3. Start the engine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until t h e r a d i a t o rf a n c o m e s o n , then let it idle. 4. Measurevoltage between PCMconnectorterminalsC17 and A9. when Doesthe voltagedecrease headlights and reardefoggerare turnedon?
Ch€d( for an op€n in tho wire IALT F linel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe negativebattery cablelrom the battery. 3. DisconnectPCMconnectorC (31P). 4. Disconnectthe 4P (3P)*connectorlrom the ALT. 5. Connectthe ALT 4P (3P)* connectorterminalNo. 4 (No. 1)* to body groundwith a iumper
wire sideof femaleterminals
c (31P| Check for a short in the wire (ALT F linel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe negativebat' tery cable from the battery. 3. DisconnectPCM connectorC (31P). 4. Checkfor continuitybetween b o d y g r o u n da n d P C Mc o n nectorterminalC17.
Ropeirshort in the wir6 betweon the PCM lC17l and the ALT.
Substitut. a known-good PCM and recheck. lf prescribed voltage is now availablo,replacethe originalPCM.
ALT FRsignal b OK. (C1O5I ALT CONNECTOR lP ALT F r-F-
lll2llw|{frREDl -| 3 . r - ' l
wne lruueen
JUMPER WIRE
wire side ol f€male terminals C I31P) PCMCONNECTOR
6. Check for continuity between body ground and PCN4con' nectorterminalCl7. ls therecontinuity?
3Pr
ALT F IWHT/REDI Repair open wi.e between the PCMlCl7l and the ALT. Wire sideof femaleterminals
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11 - 1 5 9
ldle GontrolSystem Alternator(ALT)FRSignal(cont'dl '98 - 00 modols:
ECM/PCMCONNECTORS
B (25P)
Insp€ctionof ALT FRSignsl.
AI.T F IWHT/REDI Check fo. a shon in th. wire {ALT F linel: 1. Disconn6ctthe 4P (3P)*connectorfrom the ALT. 2. Turnthe ignitionswitchON {ll). 3. MeasurevoltagebetweenECM/ PCM connectorterminalsC5 and 820.
ls thereapprox.5 V7
Checkthe opcration of the ALT: 1. Turnthe ignitiooswitchOFF. 2. Reconnectrhe ALT 4P (3P)* connectorto the ALT. 3. Start the engine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until t h e r a d i a t o rl a n c o m e s o n , then let it idle. 4. MeasurevoltagebetweenECM/ PCM connectorterminalsC5 and 820.
Doesthe voltage decreasewhen headlights and reardefoggerare turnedon?
Wire sideof femaleterminals
Ch€ck for a sho.t in iho wirc lAlT F lino): 1. Turnthe ignitionswitchOFF. 2. Disconneclthe negativebat, tery cablefrom the battery. 3. DisconnectECM,PCMconnect o r C( 3 1 P ) . 4. Checkfor continuitybetwoen body ground and ECM/PCM connectorterminalc5.
ECM/PCMCONNECTOR C {31PI
Wire sideof femaleterminals Roprir lhort in tho wirc bstween tho ECM/PCM{Csl and the ALT.
Substitut. r known-good ECM/ PCM and roch.ck. It Droscrib.d voltage b now lvrilabls, .eplacc th. o.igin!l ECM/PCM.
ALT FR3ignol is OK, (C1I}5I ALT CONNECTOR 4P
Chocklor an opon in tha wire (ALT F linel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe negativebattery cablefrom the battery. 3 . D i s c o n n e c tE C M / P C Mc o n nectorC (31P). 4. Disconnectthe 4P 13P)*con, nector from the ALT. 5. Connectthe ALT 4P {3P)*connectorterminalNo. 4 1No.1)* to body groundwith a jumper
rH] Arr F l'l'ltwHr/REo)
l3laF1 WIRE I JUMPER +
Wire sideof femaleterminals
6. Check for continuity betwe€n body ground and ECM/PCM connectorterminalC5. ls therecontinuity?
JUMPER WIRE
ECM/PCMCONNECTOR C {31P} ALT F {WHT/REDI Rsprir opan wiro batw.en tho ECM/PCMlcsl .nd th. ALT.
Wire sideot Iemaleterminals ": Canada
11 - 1 6 0
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Starter Switch Signal when the engineis cranking. This signalsthe ECM/PCM '97 model: in E or E position. Transmission PCMCONNECTORS
c t31P)
A {32P} Checkfor an opan ot short in the wire (STSlinel: Measurevoltage between PCM c o n n e c t o tre r m i n a l sC 6 a n d A g w i t h t h e i g n i t i o ns w i t c h i n t h e start(lll)position.
LGl (BBN/BLK)
STS(BLU/ORNI
Wire sideof femaleterminals
ls there batteryvoltage?
lnspectthe No. 31 STARTERSIGNAL (7.5A)Illse in the under'dash
-
Starter swiich signal i3 OK. -
Reoair short in the wire between the PCM lc6l and th. No. 31 STARTERSIGNAL175 A) tuse ot the PGM-FImain reray. Reolacethe No. 31 STARTER SIGNALt7.5Altu.e.
Repairopon in the wire betweon rh6 PCM lc6l and the No 31 STARTERSIGNAL17.5A)fuse.
'98 - 00 models: NOTE: . M/T:Clutchpedalmustbedepressed. . A/T:Transmission in E orE position A (32P)
ECM/PCMCONI{ECTORS
Checktor an open or short in the wir€ (STSline): Measurevoltage betweenECM/ P C M c o n n e c t o rt e r m i n a l sA 2 4 and 820 with the ignitionswitch in the startposition(lll).
ls therebatteryvoltage?
SIG Inspectthe No. 31 STARTER NAL(7.5A){usein the under-dash
Wire sideoI femaleterminals -
Starter switch 3ignal is OK. -
Reoair shorl in the wire betwe€n the ECM/PCMlA2,fl and the No, 31 STARTERSIGNAL t7.5 Al tu3€ ot the PGM' Fl main rclay. Repl.c. tho No. 31 STARTER SIGNAL17.5Al fu3e.
Repairopon in tho wire between the ECM/PCM{A241and the No 31 STARTERSIGNAL(7.5A) tu3e www.emanualpro.com
11 - 1 6 1
ldle GontrolSystem PowerSteeringPressure(PSP)Switch Signal This signalsthe ECM/PCM when the power steeringload is high. '97 model: Inspectionot PSPswitch signal.
Checkfor an open in the wire {PSP SYVline): 1. Turnthe ignitionswitchON (ll). 2. Measurevoltage between PCN4 connectorterminalsC16 and A9.
ls therelessthan 1.0V?
Wire sideof femaleterminals Checktor an open in lhe wire (PSP SW linel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe PSPswitch 2P connecror, 3. Turnthe ignitionswitchON (ll). 4. At the harnessside, connect the PSPswitch 2P connector t e r m i n a l sN o . 1 a n d N o . 2 with a jumperwire. 5, Measutevoltage between PCMconnectorterminalsC16 and A9.
PSPSWTTCH 2P CONNECTOR 1C135) PSPSW (GRN) JUMPERT_7
vnRE t--f
1
\
r)
GNDIBLK} Wire3id6of femaleterminals -
Check the operation oI lhe PSP switch: 1. Stanthe engine 2. Turnthe steeringwheelto the full lockposition*. 3. MeasurevoltagebetweenPCM connectorterminalsC16 and A9.
ls therelessthan 1.0V?
ls there batteryvoltage?
PSPswitch signal is OK. *: Do not hold the steeringwheel at tull lock for more than five seconds,
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(To page11-163)
-
Ropsir open in the wi.e betwoon the PCM lcl6l and the PSPswitch. Ropdir open in BLK wire between the PSP switch and G101.
{ F r o mp a g e 1 1 1 6 2 )
PCMCONNECTORS C h e c kf o r a s h o r t i n t h e P S P swilch: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 2P connector from the PSPswitch. 3. Turnthe ignitionswitchON (ll). 4 . l l e a s ur e v o l t a g e b e t w e e n PCMconnectorterminalsC16 and A9.
Wire sideof femaleterminals
c t3lPl
Checktor a short in the wire (PSP SW linol: 1. Turnthe ignitionswitchOFF. 2. DisconnectPCMconnectorC (31P). 3. Checkfor continuitybetween body ground and PCMconnector terminalC16.
Reoairshort in the wire betwoon rhe PCM {C16)and the PSP 3witch.
Substitute a known-good PCM and rocheck.lf proscribodvoltage b now available,replacethe original PCM.
(cont'd)
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1 1- 1 6 3
ldle ControlSystem PowerSteeringPressure(PSP)Switch Signal(cont'dl '98 - 00 models: ECM/FCMCONNECTORS
Inspectionof PSPswilch 3ignal.
Ch€cktor rn opon in the wire (PSP SW line): 1. Turnthe ignitionswitchON {ll). 2. MeasurevoltagebetlveenECM/ PCMconnectorterminals426 and 820.
ls therelessthan 1.0V?
Chockfor an open in the wire IPSP SW lin€): 1. Turnthe ignitionswitchOFF. 2. Disconnect the PSPswitch2P connector, 3. Turnthe ignitionswitchON (ll). 4. At the wire side.connectthe PSPswitch 2P connectorter m i n a l sN o . 1 a n d N o . 2 w i t h a
Wiresideof femaleterminals PSPSwlTCH 2P CONNECTOR ICl35} PSPSW IGRNI JUMpER f-7
T
wtRE L-5 rl
5. MeasurevoltagebetweenECM/ PCM connectorterminals 426 and 820.
\
GND (3LX} Wire sideof lemaleterminals -
Check the op€ration of the PSP switch: 1. Stanthe engine 2. Turn steeringwheelto the full lockposition*. 3. Measurevoltageb€tweenECM/ PCMconnectorterminalsA26 and 820.
lstherelessthan 1.0V?
ls there batteryvoltage?
PSPswitch signal is OK. *: Do not holdthe steeringwheelat lull lockfor morethan five seconds.
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11-164
(Topage 11-165)
-
Ropai. open in the wire betweon th6 ECM/PCM (A26) and th6 PSP.witch. R6p.ir open in BLK wire between tho PSP 3witch and G1 0 1 ,
{Frompage11 164i
ECM/PCMCONNECTORS
C h e c kf o r a s h o r t i n t h e P S P switch: 1. Turnthe ignitionswitchOFF. 2, Disconnectthe 2P connector from the PSPswitch. 3. Turnthe ignitionswitchON (ll). 4. MeasurevoltagebetlveenECM/ PCMconnectorterminalsA26 and 820. Wiresideof femaleterminals
A l32Pl
Checklor e 3hort in the wire IPSP SW linell 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e c tE C M / P C Mc o n nectorA (32P). 3. Checkfor continuitybetween b o d y g r o u n da n d E C M / P C M connectorterminalA26. Wiresideof femaleterminals
ReDairshort in the wir€ bstween the ECM/PCM(A26)and the PSP switch.
Substitute a known-good ECM/ PCM and rechock. It Drescribod voltago is now available,roplace the origin.l ECM/PCM,
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11 - 1 6 5
ldle ControlSystem BrakeSwitch Signal This signalsthe ECM/PCM when the brakepedalis depressed. Insp€ctionof Brak. Switch Signal.
Are the brakelightson without pressingthe brakepedal?
Inspectthe HORN,STOP{15 A) fuse in the undeFhoodluse/ relay box.
Do the brakelightscome on?
Reoair short in the wire between th€ b.ake switch and th6 HoRN, STOP{15 A)luso, Replacothe HoRN, STOP (15 Al fuse.
'-
-
('97model) -_-
Check tol .n open in the wire {BXSWlinel: 1. Pressthe brakepedal. 2. MeasurevoltagebetweenrcM connectorterminaisD5 and Ag with the brakepedal pressed.
Il
Repair op6n in the wir€ between the brake switch and tho HORN,STOP(15 Allus6. Inspect the brrke switch (see aection l9l.
a t32P)
PCMCONNECTORS
BKSW (GRN/WHT)
Wire sideof femaleterminals Reprir open in the wire between the PcM lD5l rnd the brake switch.
(Topage11-167)
11 - 1 6 6
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D ll6Pl
(Frompage11-166)
ECM/FCMOONNECTORS
Chock for en open in the wire (BKSWline): 1. Pressthe brakepedal. 2. MeasurevohagebetweenECM/ PCM connectorterminals A32 and 820 with the brakepedal pressed.
Ropairopon in tha wire bstwson r h e E C M / P C Ml A 3 2 l r n d t h e brako switch. Wiresideof femaloterminals
Brakeswitch signd b OK.
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11-167
ldle ControlSystem Fastldle ThermoValvelA/T) Description To preventerraticrunningwhen the engine is warming up, it is necessaryto raisethe idle speed.The fast idle t h e r m o v a l v e i s c o n t r o l l e db y a t h e r m o w a xp l u n g e r . When the engine is cold, the engine coolantsurrounding the thermowaxcontractsthe plunger,allowingadditional air to be bvDassedinto the intakemanifoldso that the engineidlesfaster.Whenthe enginereachesoperating temperature.the valve closes,reducingthe amount of air bypassinginto the intakemanifold. IDLE ADJUSTING
Inspgction NOTE:The fast idle thermo valve is factoryadjusted;it shouldnot be disassembled. 1.
Removethe intakeair ductfrom the throttlebody.
2.
Startthe engine,
3.
Put your finger over the lower port in throttlebody, and makesurethat there is air flow with the engine cold (enginecoolanttemperaturebelow 86"F,30'C).
lf there is no air flow, replacethe fast idle thermo valveand retest, IDLE THERMO VALVE
O-RINGS Replace.
AIR BYPASS VALVE
11.0kgfl.m,7.2 lbl.ftl
Startthe engine.Holdthe engineat 3,000rpm with no load (in Parkor neutral)until the radiatorfan comes on, then let it idle. Checkthat the valve is completelyclosed.lf the valve is leaking,the idle speedwill drop when you coverthe lowerpon. Checkthe enginecoolantleveland for air in the enginecoolingsystem{seesection10).lf the cooling system is OK, replacethe fast idle thermo valveand recheck.
11-168
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ldle Speed Setting Adjust the idle sp6ed,if necessary,by turning the idle adjustingscrew.
Inspoction/Adiustmont 37 modsl:
IDLE
NOTE: . Before setting the idle speed, check the following items: - The MIL has not beenreportsdon. - l g n i t i o nt i m i n g - Sparkplugs - Air cleaner - PCVsystem . lcanada) Pull the parking brake lever up. Stan the engine,then checkthat the headlightsare off. 1.
Startthe engine.Hold the engineat 3,000rpm with no load (in Park or neutral) until the radiator fan comeson, then let it idle. Connecta tachometeror a HondaPGMTester. Disconnectthe 2P connectorfrom the ldle Air Control (lAC)valve. Turn the ignitionswitchOFF. IAC VALVE
7 . Reconnectthe 2P connector to the IAC valve, then remove the BACK UP (RAD|Ol(7.5 Al fuse in the under-hood fuse/rslav box for 10 seconds to reset the PCM. Restartand let the engine idle with no-loadconditions for one minute,then checkthe idle speed. NOTE: (CanadalPullthe parkingbrakelever up. Stan the engine,then checkthat the headlightsare off.
lf the enginestalls,restartthe enginewith the accelerator pedal slightly depr6ss6d,Stabilizethe rpm at 1,000,then slowly releasethe pedaluntil the engine idles. C h e c k i d l i n g i n n o - l o a d c o n d i t i o n s :h s a d l i g h t s , blowerfan, rear d€fogger,radiatorfan, and air conditionerare not operating. ldle spood should b.: {80 t 50 rpm {in Park or noutr.ll
ldlo Ep€edrhould be: 75Ot 50 rpm (in P.rk or noutr.ll Let the engine idl6 for one minute with the headlights(Low)ON, and checkth€ idl€ speed. ldle lpcod 3hould bo: 750 t 50 ]pm (in Park or nautlal) Turn the headlights off. Let th€ engine idle for one minute with the headlights (Low) ON, heater fan switch at Hl and air conditioneron. then checkthe idle sDeeo. ldl. specd should b6: 7d) 1 50 rpm {in Park or nautral} see the lf the idle speed is not within specification, (cont'd) symptomcharton page11-64.
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11 - 1 6 9
ldleControlSystem ldle Speed Setting (cont'd) 38 - 0Omod6l3: NOTE: Beforesettingthe idle speed,checkthe following items: - The MIL has not beenreportedon. - lgnitiontiming - Sparkplugs - Air cleaner - PCVsystem 1.
lf necessary,adjust the idle speed,by turning the idle adjustingscrew. After adjustingthe idle speed,recheckthe ignition timing (seesection4). lf it is out of spec,go backto steo 4. tDt.E ADJUSTING
Startthe engine.Holdthe engineat 3.000rpm with no load (in Park or neutral) until the radiator fan comeson, then let it idle. Connecta tachometer. Disconnectthe IACvalve 2P connectorand the EVAP purge control solenoid valve 2P connector.
CONTROL SOLENOIDVALVE
VALVE SOLENOID lf the enginestalls,restartthe enginewith the accelerato. pedal slightly depressed.Stabilizethe rpm at 1,000,then slowly releasethe pedaluntil the engine idles. Che€kthe idle in no-loadconditions:headlights,blower fan, rear defogger,radiatorfan, and air conditioner are not operating, ldle speed should bo: 480 t 50 rpm {in PErkor noutrall
11-170
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6. Turn the ignitionswitchOFF. 7. Reconnectthe 2P connectorsto the IAC valve and the EVAPpurgecontrol solenoidvalve,then do the ECM/PCMreset procedure. 8. Restartand idle the enginewith no-loadconditions for one minute,then checkthe idle speed. ldle speod should be: ,98 model: 750 t 50 rpm tin Park or neutral) '9!l - 00 modsls: 730 i 50 lpm lin Psrk or neutral) NOTE:lf the idle speed increasesto 780 t 50 rpm (770 1 50 rpml*, this means the EVAPsystem is purgingthe canister.To stop the purgingtemporarily, raisethe enginespeedabove 1,000rpm with the pedal,then slowly releasethe pedal. accelerator *: '99 - 00 models 9. Let the engine idle for one minute with the headlights(Low)ON, and checkthe idle speed. ldle speed should be: 38 mod6l: 750 f 50 rpm (in Palk or neutrall '99 - 00 modols: 730 t 50 rpm (in Palk or neutral) 10. Turn the headlightsoff. Let the engine idle for one minutewith the heaterfan switchat Hl and air conditioneron, then checkthe idle speed. ldls spqed should be: '98 model: 780 t 50 rpm (in Park or neutrall '99 - 00 mod€ls: 7701 50 rpm lin Park or neutral) lf the idle speed is not within specification. see the SymptomCharton page11-64.
FuelSupplySystem FuelLines Check fuel system lines, hoses, fuel filter, and other components for damage, leaks or det6rioration, and r€place it neces-
sary. '97 model:
33N.m (3.4kg(.m,2s lbf.ftl
27 N.m 12.8kg{.m,21 lbf.ft)
'98 model:
27 N.rn (2.8 kgl.m, 21 lbf.ft)
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(cont'd)
11-171
Fuel Supply System FuelLines(cont'dl '99 - 00 models:
33 N.m (3.4kgl.m.25lbtftl
11-172
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'97 model: Checkall hoseclamps,and retightenif necessary.
{"2 /\
FUEL FILTER
,"1 <,,
___--tJ
I
FUELTUBE/ OUICK-CONNECT FITTINGS
B
' ^ s ,4\-') | EVAPORATIVE EMISSION{EVAP} CONTBOL CANISTER
ft\
I
q'l
I
/'------/ ,
/
B
To FUEL PRESSURE REGULATOR
Clampin the middle
(cont'd) 10-14mm (0.39- 0.55 inl www.emanualpro.com
11-173
Fuel Supply System Fuel Lines (confd) '98 - (X)models: Checkall hoseclamps,and retightenif necessary. SASE GASKET Replace.
FUEL FILTER
To FUEL PRESSURE REGULATOR C l a m pi n t h e m i d d l e
10-14mm (0.39- 0.ssin)
11-174
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Fittings FuelTube/Ouick-Gonnect Procautions
Disconnection
Do not smoke whils working on the fuel @ syst6m, Koop open flames away from your work ar9a.
Do not smoke while working on the fuel !@ syst6m. Keep open flames away from your work area.
The fuel tube/quick-connect fittings assemblyconnects the in-tankfuel pump with the fuel feed pipe.For removing or installingthe fuel pump and fuel tank, it is necesfittings. saryto disconnector connectthe quick-connect Payattentionto following;
1.
Disconnect the batterynegativecable.
2.
Removethe fuel fill cap to relievefuel pressurein the tank.
3.
Relievefuel pressure(seepage 11-178).
4.
Checkthe fuel quick-connectfittings for dirt, and cleanif necessary.
5.
Hold the connectorwith one hand and pressdown the retainertabs with the other hand.then pull the connectoroff.
.
.
fittings assemblyis not The fuel tube/quick-connect heat-resistant; be carefulnot to damageit duringweldprocedures. ing or otherheat-generating The fuel tube/quick-connect fittings assemblyis not acid-proof;do not touch it with a shop towel which was used for wiping batteryelectrolyte.R€placethe fittings assemblyif it came fuel tube/quick-connect into contactwith electrolyteor somethinosimilar.
NOTE: . Be carefulnot to damagethe pipeor other parts. Do not usetools, . lf the connectordoes not move,keepthe retainer tabs presseddown, and alternatelypull and push the connectoruntil it comesoff easily. . Do not removethe retainerfrom the pipe; once removed,the retainermust be replacedwith a new one.
. Whenconnectingor disconnecting the fuel tube/quickconnectfittings assembly,be carefulnot to bend or twist it excessively,Replaceit if damaged, A disconnectedquick-connectfittings can be reconnected, but the retaineron the mating pipe cannot be reusedonce it has been removed from the pipe. Replacetha retainer . . . .
LOCKII{G PAWL
replacingthe fuel pump. replacingthe fuelfeed pipe, it has beenremovedfrom the Dioe, it is damaged.
RETANENTAB
@NNCCTOR Pressdown.
6.
Checkthe contactareaof the pipe for dirt and damage. . lf the surfaceis dirW,cleanit . lf the surfaceis rusty or damaged,replacethe fuel pump or fuelfeedpipe,
RCTAINER
FUELTUBE
CONTACTANEA CONNECTOR CONNECTOR RETAINER
{cont'd}
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11-175
FuelSupplySystem FuelTube/Ouick-Connect Fittings{cont'd) 7.
To prevent damage and keep out foreign matter. coverthe disconnected connectorand oioe end with plasticbags.
Connection Do not smoke white working on the fuel E!@ system. Keepoper flamss away flom your work atea. 1.
Checkthe pipe contact area for din and damage, and cleanif necessary.
COiITACT AiEA
PL TSnCEAGS
Insena new retainerintothe connectorif the retainer is damaged,or after . replacingthe fuel pump. . replacingthe fuel feed pipe. . removingthe retainerfrom the pipe.
AASE GASKET Beplace.
11-176
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3.
Beforeconnectinga new fuel tube/quick-connect fitt i n g a s s e m b l y ,r e m o v et h e o l d r e t a i n e rf r o m t h e mating pipe.
with the tabs pulled apart, remove and discard the retarner
4.
Ncw FUELTUBE/ OUICK.CONNECT FI?TINGASSEMBLY
Align the quick-connectfittings with the pipe. and align the retainerlockingpawls with the connector grooves.Then pressthe quick-connect fittingsonto the pipe until both retainerpawls lock with a clickI n gs o u n d . NOTE:lf it is hardto connect,put a smallamountof n e w e n g i n eo i l o n t h e p i p ee n d .
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5.
Makesure the connectionis secureand that the pawls are firmly lockedinto place;checkvisually and by pullingthe connector.
6.
Reconnectthe batterynegativecable,and turn the i g n i t i o ns w i t c hO N ( l l ) .T h e f u e l p u m p w i l l r u n f o r abouttwo seconds,andfuel pressurewill rise.Repeat two or threetimes,and checkthat thereis no leakage in the fuelsupplysystem.
FuelSupplySystem SystemDescription The fuel supply system consistsof a fuel tank, in-tank high-pressure fuel pump. PGM-Flmain relay,fuel filter, fuel pressureregulator,fuel injectors,and fuel delivery and return lines.This system deliverspressure-regulated fuel to the fuel injectorsand cuts the fuel delivery when the engineis not running.
FuelPressure
Inspection 1, 2.
Relievefuel pressure. Removethe 12 mm banjobolt on the fuel filterwhile holding the fuel filter with anotherwrench.Attach the 12 mm fuel pressureadapterbolt and the special tool.
FUEL PRESSURE GAUGE 07406- 0040001
FUELPRESSURE REGULATON
Relieving Beforedisconnectingfuel pipes or hoses,releasepressure from the system by looseningthe 12 mm banjo bolt on the too of the fuel filter.
Do not smoke while working on the fuel system. Ke€p open flames or sparks away from your work area, Be sure to relieve fuel pressurewhile the ignition switch is off. 1.
Write down the frequenciesfor the radio's preset buttons. Disconnectthe batterynegativecablefrom the battery negativeterminal. Removethe fuel fill cap. Use a box end wrench on the 12 mm banjo bolt at the fuel filter while holdingthe fuel filter with another wrench. Placea rag or shoptoweloverthe '12mm banjo bolt. Slowly loosenthe 12 mm banjo bolt one complete rurn 12mm BANJo BOLT
SHOPTOWEL NOTE: Replacethe washers whenever the 12 mm baniobolt is loosenedor removed.
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11-178
The illustration shows '97 - 98 models, '99 - 00 modelsare similar.
Startthe engine.Measurethe fuel pressurewith the engineidling and the vacuumhose of the fuel pressure regulatordisconnectedfrom the fuel pressure regulatorand pinched.lf the enginewill not start, turn the ignitionswitchon (ll),wait for two seconds, turn it off, then back on again and read the fuel pressure. Pressureshould be: '97 - 98 mod€ls: 260 -31O kPa 12.7- 3.2 kgf/cm,, 38 - 46 psil '99 - 0Omodels: 270 - 32OkPa Q.A - 3.2 kgf/cm', ifo - /U psil Reconnectvacuumhoseto the fuel pressureregulator. Prgs3ureshould be: '97 - 98 models: 210 - 25OkPa 12.1- 2.6 kgf/cm', 30 - 37 psi) '99 - 00 models: 22O-26iJ kPa 12.2- 2.7 kgt/cm', 31 - 38 psi) lf the fuel pressureis not as specified,first checkthe fuel pump (seepage 11-183).lf the fuel pump is OK, checkthe following: . l f t h e f u e l p r e s s u r ei s h i g h e r t h a n s p e c i f i e d , inspectfor: - Pinchedor cloggedfuel returnhoseor line. - Faultyfuel pressureregulator(see page 11181). . lf the fuel pressureis lower than specified.inspect for: - Cloggedfuel filter. - Faulty fuel pressureregulator(see page 111811. - Fuelline leakage.
FuelInjectors R6placomoni 1. Relievethe fuel pressure(seepage 11-178). 2. Removethe resonato.chamber('99- 00 models).
S O.RING Beplace.
Disconnectthe connectorsfrom the fuel injectors, and disconnectthe IAT sensor 2P connector ('97 - 98 models) and EVAPpurge control solenoid valve 2P conn€ctor ('97 - 98 models), Disconnectthe PCVvalve and the vacuum hose from the fuel pressureregulator. Placea shop towel overthe fuel returnhose,then disconnectit from the fuel pressureregulator. Removethe retainernuts on the fuel rail. Disconnect the fuel rail. 7, Removethe fuel injectorsfrom the intake manifold. '97 - 98 model3: EVAPPURGE CONTROL SOLENOID VALVE2PCONNECTOR FUELPULSATION
IAT SENSOR 2P CONNECTOR
12 N.m {1.2 kgt'm, 8.7 tbtft) FUEL PRESSURE REGULATOR O.RING CUSHION Replace. SEAL RING Replace.
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FUEL PRESSURE REGULATOR O.RING Replace. CUSHION RING Replace. SEAL RING Replace.
11-179
FuelSupplySystem FuelInjectors{cont'dl 8. Slidenew cushionringsonto the fuel injectors. 9 , C o a tn e w O - r i n g s w i t ch l e a ne n g i n eo i l , a n dp u t t h e mo n t h e f u e li n i e c t o r s . '10. lnsertthe fuel injectorsinto the fuel rail first. p r e s st h e m i n t ot h e i n t a k em a n i f o l d nngineoil,and 1 1 . C o a t n e w s e arl i n g s w i t h c l e a e 12. To preventdamageto the O-rings,installthe fuel injectorsin the fuel rail first, then installthem in the intakemanifold. FUELRAIL
The ill!strationshows '97 -98 models,'99- 00 models are similar.
13. lnstalland tightenthe retainernuts. 14. Connectthe vacuumhosesand fuel returnhoseto the fuel pressureregulator. 15. Connectthe PCVvalve. 16. Connectthe connectorsto the fuel injectors,the IAT sensor('97 - 98 models),and the EVAPpurge controlsolenoid valve{'97- 98 models). 1 1 . Coata new O-ringwith cleanengineoil, and installthe resonatorchamber('99- 00 models). 1 8 . Turn the ignition switch ON (ll), but do not operatethe starter.After the fuel pump runs for approximatelytwo seconds, the fuef pressurein the fuel linerises.Repeatthis two or threetimes,thencheckwhetherthereis any fuel leakage.
11 - 1 8 0
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FuelPressureRegulator Replacement
Tesiing 1.
Attachthe specialtool and the 12 mm fuel pressure adapterbolt to the fuel filter (seepage 1l-178)
'1. Placea shop towel under the fuel pressureregulator, then relievefuel pressure(seepage 11-1781.
2.
Startthe engine.
2.
Disconnect the vacuumhoseand fuel returnhose.
Prasgureshould be: '97 - 98 models; 260- 310 kPa (2.7- 3.2 kgl/cm' ,38 -,16 psi) '9!t - 00 models: 27O- 32o kPa l2-8- 3.3 kgf/cm', 40 - /l7 psil (with the lugl pressure rsgulator vacuum hose disconnestedand pinched)
3.
Removethe two 6 mm retainerbolts and the fuel pressurereguralor.
12 N.m (1.2kgf.m, 8.7 tbf.ft)
FUEL PRESSURE GAUGE 07406 - 0040001 CLAMP
Replace.
FUELPRESSURE NEGULATOR
shows Theillustration '97- 98models,'99 -00 models aresimilar.
Reconnectthe vacuum hose to the fuel pressure regulalor. 4.
Checkthat the fuel pressureriseswhen the vacuum hosefrom the fuel pressureregulatoris disconnected agarn.
shows Theillustration '99 00models '97- 98models, similar. are
Apply cleanengineoil to a new O-ring.and carefully installit into its properposition. Install the fuel pressure regulator in the reverse orderof removal,
l f t h e f u e l p r e s s u r ed i d n o t r i s e , r e p l a c et h e f u e l pressureregulator.
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11 - 1 8 1
FuelSupplySystem FuelFilter Replacamont
. .
Do not smoke whilo working on tuol syslom, Keepopen flame away from your work area. While rsplscingths fuolfihor. bo carefulto ko€p a safe distanca betweon baftsry tarminals and any tools,
The fuel filter should be replacedwheneverthe fuel Dressure drops belowthe specifiedvalue*with the fuel pressure regulatorvacuum hose disconnected and pinchedl after makingsure that the fuel pump and the fuel pressure regulatorare OK.
12 mm SEAUNG BOLT 33 hl.m l3.a kgt m, 25 lbt frl
i: '97 - 98 modelsi 260 - 310 kPa 12.7- 3.2 kgllcm2,3g 46 psil '99 - 00 mod6fs: 270 - 320 kP8 12.8- 3.2 kgilcm2, 40 il7psi) 1,
Placea shop towel underand aroundthe fuel filter.
2.
Relievefuel pressure(seepage l1-l7B).
3.
Removethe enginewire harnessbracketand power steeringfeed hoseclamp.
4.
Removethe banjo bolt and the fuel feed pipe while supportingthe fuel filter with another wrench. as snown. Removethe fuelfilter clampand fuel filter, Install the new fuel filter in the reverse orde. of removal,and notetheseitems: . .
Whenassembling,use new washersas shown. C l e a nt h e f l a r e d j o i n t o f h i g h p r e s s u r en o s e s thoroughlybeforereconnecting them.
11 -1 8 2
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9.8 N.|n 11.0kgf'm, t.2 tbt.ftl
FuelPump Testing
Raplac6mont
lf you suspect a problem with the fuel pump, checkthat the fuel pump actuallyruns;when it is oN (ll),you will hearsome noiseif you hold your ear to the fuel fill port with the fuel fill cap removed.The fuel pump shouldrun for two secondswhen ignition switch is first turned ON (ll). lf the fuel pump does not make noise,checkit as follows:
1.
Foldthe left rear seatcushionforward,and remove the baseframe cover(seesection20).
2.
Removethe accesspanelfrom the floor.
3,
Relievethe fuel pressure(seepage 11-178).
4.
the fuel lines. Disconnect
5.
the 5Pconnectorfrom the fuel pump. Disconnect
6.
Removethe fuel pump mountingnuts.
7.
Removethe fuel pump from the fuel tank.
8.
I n s t a l lt h e f u e l p u m p i n t h e r e v e r s eo r d e r o f removal.
1.
Foldthe left rear seat cushionforward,and remove the baseframe cover (seesection 20).
2,
Removethe accesspanelfrom the floor.
3.
Make sure the ignition switch is OFF,then disconnectthe fuel pumP5P connector.
4.
Connectthe PGM-FImain relay7P connectortermrnal No. 4 and No, 5 with a jumperwire. PGM.FIMAIN (Cit:}2l RELAY7P CONNECTOR
I'TtlJil -r'-r t f
l
l . l 5 l 5 1 7 l
,frTt-
, a t \. tcl tyEL/cRNl FUELpUMp LrrYEL/cRNl I I Wir€sideof JUMPER femaleterminals WIRE
5.
Checkthat battery voltage is available between the fuel pump 5P connectorterminal No. 4 and body groundwhen the ignitionswitchis turnedON (ll). {C562} FUELPUMP5PCONNECTOR 2
1
3
a
5
FUELPUMP (YEL/GRNI wire sideof femaleterminals
l f b a t t e r yv o l t a g e i s a v a i l a b l e ,c h e c kt h e f u e l pump ground. lf the ground is OK, replacethe fuel oumo. lf there is no voltage,checkthe wire harness(see p a g e1 1 - 1 8 8 ) .
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11-183
FuelSupplySystem FuelGauge Tssting
Turnthe ignitionswitchOFF.
NOTE:Referto section23 for the fuel gaugesystemcircuit diagram. '1.
Checkthe No. 25 METER(7.5A) fuse in the underdash fuse/relaybox before testing.
2.
Foldthe left rear seatcushionforward,and remove the baseframe cover{seesection20).
3.
Removethe accesspanelfrom the floor.
4.
Disconnect the 5Pconnectorfrom the fuel pump.
5.
Measurevoltage betweenthe 5P connectorterminalsNo.2 and No. 5 with the ignitionswitchON ( ). Thereshouldbe between5 and 8 V.
FUELPUMP 5P CONNECTOR
tc56al
Wire side of female t€rminals
a lf the voltageis as specified, go to step 6. a lf the voltageis not as specified, checkfor:
-
an open in the YEUBLKor BLKwrre. poor ground (c552).
1 1 -1 8 4
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7 . Attach a jumper wire betweenthe No. 2 and No. 5 terminals,then turn the ignitionswitchON fll). Checkthat the pointerof the fuel gaugestartsmoving toward the "F" mark. Turn the ignition switch OFF before the pointer reaches"F" on the gauge dial. Failureto do so may damagethe luel gauge. NOTE:The fuel gaugeis a bobbin (cross-coil) type, hencethe fuel level is continuouslyindicatedeven w h e n t h e i g n i t i o ns w i t c h i s O F F ,a n d t h e p o i n t e r movesmore slowlythan that of a bimetaltype. . .
lf the pointerof the fuel gaugedoes not move at all. replacethe gauge. lf the gauge is OK, inspectthe fuel gauge sendingunit.
FuelGaugeSendingUnit Tgsting Do not smoke while working on tho fuel @ systom. Keop open flamo 8waYfrom your work araa. 1.
Foldthe left rearseat cushionforward,and remove the baseframe cover(seesection20).
2.
Removethe accesspanel.
3.
With the ignitionswitchOFF.disconnectthe 5P connectorfrom the fuel pump.
4.
Relievefuel pressure(seepage 11-178).
5.
Disconnect the fuel lines.
6.
Removethe fuel pump,
7.
Measurethe resistancebetweenthe No. 2 and No. 5 terminalsat E (EMPTY),1/2(HALFFULL)and F (FULL) by movingthe float.
lf you do not get the above readings,replacethe fuel pump.
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11-185
FuelSupplySystem Low Fuel Indicator System Indicator Light Testing
8.
NOTE:Referto section23forthe lowfuel lndicatorcircuit clragram. 1. 2.
Checkthe No. 25 METER(7.5A) fuse in the underdash fuse/relaybox before testing. Parkthe vehicleon levelground.
Add 4 / of fuel (1.1U.S.Gal,0.9 lmp. Gal).The light shouldgo off within four minutes. .
lJ the light does not go off, checkfor: - a short in the GRNA/ELwire between the fuel gaugesendingunit and fuel gaugeassembly. - faultygaugeassembly. . lf the light goes off, the low fuel indicatorlight is
oK. Do not smoke while working on the @ fuel system. Keep open flame away trom the work aroa. Drain fuel only into an approved container. D r a i n t h e f u e l i n t o a n a o D r o v e dc o n t a i n e r T . hen installthe drain bolt with a new washer. Add lessthan 8 f (2.1U.S.Gal. 1.8lmp. Gal)of fuel, and turn the ignitionswitchON {ll).The low fuel indicatorlightshouldcome on within four minutes.
INDICATONLIGHT
.
lf the light comes on within four minutes,go to step8. lf the lightdoesnot comeon withinfour minutes. go to step 5.
.
7.
Removethe seatcushion(seesection20). Removethe fuel tank accesspanel from the floor, and disconnectthe 5Pconnectorfrom the fuel pump, Connectthe No. 1 and No. 2 terminalswith a jumper wire. . .
l f t h e l i g h t c o m e s o nc, h e c k t h es e n d i n gu n i t . lf the light does not come on, checkfor: - a n o p e n i n t h e G R N / y E Lw i r e b e t w e e nt h e fuel unit and fuel gaugeassembly. - blown bulb. - poor ground (G552). (C562) FUEI-PUMP5PCONNECTOR WIRE JUMPER IGRN/YEL}
Wiresid€ol tem€leterminals
1 1 - 18 6
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PGM-FIMain Relay Description The PGM-Flmain relav actuallvcontainstwo individual relays.This relay is locatedat the passengerside of the cowl. One relay is energizedwheneverthe ignitionis on w h i c h s u p p l i e st h e b a t t e r yv o l t a g et o t h e E C M / P C M , power to the fuel injectors,and power for the second relay. The second relay is energizedfor two seconds when the ignition is switchedon, and when the engine is running,to supplypowerto the fuel pump
PGM.FI MAIN RELAY
Belay Testing N O T E :l f t h e e n g i n es t a r t sa n d c o n t i n u e st o r u n , t h e PGM-FImain relayis OK. 1. 2. 3.
R e m o v et h e g l o v e b o xa n d t h e p a s s e n g e r 'ds a s h boardlowercover (seesection20). Removethe PGM-FImain relay Aftachthe batterypositiveterminalto the No. 2 terminal and the batterynegativeterminalto the No. 1 terminal of the PGM-Flmain relay.Then checkfor continuitybetweenthe No. 5 terminaland No. 4 terminal of the PGM-FImain relay . lfthere is continuity,go on to step3. . lf there is nocontinuity,replacethePGM-Flmain relavand retest. No.2
No.5 No.5 To lGN.1
To GROUND
To ST. SWITCH To ECM/PCM CONNECTOR TERMINAL A16 (FLR)
To BAT O To FUELPUMP To ECM/PCM CONNECTOR TERMINAL (411and A24, Bl .nd Bgal (IGP)
To FUELPUMP
98- 00 models Attachthe battervDositiveterminalto the No. 5 terminal and the batterynegativeterminalto the No. 3 termjnalof the PGM-Flmain relay.Then checkthat there is continuitybetweenthe No. 7 terminal and No. 6 terminalof the PGM-FImain relay. . lf there is continuity,go on to step 4. . lf there is nocontinuity,replacethePGM-Flmain relayand retest. 5 . Attachthe battervoositiveterminalto the No.6 terminal and the batterynegativeterminalto the No. 1 terminalof the PGM-Flmain relay.Then checkthat there is continuitvbetweenthe No. 5 terminal and No. 4 terminalof the PGM-Flmain relay. . lf thereis continuity,the PGM-Flmain relayis OK. P G M - Fm I ain . l f t h e r ei s n o c o n t i n u i t yr,e p l a c e t h e (cont'd) relayand retest.
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11-147
FuelSupplySystem PGM-FIMain Relay(cont'dl Troubleshooting -
Enginewill not start. InsDection ol PGM-FI main relay and relay harness, PGM.FIMAIN RELAY7P CONNECTOR lc(}21 GND
Check fo. an open in the wire IGNDlinol: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe PGM Fl main relay7P connector. 3. Checkfor continuitybetween the PGM'FImain relay7P connectorterminalNo.3 and body ground.
trTr]--Flq FI,Til'I A
Y
Wire sideot femaleterminals Repairopcn in th€ wire between the PGM-FImain relavand G101.
Checktor an open or short in the wiro (BATline): M e a s u r ev o l t a g e b e t w e e nt h e PGM'FImain relay 7P connector terminalNo.7 and bodyground. ls there bafteryvoltage? -
Repai. open or short in lhe wir6 belween the PGM-FI main relay and the Fl E/M (15 Al fu3e. Replace th6 FIE/M (15Altus6 in th€ under-hood fuse/.6lay
Checklor an open or short in the wire (lGl line): L Turn the ignitionswitch ON (ll). 2. Measurethe voltage between the PGM-FImain relay7P con nectorterminalNo. 5 and body ground. -
Checkfor an open or short in the wire {STSline): 1. Turnthe ignitionswitchto the START(lll)position. NOTE: . M/T: Clutch pedal must be depressed. . A/T: Transmissionin E or Elposition. 2. Measurethe voltage between t h e P G M - F lm a i n r e t a y7 P connectorterminalNo. 2 and body ground.
-
('97model:To page11-189) ('98 00models:Tp o a g e1 l 1 9 0 )
11 - 1 8 8
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Repair open or shorl in the wire between the FGM-FImain relayand the No. 13 FUEL PUMP115A) tuse. Replacothe No. 13RJELPUMP 115A) luse in the und6.-d$h fuso/ relav box.
Repair open or short in the wire betwe€n the PIGM-FIm.in rclay and th€ No. 31 STARTER SlGllAL 17.5A) tuse. Repl.ce the No. 31 STARTER SIGNAL 17.5Al tuse in the under-dashtuse/relaybox.
lFrompage11 188)
-t
('97model) (C432I PGM.FIMAIN RELAY7P CONNECTOR FLR IGRN/YELI
Ch6ck lor an open in the wir€ {FLRline): 1. Turnthe ignitionswitchOFF. 2. Disconnectthe PCM connector A (32P). 3. Checkfor continuitybetween the PGM-FImain relay 7P connectorterminal No. 1 and PCM terminalA16. connector Wire sideof lemaleterminals Repairopen in the wire be{weon the PCM lAl6l and the PGM-FI main relay.
Checkfor an open in the wir€s {lGP1,lGP2lin€s): '1. Reconnect the PCMconnector A (32P). 2 . R e c o n n e ct th e P G M ' F lm a i n relayconnector. 3. Turnthe ignitionswitchON (lli. 4. MeasurevoltagebetweenPCM connectorterminalsA11 and A 1 0 , a n d b e t w e e nA 2 4 a n d A10.
IGP2 (YEL/BLK)
ls therebatteryvoltage? -
Repair open in the wir€ bet' ween th€ PCM {A11,A2ia}end the PGM-FImain relay. Reolscethe PGM-FImain rolaY.
Checktor an open in the PCM: 1. Turnthe ignitionswitchOFF. 2 , M e a s ur e v o l t a g e b e t w e e n PCMconnectorterminalsA16 a n d A 1 0w h e nt h e i g n i t i o n switch is first turned ON {ll) for
ls there'1.0V or less?
Substitute a known-good PCM and recheck. lf ptesctibed volttge is now available,roplacotho orig' in.lPCM.
(cont'd) C h e c k t h e P G M - F lm . i n . e l a V (seepage11-187). _l www.emanualpro.com
1 1 - 18 9
FuelSupplySystem PGM-FIMain Relay(cont'dl (Frompage11,188) ('98- 00 models)
-l
PGM.FIMAIN RELAY7P CONNECTOF(C€2) Check lor an open in the wire (FLRline): 1. Turn the ignitionswitchOFF. 2. Disconnectthe ECM/PCMcon nectorA (32P1. 3. Checkfor continuitybetween the PGM-FImain relay7P connectorterminalNo. '1and ECM/ PCMconnectorterminal416. Wiresid€of femaleterminals Repaiaopen in the wire between the EcM/PcM lAl5l .nd the PGM-FIm.in relay.
Check for an open in the wires llcPl,lGP2linos): 1. Reconnectthe ECM/PCN4 connector I (25P). 2. Reconnectthe PGM Fl main retayconnector. 3. Turn the ignitionswitchON l). 4, Measurevoltage between ECM/PCMconnectorterminals B1 and 82, and between 89 and 82.
ECM/PCMCONNECTOR B I25PI
Dde"Jt;;li L-F-T-PGl (BLK} 3
s l 1 0
IGP2 (YEL/BLKI 1 9
Ropai. open in tho wire b6twe€n th. ECM/PCM lBt, Btl .nd the FGM-FImain rd.y. R€plac€th6 FGM+| main retay,
20
11
13 21 22
8 17
Wire side of female terminals
ECM/PCMCONNECTORS Chock for an open in the ECM/ PCM: 1. Turnthe ignitionswitchOFF. 2, Measurevoltage between ECM/PCMconnectorterminals 416 and 82 when the ignition switch is first turned ON (tl) for
ls there1.0V or less?
a t32Pl
Subrtitute e known-good ECM/ PCM and recheck. lf prescribsd voltage b now ovrihble, replaco the originelECM/PCM. Wiresideof f€maleterminsls
Check the PGM-FI main.elav (s6epage 11-1871.
11 - 1 9 0
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FuelTank Replacement Do not smoke while working on fuol systam Keep open flame away from your work area'
@ 1. 2. 3. 4. 5. 6. 7. 8. g.
Relievethe fuel pressure(seepage11-178). Foldthe left rearseatcushionforward,and removethe baseframecover{seesection20). Removethe accesspanelfrom the floor. and 6P connector(C580)('98-00 models)' the 5Pconnector1C562) Disconnect fittings{seepage 11-175} Disconnect the fuel returnhoseand quick-connect jackstands. Jackup the vehicle,and supportit with Removethe middlefloor beam. Removethe drain bolt, and drainthe fuel into an approvedcontaaner. the hoses(seepage 11-173,174).slide backthe clamps.then twist hosesas you pull, to avoid damaging Disconnect
them. 10. Placea jack,or othersuppon,underthe tank 11. Removethe strapnuts,and let the strapsfall free 12. Removethe fuel tank.lf it stickson the u ndercoatappliedto its mount,carefully pry it off the mount, '13. lnstallthedrain bolt with a new washer,then coatthe drain bolt with Noxrust1248' Allow the Noxrustto dry for 20 minutes. 14. Installpartsin the reverseorderof removal. '97 modol: AOCESSPANEL
CONNECTOR
DRAINEOLT 49 N.m 15.0kgf'm, 36 rbt frl www.emanualpro.com
(cont'd)
11 - 1 9 1
FuelSupplySystem FuelTank (cont'd)
I
,98 - 00 models:
5P CONNECTOR 6P CONNECTOR
I
38 N.m (3.9ksf.m,28lbtftl
\
11-192
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Intake Air System SystemDescription The systemsuppliesair for all engine needs.lt consistsof the intakeair pipe,Air Cleaner,intakeair duct, ThrottleBody (TB),ldle Air Control(lAC)Valve,fast idle thermo valve,and intakemanifold.A resonatorin the intakeair pipe provides additionalsilencingas air is drawn into the system.
T
YEL| BLK
Fiom PGM'FI MAIN RELAY
vaRtous SENSORS
IDLE THERMO
INTAKEMANIFOLD
lJ-_iuo'u'j"'
FESONATON
THROTTLE BODY(TB) INTAKE AIR DUCT
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11 - 1 9 3
IntakeAir System Air Cleaner
ThrottleCable
Air CleanerEloment Rsplacomsnt
Inrpection/Adiustmcnt
NOTE:Do not cleanthe air cleanerelementby blowing it off with compressedair,
1.
Stan the engine.Hold the engineat 3,000rpm with no load (in Parkor neutral) until the radiatorfan comes on, then let it idle.
2.
Checkthat the throttlecableoperatessmoothlywith no bindingor sticking.Repairas necessary,
3.
Checkcable free play at the throttle linkage.Cabte deflectionshouldbe 10- 12 mm (3/8- 1l2in.l.
'97 - 98 modols: CABLE BRACKET
m DEFLECTION 10-12mm BIA- 112i^l
LOCKNUT
'99 0O modsls: DEFLECTION l0-12mft Bla - 112inl
AIR CLEANERELEMENT No.mal conditions: Replaceair cleanerelementevery 30,000miles{48,000km) or 24 monthswhichevercomesfirst. Severecondition3: Replaceair cleanerelementevery 15,000miles124,000 km) or 12 monthswhichevercomestirst.
NUT lf deflectionis not within specs,loosenthe locknut, turn the adjustingnut untilthe deflectionis as specified,then retightenthe locknut. With the cableproperlyadjusted.checkthe throttle valve to be sure it opens fully when you push the acceleratorpedal to the floor. Also check the throttle valve to be sure it returns to the idle position whenever you releasethe acceleratorpedal.
11-194
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'97 - 98 modals:
lnstellation 1.
Openthe throttlevalvefully,then installthe throttle cable in the throttle linkage,and install the cable housingin the cablebracket.
lhere shouldbe no clearance.
97 - 98 modols: CABLE
LINKAGE THRoTTLE
AD.'USTINGNUT 9.8 N.m (1.0 kg{.m, 7.2lbllrl
'99 - 00 modeb: LOCKNUT
INNERCABLE
CABLE BRACKET
'99 - (Xl modols: ADJUSTING
BRACKET 2.
Sta.t the engine.Hold the engineat 3.000rpm with no load (in Park or neutral) until the radiator fan comeson, then let it idle. Hold the cable sheath,removingall slackfrom the cable. Set the locknut on the cable bracket. Adiustthe adjustingnut so that its free play is 0 mm. Rimove the cable sheath from the throttle bracket, resetthe adjustingnut and tightenthe locknut.
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9.8 N.m l'1.0kgt'm, 7.2 tbr.ft)
IntakeAir System ThrottleBody Doscription The throttle body is a single-barrelside-drafttype. The lower portion of the throttle valve is heatedby engine coolantfrom the cylinderhead.The idle adjustingscrew which regulatesthe bypassair is locatedon the top of the throttlebodv.
lnspection Checkthat the throttlecableoperatessmoothlywithout bindingor sticking. lf thereare any abnormalities, checkfor: . Excessive wear or play in the throftlevalveshaft. . Sticky or binding throttle lever at the fully closed positton. . Clearancebetweenthrottle stop screw and throttle leverat the fully closedposition. 97 - 98 models: THROTTLE LINKAGE
The illustration shows '97 - 98 models,'9900 rnodels are similar.
THROTTLELINKAGE
Replacethe throttle body if there is excessiveplay in the throttlevalveshaftor if the shaft is bindingor sticking.
11 - 1 9 6
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Removal '97 - 98 models:
GASKET MAP SENSOR
R \ t
,:4W) TP SENSOR
FASTIDLETHERMO VALVE(A/T onlyl
'99 - O0models:
TP SENSOR
a
F(
\g-.-'
22 N.m 12.2kgl m, 16 tbtft)
NOTE: . Do not adjustthe throttlestop screw. . After reassembly, adjustthe throftlecable(seepage11-194). . The TP sensoris not removable.
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FASTIDLETHERMO VALVElA/T only)
(cont'd)
11-197
IntakeAir System ThrottleBody (cont'd) Disassembly
O-RING{A/l only) Replace.
ADJUSTING SCREW
IDLETHERMO VALVE (A/T only)
9.8 N.m (1.0kgl.m,7.2lbf.ftl The illustration shows'97- 98 models,'99 00 modelsare similar.
11 - 1 9 8
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EmissionControlSystem SystemDescription
ThreeWayCatalyticConverter(TWCI
T h e e m i s s i o nc o n t r o l s y s t e m i n c l u d e s ,a T h r e eW a y CatalyticConverter{TWC),PositiveCrankcaseVentilation (PCV)svstem and EvaporativeEmission(€VAP)Control system.The emissioncontrol system is designedto meet federaland stateemissionstandards.
DsscriDtion
TailpipeEmission
Three Way Catalytic Convertsr lTwcl: The Three wav CatalvticConverter (TWC) is used to converthydrocarbons(HC),carbonmonoxide(CO),and oxides of nitrogen(NOx) in the exhaustgas to carbon dioxide(COr),dinitrogen(Nr)and water vapor,
Inspsction Do not smoke during this procsdura. Keep !@ any open tlame away from your work area. 1.
Startthe engine.Hold the engineat 3,000rpm with n o l o a d ( i n P a r ko r n e u t r a l )u n t i l t h e r a d i a t o rf a n comeson, then let it idle, Connecta tachometer. adjustthe idle speed,(see Checkand, if necessary, p a g e1 1 - 1 6 91, 7 0 ) .
4.
Warm up and calibratethe CO meteraccordingto the instructions. metermanufacturer's heaterblower,rear Checkidle COwith the headlights, off. windowdefogger,coolingfan,and air conditioner (Canada)Pull the parkingbrake lever up. Start the engine,then checkthat the headlightsare off. 0 . 1 %m a x i m u m . C Om e t e rs h o u l di n d i c a t e
{cont'd)
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11 - 1 9 9
EmissionControlSystem ThreeWay CatalyticConverter{TWCI(cont'd} 1P0420 Thescantool indicatesDiagnosticTroubleCode(DTC)P0420:Catalystsystemefficiencybelowthreshold. DescriDtion This systemevaluatesthe catalyst'scapacityby meansof the HO2S(Primaryand Secondary)outputduring stabledriving hasbeendetectedduringthreeconsecutive drivingcycles,the MILcomeson and DTCP0420will conditions.lf deterioration be stored. NOTE:lf some of the DTCSlistedbelow are storedat the same time as DTCP0420,troubleshootthose DTCSfirst. then troubleshootDTCP0420. P0137,P0138:SecondaryHO2S(Sensor2) P0141:SecondaryHO2S(Sensor2) Heater PossibleCause . IWC Deterioration . Exhaustsystemleakage Troubleshooting Flowchart -
The MIL has been reDoriedon. DTCP0420is stored.
Problemverification: 1. Do the ECM/PCM ResetProce dure, 2 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutraliuntil the radiatorfan comeson. 3. Connectthe SCSservicecon nector. 4. Test-drive40 - 55 mph (64- 88 km/h)for approx.lwo minutes. Then deceleratefor at least3 secondswith the throftlecom p l e t e l yc l o s e d .T h e n r e d u c e t h e v e h i c l es p e e dt o 3 5 m p h 1 5 6k m / h ) ,a n d t r y t o h o l d i t u n t i l t h e r e a d i n e s sc o d e
ls DTCP0420indicated?
Checkthe TWC (seesection 9). lI nocessary,replacethe TwC.
11-200
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Intermittent tailure. system is OK at this time.
PositiveGrankcase Ventilation(PGVISystem Description
Inspoction
T h e P o s i t i v eC r a n k c a s eV e n t i l a t i o n( P C V )s v s t e m i s designed to prevent blow-by gas from escaping to the atmosphere.The PCVvalve contains a spring-loaded plunger,When the enginestarts,the plungerin the PCV valve is lifted in proportionto intakemanitoldvacuum and the blow-by gas is drawn directlyinto the intakemanifold.
1.
Checkthe PCVhosesand connectionsfor leaksand clogging.
'97 - 98 models:
'99 - (X) models:
i/lAlrllFOLD -: BLOW.BY VAPOR -: FRESHAIR
BREATHER HOSE
(cont'd)
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11-201
EmissionControlSystem PositiveCrankcase Ventilation(PCV)System(cont'dl 2.
At idle,makesurethere is a clickingsoundfrom the PCVvalve when the hose betweenthe PCVvalve and intakemanifoldis lightly pinchedwith your fingers or pliers.
'97 - 98 models:
Gently pinch here.
'99 - 00 modelsi
Gentlypinchhere.
lf there is no clickingsound, checkthe PCVvalve grocrmet for cracksor damage,lf the grommet is OK, reDlacethe PCVvalveand recheck.
11-202
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Evaporative Emission(EVAP)Controls Description: The evaporativeemissioncontrolsare designedto minimizethe amount of fuel vapor escapingto the atmosphere.The systemconsistsof the followingcomponents: A.
EvaporativeEmission(EVAPIControl Canister An EVAPcontrolcanisteris usedfor the temporarystorageof fuel vapor until the luel vapor can be purgedfrom the EVAPcontrolcanisterinto the enqineand burned.
B. Vapor PurgeConirolSystem EVAPcontrolcanisterpurgingis accomplishedby drawingfreshair throughthe EVAPcontrolcanisterand into a pon on the intakemanifold.The purgingvacuumis controlledby the EVAPpurgecontrolsolenoidvalve. E V A P P U R G EC O N T R O LS O L E N O I DV A L V E D U T Y C O N T R O L L E D AFTER S T A R T I NE GN G I N E
ENGINECOOLANTTEMPERATURE ABOVE154"F(68'C) C.
FuelTank Vapor Control System Whenfuel vapor pressurein the fuel tank is higherthan the set valueof the EVAPtwo way valve,the valveopensand regulatesthe flow ot fuel vaporto the EVAPcontrolcanister. '97 model: EVAP PURGE CONTROL From No. 15 /ALTERNATOR I sP SENSORr7.sAt (in the under-dash fuse/relaybox)
VALVE BLK/ YEL
VARIOUS SENSOR FEESHAIF
BLK
I
FUEI-TANK
INTAKEMANIFOLD
(cont'd)
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11-203
EmissionGontrolSystem EvaporativeEmission(EVAP)Controls(cont'dl '98 - 0Omodels:
EVAP THREEWAY VALVE
EVAP CONTROL CANISTER VENTSHUT VALVE
Frofi
< NO.15
BLK/WHT
'EL/BLU ._^_-:.*,".. GRN/BLK
<3|ltAIS"o[..^, 1inthe under-dash tuse/relay box)
BLU L
VARIOUS SENSOR
LT GRN/WHT ,
RED/YEL
EVAP TWOWAY VALVE
EVAP BYPASS SOLENOID
EVAPPURGE CONTROL SoLENOtO VALVE
SLK
VALVE FUELTANK
MANIFOLD
11-204
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'97 model: The scan tool indicatesDiagnosticTrouble Code (DTC)P0441:EvaporativeEmission(EVAP)control system insufficientpurgeflow. Description By monitoringthe purge line vacuumwith the MAP sensor,the PCM can detectinsufficientEVAPcontrol system purge flow. PossibloCause . EVAPPurgeControlSolenoidValve . EVAPPurgeControlSolenoidValveCircuit . EVAPControlCanister . VacuumLines . PCM TroubleshootingFlowchart Th€ MIL has b€en reooited on. DTCP0441is .tored. Problemverificationl 1 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neut.al)until the radiatorfan comeson. 2. Do the PCMResetProcedure. 3. Connectthe SCSserviceconnector, 4. Test drive underfollowingcon' ditionson the road. - without any electricalload - Transmission in @ or @ position - Engine speed between - 2,4OO 1,2OO rpfi. - Decelerate from 50 mph (80 km/h)to15mph (24km/h) ls DTCP0441indicated?
Intermittent trilure, sydern is OK at this time. Checkfor Door connections or loose wir€3 at C108 IEVAP purge control solonoid valvol .nd at the PCM.
Checktor an open in the wire (lcl linel: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e E V A Pp u r g e controlsolenoidvalve2P connector. 3. Turnthe ignitionswitchON (ll). 4. Measurevoltagebetweenbody ground and the EVAPpurge control solenoidvalve 2P connectorterminalNo. '1, ls there batlery voltage?
EVAPPURGECONTROL SO1TNOIDVALVE2P CoNNECTOR(C108)
(v) YL
Wire side of female termrnals R€pafuopen in thc wir6 b€tw€en thG EVAP purge control solenoid valve and the No. 15 ALTEBNATORSP SENSOR(7.5A)fuse.
(To page11'206)
(cont'd)
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11-205
EmissionControl System EvaporativeEmission(EVAP)Controls(cont'dl (Frompage11-205)
PCMCONNECTOR A (32PI PG1(BLKI
Chsck th6 EVAP purgo control solonoidvalve: ' L R e c o n n e ctth e E V A Pp u r g e controlsolenoidvalve2P connector. 2. ConnectPCMconnectortermi nals 415 and A10 with a
Does the solenoid valve click when the jumper is connected?
PCSIRED/YELI JUMPERwlRE
Wire side of femaleterminais
Chscl to. an op6n or 3hort in th€ wiro (PCSlin6): Measurevoltage between PCM connectorterminalA15 and body grouno,
ls there batteryvoltage?
Chockfor . .hort in tho wiJe IPCS line): 1. Turnthe ignitionswitchOFF. 2. Disconnectthe PCMconnector A (32P). 3. Disconnectthe EVAP purge controlsolenoidvalve2P connector, 4. Checkfor continuitybetween body ground and PCM connectorterminalA15.
Rooair short in tho wir6 bctween the EVAP purge control 3olenoid valvo and tho PCM(A151.
Checkthe vacuum lin6: Checkthe vacuum linesof EVAP systemtor misrouting,leakage, brsakagoand clogging.
Are the vacuumlinesOK?
(Topago11'207)
11-206
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Ropair open in the wir6 betwoon the EVAP pu]go control .olonoid v.lve end the PCM(A15).
(Frompage11-206)
<\
Chack iho EVAP purge control solenoidvalve: 1. Disconnectthe vacuum hose trom the EVAPcontrolcanister. 2, Connectthe vacuumpump to the hoseand applyvacuum, EVAPCONTNOL CANISTER
VACUUM PUMPI GAUGE, 0-30 in.Hg 4973X 0il1 -
xxxxx Doesit hold vacuum?
Chgckthg EVAPcontrol csnbter: 1. Reconnectthe vacuum hoseto the EVAPcontrolcanister. 2. Connecta vac!um gauge to the purge air hose. 3. ConnectPCM connectorter m i n a l sA 1 5 a n d 4 1 0 w i t h a jumperwire. 4. Stanthe engine. 5. Checkthe vacuum.
JUMPEFWIRE wire side of femaleterminals
Checkthe EVAPtwo way valve (seepage11'224).
Doesthe EVAPtwo way valve work properly?
Rapbcethe EVAPtwo wey valve. VACUUM/PRESSURE GAUGE 0-4 in.Hg 07JA2 - ml(x)o8
Substitute a known-good PCM and rechock. It symptom/indication gocs away, roplacgtho originrl rcM.
{cont'd)
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1 1-207
EmissionControlSystem EvaporativeEmission(EVAP)Controls(cont'd) 99 - 00 models: The scan tool indicatesDiagnosticTrouble Code {DTC)P0451:The Fuel Tank Pressuresensor circuit range/ oerformanceDroblem. -
The MIL har been rooort€don. DTCP0451b storod.
ECM/PCMCONNECTORS
a t32Pl Check lor th6 tu6l tank pr€ssure len30r: 1. Do the ECM/PCM ResetProce, oure. 2. Removethe fuelfill cap. 3. Turnthe ignitionswitchON (ll). 4. Monitor the FTPSensorvolt a g e w i t h t h e H o n d aP G M T e s t e r ,o r m e a s u r ev o l t a g e between ECM/PCMconnector terminalsA29 and C18.
ls thereapprox.2.5V?
Check for the fuel tank piessure Sensot: L Disconnectthe hose between the EVAPtwo way valve and the fuel tank pressuresensorat the EVAPtwo way valveend. 2 . C o n n e c ta v a c u u mp u m p t o the openend ofthat hose. 3. Turn the ignitionswitchON (lll. 4. Monitor the FTPS€nsorvoltage with the Honda PGM T e s t e r ,o r m e a s u r ev o l t a g e between ECNI/PCNI connector t e r m i n a l sA 2 9 a n d C 1 8 ,a n d carefullyappiyvacuumon the hose one strokeat a time. 5. The voltageshould smoothly dropfrom the staningapprox. 2.5 V down to approx. 1.5 V. STOPapplyingvacuumwhen the voltage drops to approx. 1 . 5 V o r d a m a g et o t h e t u e l t a n k p r e s s u r es e n s o r m a y
PTANKILT GRNI
SG2 {GRN/BLK) Wire sideof {emaleterminals Chock tho vacuum lin6s tor rGlriction o. blockago repair as necessary.lf OK, roplacethe fuel tank Drer3ur€sentor.
FUELTANK PRESSURE SENSOR
VACUUM -30 in.H9 PUMP/GAUGE.0 A973X- 041 XXXXX
WAYVALVE Doesthe voltage drop to approx. 1 . 5V a n dh o l d ?
Intermittent tailuro. sv3tem is OK at this tim€. Chack to. poor conn€ction6 or 10036hose at fu6l tank pres3ure ionsor and fuel trnk.
11-208
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'98 - 00 mod€ls: The scantool indicatesDiagnosticTroubleCode(DTC)P0452:A low voltageproblemin the FuelTank Pressure sensof. The fuel tank Dressuresensorconvertsfuel tank absolutepressureinto electricalsignalsand inputsthe ECM/PCM. OUTPUT VOLTAGE tvl {.5
Th. MIL has been reoortedon. DTCm452 is stored. Checkthe vacuum lin6: Checkthe vacuumlinesof the fuel tank pressuresensorfor misrout ing, leakage,breakageand clogging.
0,5 -? KPA (-50 mmHg, -2 in.Hgl
+7 kPr l5OmmHg, 2 in.Hgl PRESSURE
Are the vacuumlinesOK? A (32P) ECM/PCMCONNECTOR Problemveriticstion: 1. Do the ECM/PCM Reset Procedure2. Removethe luelfillcap. 3 . T u r n t h e i g n i t i o ns w i t c hO N flr). 4. Monitor the FTPSensorvolt' age with the Honda PGM T e s t e r ,o r m e a s u r ev o l t a g e b e t w e e nb o d y g r o u n d a n d ECM/PCM terminalA29. ls lhereapprox.2.5V?
Intermittent failuro, system is OK at this lima. Chacklor Door connections or loose wi.es at C580 llocrted rt access panell, C646 lluel tank Daessuresensor) and at the ECM/PCM.
Checklor an open in wir€ lVeC2 line): 1. Turnthe ignitionswitchOFF. 2. Reinstallthe fuel fill cap. 3. Disconnectthe fuel tank pressuresensor3P connector, 4. Turnthe ignitionswitchON (ll). 5- Measurevoltage betweenthe fLreltank pressuresensor3P connectorNo. 1 terminaland N o . 2t e r m i n a l . ls thereapprox.5 V?
Wire sideot femaleterminals
FUELTANK PRESSURE SENSOR 3PCONNECTOR tc6a6l
voc2 (YEL/BLUI
Wire sideol fsmaleterminals Replir opon in the wire b€tw€en th6 tuel tank pressurelensot and the ECM/PCM{A29).
(cont'd)
YES ( T op a g e1 1 - 2 1 0 ) www.emanualpro.com
11-209
EmissionControlSystem EvaporativeEmission(EVAP)Controls(cont'dl (Frompagel1'209)
FUELTANK PRESSUNE SENSOR 3PCONNECTOR tc646l
Check lor a short in the wire IPTANKIine}: Measurevoltagebetlveenthe fuel tank pressuresensor3P connector No.3terminaland No.2terminal.
ls thereapprox.5V? Wire side of female terminals Check for a short in the wire (PTANKline): 1. Turnthe ignitionswitchOFF. 2 . D i s c on n e c t t h e E C M / P C M connectorA {32P). 3. Checkfor continuity between the fuel tank pressuresensor 3P connectorNo. 3 terminals and bodyground.
Repairshort in the wira betwgon the fuel trnk prossures6nsorand tho ECM/PCMlA29).
Sub.tituto a known-good ECM/ PCM and r€check. lf 3ymptom/ indication goer !way. replace th6 original ECM/PCM.
11 -2 1 0
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'98 - 00 modals: The scantool indicatesDiagnosticTroubleCode(DTC)P0453:A high voltageproblemin the FuelTankPressure sensor. Thc MIL has b6on ropottcd on. DTCmia53is dorcd.
Ch6cktho vacuum linos: C h e c kt h e v a c u u m l i n e s o f t h e fueltank pressuresensorlor misrouting, leakage,breakageand cloggrng.
A {32PI ECM/PCMCONNECTOR
Are the vacuumlinesOK? PTANK ILT GRN) Problornverification: 1. Do the ECM/PCM Reset Procedute. 2. Removethe fuel fill cap. 3. Turn the ignition switch ON
t€rminals Wire sidoot fema16
{[).
4. Monitor the FTPSensorvoltage with the Honda PGM Tester, or measure voltage b e t w e e nb o d y g r o u n d a n d terminal429. ECM,PCM
ls thereapprox.2.5V?
Intarmittent tailuro, sv3iom b OK at this timo. Chock for poor connection3 or loo$ wire3 at C580 (locstod .t .cc$r p.nell, C6a6 (fucl tank pros3ure son3orl and .t the ECM/FCM.
Check lor an open in tho wiro lSG2lin6l: 1. Turnthe ignitionswitchOFF. Iuel fill cap. 2. R6installthe 3. Disconnectthe Iu6l tank pres_ suresensor3P connector, 4. Turn the ignitionswitchON (ll). 5. M€asurevoltago between the tuel tank pressuresensor3P '! connectorterminalsNo. and No.2.
ls thereapprox.5 V?
Ch€ck for an opon in tho wiro (PTANKlinel: M e a s u r ev o l t a g e b e t w e e nt h e fuel tank pressuresensor3P connectorNo. 3 terminaland No. 2 terminal.
FUELTANX Pf,ESSUBESENSOR 3p CONNECTOR{C6,a6l
vcc2 IYEL/BLUI
sG2 (GRN/BLK} Replir op€n in th. wi.c b€{ween tha fuel tank Dio'sute sansot and tho EC|,/PCM {Cl8}.
Wire sideot femaleterminals
1
sG2 IGRN/BLKI
2
3 PTANK ILT GRNI
ls thereapprox.5 V? (cont'd) \To page 11-212) www.emanualpro.com
11-211
EmissionControlSystem EvaporativeEmission(EVAP)Controls(cont'dl ( F r o mp a g e1 1 , 2 1 1 ) ECM/PCMCONNECTORS Check fo. an open in the wire (PTANKlinel: Measurevoltage betweenECM/ PCMconnectorterminalsA29 and c18. PTANK {LT GRNI ls thereapprox.5V?
Ropairopen in the wire betweon the ECM/PCM{A291and tho fuol tank pressule3ensor.
Substitute a known-good ECM/ PCM and recheck. lf symptom/ indication goes away, r€place tho originrl ECM/PCM. SG2 (GRN/BLK} Wire sideof temaleterminals
11-2 1 2
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-
'98 - 00 models: Emission(EVAP)controlsystemleak The scantool indicatesDiagnosticTroublecode (DTC)P1456:Evaporative detected{fueltank system). Troubleshooting Flowchart -
The MIL has been reported on. DTC P1456 is stored.
Check the fuel fill cap: Checkthe fuel fill cap (the caP must be a gray OEM cap and be "clicks" to t i g h t e n e d a t l e a s tt h r e e p r o p e r l y s e a lt h e s y s t e m ) -
ls the properfuel fill cap installed and properlytightened?
Replaceor tighton the cap.
Checkthe lueltill cap seal: Checkthe fuel fill capseal.
ls the tuel fillerpipedamaged?
Fuel till caD is OK. Do the luel tank pressureSensortest (see page 11-2111.(EVAP Purge control solenoid valve t€sl (seePage 11-2151.1r
Replacethe luelfiller pipe.
' : ' 9 9 - 0 0m o d e l s
(cont'd)
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11-213
EmissionControlSystem EvaporativeEmission(EVAPIControls(contd) lP14s6l("ont,a)
Fueltank pros3uresensortost. (Thecontinuetion of DTCPl456 t.oubls3hooting.,
ECM/PCMCONNECTORS
Chockthe tusl trnk pr€3suresensor: 1. Removethe fuel fill csp. 2. Turn the ignitionswitchON fll). 3. Monitor the FTPSensorvohage with th€ Honda PGM T e s t e r ,o r m e a s u r ev o l t a g e between ECM/PCMconn€ctor terminalsA29and C18. SG2 IGRN/BLKI ls there approx. 2.5 V?
Checkthe fuel t nk pressuae3ensor: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe hose between the EVAPtwo way valve and the tueltank pressuresensorat the EVAPtwo way valveend. 3 . C o n n e c ta v a c u u mp u m p t o the openend ofthat hose. 4. Turn the ignitionswitchON 0l). 5. Monitor the FTPSensorvoltage with the Honda PGM Testet, or measure voltage between ECM/PCMconnector t e r m i n a l s4 2 9 a n d C 1 8 ,a n d carefullyapplyvacuumon the hose one strokeat a lime. 6. The voltageshould smoothty drop from the staning approx. 2.5 V down to approx. 1.5 V. Stop applyingvacuum when the voltagedrops to approx. 1 . 5 V o r d a m a g et o t h e f u e l t a n k p r e s s u r es e n s o r f i a y occur,
Doesthe voltage drop to approx. 1.5V and hold?
11-2 1 4
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Choct ths vacuum linsr for ra3triction o. blockago ropair a! nect*rary. It OK, replaca the fu6l tank praituJc sentot.
Wire sideoI femaleterminals
FUEI-TANK PRESSURE SENSOR
VACUUM - 30in.Hg PUMP/GAUGE,0
A973X - ill -
xxxxx
EVAP TWO WAY VALVE
Fu.l tank pressu.c a€nlor b OK. Oo thc EVAP pulge control solenoid valve toat (3€€prgo 112151.
EVAP purge control 3ol€noid valve test. {Tho continu.tion of DTC Plil56 trouble3hootin9.)
VACUUM - 30 in.Hg PUMP/GAUGE,0 A973X- 041 -
xxxxx
Check the EVAP purge control solenoidvalve: 1. Disconnectthe vacuum hose trom the EVAPcontrolcanist e r , a n d c o n n e c ta v a c u u m pumpto the hose. 2. Turnthe ignitionswitchON (ll). 3. Applyvacuumto the hose.
Doesthe valvehold vacuum?
EVAP CONTROL CANISTER
EVAP purge contlol solenoid v.lvo is OK. Do the EVAP bypai3 solenoid valve test (see Page 112161 EVAPPURGECONTROLSOLENOID (Cl08} VALVE2P CONNECTOR
Check tho EVAP purge control solenoidvalve: 't. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e E V A PP u r g e controlsolenoidvalve2P connector, 3. Checkfor continuity between t h e E V A P p ur g e c o n t r o l solenoidvalve 2P connector t e r m i n a lN o . 2 a n d b o d Y ground,
Wiresideof female terminals
Check for s short in the wire {PCSlinel: 1 . D i s c o nn e c t t h e E C M / P C M connectorA {32P). 2. Checkfor continuitybetween the EVAP purge control solenoidvalve 2P connector terminalNo. 2 and body ground.
ls there continuity?
neprir short in tho wite bot$reon the ECM/FCMlAGl and thc EVAP purge control 3olenoidvalve.
Substitut€ a known-good ECM/ PCM and recheck. lf symptom/ indication goe3 away. repl.ce thc originsl ECM/PCM.
(cont'd)
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1 1-215
EmissionControlSystem EvaporativeEmission(EVAPIControls(cont,dl (conro) 1T1456I EVAPbypa3ssolenoid valve test. (The continuation ot DTC P1456 troubleshooting.l
€VAP BYPASS
SoLENOtO VALVE
Checkthe EVAP bypasssotenoid 1. Disconnectthe vacuum hose from the EVAPtwo way valve, and connecta vscuum pump to the hose, 2 . C o n n e c t h e E C M / P C Mc o n nectorterminal 43 to the body groundwith a jurnperwire. 3. Turnthe ignitionswitchON 0t). 4. Applyvacuumto the hose.
ECM/PCMCONNECTOR A I32P) 2WBS (BLU} / 3
4l
o /
6
7,x , /
1 6 1 7 1 8 't9 2 0 2 1 1 / 26 27 2A 29 solT
VACUUM PUMP/ GAUGE. 0 -30 in.Hg A373X041 -
to z3 32
JUMPERWIRE
Wiresideof femaleterminals
xxxxx
Doesthe valvehold vacuurn?
EVAP bypass solenoid valve/ EVAP two way valve is OK. Do th6 EVAP control crnister vent shut vafvele3t lso€ page 11-2'111. EVAPBYPASSSOLENOID VALVE2P CONNECTOR lcorlTl
Check for an op€n in the wir€ (2WBSline): 1. Turnthe ignitionswitchOFF. 2. Disconnectthe EVAPbypass solenoidvalve2P connector. 3. Checkfor continuity between t h e E V A P b y p a s s s ot e n oi d v a l v e2 P c o n n e c t o tre r m i n a l No.2 and body ground.
2WBS (BLU}
I
I
Wire sideof female termrnats Repairopen in the wire between the EVAP bypass solenoid valv. and ECM/PCMlA3). tGl IBLK/WHT}
Chack tor an op6n in the wire llcl line): 1. Turnthe ignitionswitchON l). 2. Measurevoltagebetweenthe EVAPbypasssolenoidvalve 2 P c o n n e c t o tre r m i n a lN o . l and body ground.
Replacethe EVAP byps.,s solonoid vatus and O-ring3.
Ropairo,penin the wire botwoen th6 EVAP bypa$ sotenoid vatvo a n d N o . 1 5 A L T E R N A T O RS p SENSOR(7.5Altuso.
1 1 -2 1 6
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-/
VACUUM - 30 in.Hg PUMP/GAUGE,0 A973X- 041 XXXXX
EVAP control canister vent shut valvel€st, lThe conlinualion ot DTC P1456 troubleshooting.) EVAP THREE Check the EVAP control cankter vent 3hut valve: 1. Disconnectthe vacuum hose from the EVAPthreeway valve, and connecta vacuumPUmP to the hose. 2. Turnthe ignitionswitchON (ll). 3. Applyvacuumto the hose
Doesthe valvehold vacuum?
VALVE
EVAP control crnisier vent lhul valve is OK. Do the v.cuum hoses and connections te3l lsee page11-218).
EVAP CONTROL CANISTER
EVAPCONTROL CANISTERVENT SHUT IC361) VALVE2P CONNECTOR
r+ l 1 f
Chock the EVAP control canbtel vent shul valvo: 1. Turn the ignitionsw;tchOFF. 2. Disconnectthe EVAPcontrol c a n i s t e rv e n t s h u t v a l v e 2 P connector. 3. Checkfor continuitybetlveen the EVAPcontrol canistervent shutvalve2Pconnectorterminal No. 1 snd body ground.
t 2 l
1 VSV
(o) tLTcnrulwxrt
1 Wire sideof femaleterminals
Roplac€the EVAPcontlol canbt€] venl shut valve and O-ring.
Chock lor a short in the wire (VSV lino)r 1 . D i s c on n e c t t h e E c M / P C N 4 connoctorA (32P). 2. Checkfor continuitybetween the EVAPcontrol canistervent shutvalve2Pconnectorterminal No. 1 and body ground.
EVAP CONTROL CANISTER VENT SHUT VALVE O.RING Replace.
Reorir 3hort in tho wiro bgtweon the EC1I/I/PCMlAal .nd the EVAP codrol canbtor vent shut valv6.
Substitute a known.good ECM/ PCM and recheck. lf symptom/ indicrtion goes awaY, replace the original ECM/PCM.
ILT GRN/WHT)
(cont'd)
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1 1- 2 1 7
EmissionControlSystem EvaporativeEmissionIEVAPIControls(cont'd) lTi,t56l ("onto) Vacuum hoses and connections telit.
(The continuarion of DTC P1456 troubleshooiing.l
C h e c kt h e v a c u u m h o 3 e s a n d connect|ons: C h e c kt h e f o l l o w i n g p a r t s f o r l e a k sa t a t m o s p h e r i cp r e s s ur e {seepage11-204). . Fueltank . Fuelfill cap . F u e l f i l pl i p e . EVAPtwo way valve . Fueltankpressuresensor
Repairor replacothe parts.
Substitute a known-good ECM/ PCM and recheck.lf symptom/ indication goes away, replac€ the original ECM/PCM.
1 1 -2 1 8
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'98 - 00 mod€ls: Emission(EVAP)Controlsystemleak The scantool indicatesDiagnosticTroublecode (DTc)P1457:Evaporative detected(EVAPcontrolcanistersystem). Troubl6shootingFlowchart -
('98 model only)
_]
The MIL has been rePortedon. DTCP1,157is storod.
Do the fuel tank Pressuresensor test {seepage11-214).
ls the {ueltankpressuresensorOK?
Do the EVAP Purge contlol solenoid valve test lsea Page 1l_ 220t.
I
(cont'dl
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11-219
EmissionControlSystem EvaporativeEmission(EVAP)Controls(cont,dl iTl457l ("ont'or - The MIL has been reportedon. - DTCP1457is stored. {EVAP purge control solenoid valve test.l*
Check the EVAP purge conrrol 30lenoidvelve: L Disconnectthe vacuum hose from the EVAPconlrol canis, t e r , a n d c o n n e c ta v a c u u m pump to the hose. 2 . C o n n e c t h e E C M / P C Mc o n nectorterminalA6 to the body groundwith a jumperwire. 3. Turnthe ignitionswitchON (tl). 4. Applyvacuumto the hose.
Doesthe valvehold vacuum?
VACUUM PUMP/GAUGE, O-30 iN.Hg A973X- 0rl -
xxxxx '\)
AP CONTROL CANISTER
Check for an open in the wire (lGl line): 1. Turnthe ignitionswitchON t). 2. Measurevoltage between the EVAPbypasssolenoidvalve2p coonectorterminalNo. 1 and body ground.
ls there battery voltage?
Repah open in lhe wir6 betwoen the EVAP pu.ge cont.ol solonoid vdlvo and No. 15 ALTERNATOR SP SENSOR{7.5Al fu!€. *: Continuedfrr '98 model
1 -220
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4 5 8 / ,/3 't6 1 7 1 8 l 9 20 ,,/ 14 ,/ ,/ 26 29 30
't0 24
JUMPER WIRE
Wire sideof lemaleterminals EVAPpurge control solenoid valve is OK. Oo the EVAPbypass solenoid valve t€3t {see psge 1l221t.
Check for an open in the wire (PCSline): 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e E V A Pp u r g e controlsolenoidvalve2P con nector, 3. Checkfor continuitybetween t h e E V A P p ur g e c o n t r o l solenoidvalve 2P connector t e r m i n a lN o . 2 a n d b o d y grouno,
ls therecontinuity?
ECM/PCMCONNECTOR A {32P} PCS(RED/YELI
EVAPPURGECONTROLSOI.ENOID VALVE2P CONNECTOR (Cl08) PCS IRED/YELI
female termanals
Ropairop€n in th6 wire between the EVAP purge control 3olenoid velve and ths ECM/PCM(A61.
EVAP BYPASS SOLENOID VALVE
EVAPbypasssolenoidvalv€ test. {The continuation of DTC P1457 troubleshooting.l
FUELTANK SENSOR PRESSUBE EVAPTWOWAY VALVE
Checkthe EVAP bypass 3olenoid VACUUM PUMP/ GAUGE, 0-30 in.Hg A973X041 -
1. Disconnectthe vacuLlmhose from the EVAPtwo way valve, and conned a vacuumPUmP to the hose. 2. Turnthe ignitionswitchON (ll). 3. Applyvacuumto the hose
Does the valve hold vacuum?
xxxxx
EVAP bvpas3 30lsnoid vrlvo/ EVAPtwo way v.lve is OK. Do the EVAP control canisler vent 3hut v.lve te3l (seePsge11'2221. EVAPAYPASSSOLENOID (C647} VALVE2P CONNECTOR
Ch6ckthe EVAP byp.ss solenoid '1. Turnthe ignitionswitchOFF 2. Disconnectthe EVAPbypass solenoidvalve2P connector. 3. Check{or continuitybetween t h e E V A P b y p a s s s o l e n oi d v a l v e 2 P c o n n e c t o tre r m l n a l No.2 and body ground
t.'-+l
t1t?l | 2wBs
(d1terul
Y-L ReDlacethe EVAPbypass 3olenoid valveand O-rings.
q
C h e c kf o r a s h o r t i n l h e w i r e {2WBSlinel: connec ECM/PCM 1. Disconnect tor A (32P). 2. Checklor continuity betlveen t h e E V A P b y p a s s s o l e n oi d valve 2P connectortermrnal No.2 and body ground.
ls therecontinuitY?
Wire sideof female terminals
2WBS (BLU}
@)
T
Rcpsir short in th. wire bgtwoen the EcM/PCtrl lA3l lnd the EVAP bypa$ solenoidvalvo.
Sub3tiiute . known'good ECM/ PCM End recheck.lI sYmptom/ indication goe3 away, tePlace the originalECM/PCM.
(cont'd)
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11-221
EmissionControlSystem EvaporativeEmission(EVAP)Controls(cont,dl lT145il ("ont'o)
VACUUM - 30 in.Hs PUMP/GAUGE,0 A973X- 041 -
EVAP control canistor vent shut valve t6t. (The continuation of DTC p1457 troubl€ahooting.)
xxxxx
ECM/PCMCONNECTOR A {32PI
vsv {LTGRN/WHT)
Chcck the EVAP control c.nirt6l vent ahut vrlve: 1. Disconnectthe vacuum hose trom the EVAPthre€way valve, and connecta vacuum pump to the hose. 2. Connectthe ECM,PCMconn6c, t o r t e r m i n a lA 4 t o t h e b o d y groundwith a jumper wire. 3. Turn the ignitionswitchON fil). 4. Applyvacuumto the hose.
Doesthe valvehold vacuum?
3
a
6
l 4 / 1 6 1 7 l 8 't9 20 2l 26 27 2a 29 30
EVAP THREE
10 23
JUMPER
WIRE
VATVE \
Wiresideof femaleterminals
't
EVAP CONTROL CANISTER EVAP control crni3ter v6nt shut velve b OK. Do the canistsr syslern loak test {3eepage 11-2231.
EVAPCONTROL CANISTERVENT SHUT VALVE2P CONNECTOR {C361}
riEr
r+J
I vsv
Check for an open in the wire IVSV linGll 1. Turnthe ignitionswjtchOFF. 2. Disconnectthe EVAPcontrol c a n i s t e rv e n t s h u t v a l v e 2 p connector. 3. Check for continuity between the EVAPcontrol canistervent shul valve 2P connectorterminal No. l and body ground.
/A\ {Lr GRN/WHT|
Y I
Wiresideof femaleterminals
EVAP CONTROL CANISTEF VENT SHUT VALVE
Ropril op6n in tho wire botweon the EVAP control canister v6nt shut v.lve and the ECM/PCM (A41.
(}BING Replace.
Check tor an open in the wire (lGl line): 1. Turn the ignitionswitch ON l). 2. Measurevoltage between the EVAPcontrolcanistervent shut valve 2P connectorterrninal No. 1 and body ground.
RoplacethG EVAP cont.ol canister Yentshut velve and O-ring.
Repai. opon in the wire betwoen th6 EVAP control canister vont shut valve .nd No. 15 ALTERNATOB SP SENSORt?.5 Alfus6.
11-222
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ffil r c r e
I
(BLK/wHr)
24
EVAP CONTROL Canbter system leak test {Thecontinuation of DTCP1457 trouble3hootin9.)
Chock the EVAP control canister vent shut valve line and connoc' tonS: 1. Turnthe ignitionswitchOFF 2. Connectto three'waytee fit_ tings into the hose from the EVAPcontrol canisterto the EVAPtwo way valve. Connect the fuel tank pressuresensor to one of the tee fittings and the vacuum PumPto the other' 3. Removethe vent hose from the EVAPcontrol canistervent shut valveand cap the Pon to sealthe fresh air vent Ior the EVAPcontrol canister. 4. Turnthe ignitionswitchON (ll). 5. While monitoring the FTP Sensorvoltagewith the Honda P G M T e s t e r ,o r m e a s u r a n g v o l t a g e b e t w e e nE C M / P C M connectorterminalsA29 and C18slowly PumPthe vacuum pump using a strokeevery 1 2 seconds. 6 . C o n t i n u et o P u m P v a c u u m u n t i l t h a t v o l t a g ed r o P st o approx.1.5V. N O T E :M a k e s u r e t h a t t h e e n g i n ec o o l a n tt e m P e r a t u r e stillabove95'F(35'ClandYour vacuumPumPhasno leak 7 . M o n i t o r t h a t v o l t a g ef o r 2 0 seconds.
Doesthevoltagedrop to 1.5V and holdsat least20 seconds?
lGp€ct the EVAPcontrol cani3tel vent 3hut valvo line and connec_ tion5.
EVAP FUELTANK BYPASS SENSOR SOLENOID EVAPTWOWAY VALVE VALVE EVAP THREE VALVE
EVAP CONTROL CANISTER
ttrrL t a VACUUM PUMP/ GAUGE, 0 - 30 in.Hg A973X041 XXXXX
FITTINGS
ECM/PCMCONNECTORS A {32P)
PTANKILT GRN) Check the EVAP Pu.ge control solenoidvalve line and connections: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e P u r g e l a n e hose from the EVAPcontrol canisterand Plugthe Port 3. Turnthe ignitionswitchON (lli. 4. While monitoringthe FTP Sensorvoltagewith the Honda P G M T e s t e r ,o r m e a s u r i n g v o l t a g e b e t w e e nE C M / P C M connectorterminalsA29 and Cl8 slowly PumPthe vacuum pump using a strokeevery 1 2 seconds. 5 . C o n t i n u et o p u m p v a c u u m u n t i l t h a t v o l t a g ed r o P st o approx.1-5V. N O T E :M a k e s u r e t h a t t h e e n g i n ec o o l a n tt e m P e r a t u r e andYour stillabove95'F(35"C) vacuumpumphasno leak6 . M o n i t o r t h a t v o l t a g et o r 2 0 seconds.
Does the voltage drop to 1.5V and holds at least 20 seconds?
Reolacethe EVAPconirol canister.
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VENT SHUT VALVE
c (31Pt
SG2 {GRN/BLK) Wiresideof femaleterminals
Inlpect tho EVAP Putge control solenoid valvo line and connec' tion3. It th6y lro OK, do the EVAP two way valve te3t (seo page 112211.
{cont'd)
11-223
EmissionControlSystem EvaporativeEmission(EVAP)Controls(cont,dl EvaporativeEmission (EVAP)Two Way Valve Testing '97 model:
1. 2.
1.
Removethe fuelfill cap.
2.
R e m o v et h e v a p o r I i n e f r o m t h e E V A Pt w o w a y valve on the fuel tank, and connectit to a T_fitting f r o m a v a c u u mg a u g ea n d a v a c u u m p u m p a s shown.
VACUUM PUMP/GAUGE, 0 - 30 in.Hg A973X-041-XXXXX
.98 -
0Omodels: Removethe fuel fill cap. R e m o v et h e v a p o r l i n e f r o m t h e E V A Pt w o w a y valve{locatedabovethe EVAPcontrolcanister).and c o n n e c ti t t o a T - f i t t i n gf r o m v a c u u mg a u g e a n d vacuumpump as shown.
VACUUM/PRESSUFE
VACUUM,/ PRESSURE GAUGE otJAz - 001rDoB T-FITTING VACUUM PUMP/ GAUGE,0- 30 in.Hg A973X- 041 -
xxxxx
T-FITTING T-FITTING
3 . A p p l y v a c u u m s l o w l y a n d c o n t i n u o u s l vw h i l e watching the gauge.The vacuum should stabilize momentarilyat 0.7- 2.0 kpa (5 - 1SmmHg,0.2_ 0.6 in.Hg). l f t h e v a c u u m s t a b i l i z e s( v a l v e o p e n s ) b e l o w 0 . 7 k P a ( 5 m m H g , 0 . 2 i n , H g )o r a b o v e 2 . 0 k p a (15 mmHg,0.6 in.Hg),installa new valveand retest. 4.
A p p l y v a c u u m s l o w l y a n d c o n t i n u o u s l yw h i l e watchingthe gauge. The vacuum should stabilizemomentarilyat O.g_ 2.1 kPa(6 - 16 mmHg,0.2- 0.6 in.Hg). l f t h e v a c u u m s t a b i l i z e s( v a l v e o p e n s ) b e l o w 0 . 8 k P a ( 6 m m H g , 0 . 2 i n . H g )o r a b o v e 2 . 1 k p a (16 mmHg,0.6 in.Hg),installa new valveand retest. Move the vacuum pump hosefrom the vacuumfitting to the pressurefitting. and move the vacuum gauge hose from the vacuum side to the pressure side as shown.
Move the vacuum pump hosefrom the vacuumfit_ ting to the pressurefitting, and move the vacuum gauge hose from the vacuum side to the pressure side as shown.
PiESSURE SIDE
5.
Slowly pressurize the vapor line while watchingthe gauge.The pressureshouldstabilizeat 1.3- 4.7 kpa ( 0 - 3 5 m m H g ,0 . 4- 1 . 4i n . H g ) . . l f t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e s( v a l v e opens)at 1.3- 4.7 kpa (10 - 35 mmHg, 0.4 _ 1.4 in. Hg),the valveis OK. . lf th6 pressurestabilizes below 1.3kpa fio mmHg, 0.4 inrHg)or above4.7 kpa (35 mmHg, 1.4 in.Hg), installa new valve and retest.
11-224
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5.
Slowly pressurizethe vapor line while watchingthe gauge. The pressureshould stabilizemomentarilvabove 1 . 0k P a( 8 m m H g ,0 . 3i n . H g ) . a l f t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e s( v a l v e o p e n s )a b o v e 1 . 0 k P a ( 8 m m H g .0 . 3 i n . H g ) t, h e valveis OK. . lf the pressurestabilizesbelow ,|.0kpa {g mmHg. 0.3 in.Hg),installa new valveand retest.
Transaxle ...........12-1 Clutch . . . . . . . . . . . . . . . . . . . . .1. .3. -. 1 ... M a n u a lT r a n s m i s s i o n . 4-1 A u t o m a t i cT r a n s m i s s i o .n. . . . . . . . . . . ..........1 ... 15-1 Differential ... 16-1 Driveshafts
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Clutch 12-2 ..........' Tools....,..... Speciaf .'." 12'3 lllustratedlndex........... ClutchPedal ........."."."".12-4 Adjustment ClutchMasterCylinder '." 12'5 RemovaUlnstallation SlaveCylinder .'.. 12-6 Removal/lnstallation PressurePlate ..'." 12-7 RemovaUlnspection ClutchDisc ."'.. 12-8 Removal/lnspection Flywheel 12-9 ...................... Inspection 12-9 ....................................... Replacement ClutchDisc,PressurePlate 12-10 ....................' lnstallation ReleaseBearing ......12'11 Removal/lnspection 12-12 ..................... lnstaflation
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SpecialTools
Rel.No.
a IA
@ !c, Lo,
I
Tool Number OTJAF- PM70,I1A 07NAF- PR30l00 07LAB- PV00100 or 07924- PD20003 07746 0010100 07749- 0010000 07936- 3710100
Description ClutchAlignmentDisc ClutchAlignmentShaft R i n gG e a rH o l d e r
1 1 1
Attachment,32 x 35 mm Driver H an dl e
1
b)
2-2
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Oty
1 1
PageReference |
I I
t2-7 12-7, A, ' t0,11 1 2 - ,79 , 1 0 ,1 ' l
12-10 12-10 1 2 - 7, a , 1 0 , 1 1
lllustratedIndex
NOTE: . Wheneverthe transmissionis removed,cleanand greasethe releasebearingslidingsurface .lfthepansmarked*areremoved,theclutchhydraulicsystemmustbebled(seepage12-6). and twisting. . Inspectthe hosesfor damage.leaks.interference,
LOCKPIN
*CLUTCHLINE 19 N.m (1.9kgj.m, 14 tbtft)
PEDALPIN
.RESEFVOIR HOSE
8 x 1.25mm 13 N.m {1.3kgf m,9.4lbtft)
*RESERVOIR TANK
.o-.9r
CLUTCHPEDAL Adjustment,page12-4
*CI-UTCHMASTERCYLINDER page12-5 Femoval/lnstallation,
WM\,".0-ffi-P"8Nmlloks{m'
6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbf.ft) *CLUTCHLINE 15 N.m (1.5kgt m, 11 tbr.ft)
CLUTCHDISC page 12-8 Removal/lnspection, page12,13 Installation,
*CLUTCHLINE 24 N.m {2.4 kgf.m, 17 tbf.ft) 8 x 1.25mm 25 N.m {2.6kgt m,
19rbf.ftt FLYWHEEL page12I Inspection, page12-9 Repiacement, 1 2x 1 . 0m m 103N.m (10.5kgtm,75.9lbf ftl PLATE PRESSURE page'12-7 Removal/lnspection, page'1213 Installation, RELEASEBEARING page12-1'! Removal/lnspection, page12-12 Installation, *CLUTCHLINE 15 N.m (1.5kgt m, 11 tbf.ft)
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I x 1.25mm 22 N.m 12.2kgl'm, 16lbfft)
12-3
ClutchPedal Adiustment NOTE: . T o c h e c k t h e c l u t c h i n t e r l o c ks w i t c h a n d c l u t c h switch,seesection23. . The clutchis self-adjusting to compensatefor wear. CAUTION:lf there is no clearancebstwa€n the master cylinder piston and push rod, ths roloasebearing is held againsi the diaphragm spring, which can resuh in clutch slippageor other clutch probloms. 1.
LoosenlocknutA, and backoff the clutchswitch(or sdjustingbolt) until it no longertouchesthe clutch peoar.
2.
LoosenlocknutC, and turn the push rod in or out to get the specifiedstroke (@) and height (@) at the clutchoedal.
3.
TightenlocknutC.
4.
Thread in the clutchswirch (or adjustingbolt) until it contactsthe clutchoedal.
5 . Turn the clutchswitch{or adjustingbolt} in an additional3/4to 1 full turn. TightenlocknutA. 7 . LoosenlocknutB on the clutchinterlockswitch. 8 . Measurethe clearancebetweenthe floor board and clutchpedalwiththe clutchpedalfully depressed. q
Releasethe clutchpedal 15 - 20 mm (0.59- 0.79in) from the fully depressedpositionand hold it there, Adjustthe positionof the clutchinterlockswitch so that the engine will start with the clutch pedal in this position.
1 0 .TightenlocknutB.
LOCKNUT B 9.8 N.m 11.0kgf.m, 7.2 lbf.ftl CLUTCHINTERLOCK SWITCH CLUTCHSWTTCH {or ADJUSTINGBOLTI L(rcKNUT A 9.8 N.m {1.0kg{.m,7.2 lbf.ftl
CLUTCHMASTERCYLINDER PUSHROD Pedal in contact with swhch LOCKNUTC 18 N.m (1.8kgf.m,13lbtftl
a_-_--/
@ @ @ o
\
,
/
at PEDAL):135- 1itsmm (5.31- 5.71in} {STROKE (TOTALCLUTCHPEDALFREEPLAY)i7-22mm (0.28-0.87in) inctudethe pedatptay 1 - 9 mm (0.0it- 0.35inl (GLUTC,H PEDALHE|GHTI:ltxt mm (7.20inl ro rhe ftoor (CLUTCHPEDALDTSENGAGEMENT HEtcHTl: 72 mm {2.txtinl minimum to the floor
12-4
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GlutchMasterCylinder Removal/lnstallation CAUTION: . Do not spill brake fluid on the vehicle; it may damage the paint; if brake tluid does contact the paint. wash it off immediately with water. . Plug the end ol the clutch line and leservoir hose with a shop towel to prevent brake tluid trom coming out.
4.
Prv out the lock pin, and pull the pedal pin out of the voke.Removethe nuts. NUTS I x 1.25mm 13 N.m t1.3kgt.m,g.illbtft)
' t . The brakefluid may be suckedout through the top of the mastercylinderreservoirwith a syringe. Disconnectthe clutch line and reservoirhose from the clutchmastercylinder,
9.8N.m11.0kst m, 7.2tbf.ftl
5,
Removethe clutchmastercylinder.
CLUTCHLINE 19 N'm 119 kgJm' 14 lbf.frl
Remove the reservoir from the engine compartment bulkhead.
MASTER CLUTCH CYLINDEF I n s t a l lt h e c l u t c h m a s t e rc y l i n d e r i n t h e r e v e r s e orderof removal. NOTE:Bleedthe clutchhydraulicsystem{seepage 12-61.
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12-5
SlaveCylinder RemovaUlnstallation CAUTION: . Do nol spill braketluid on the vehicle;itmaydamage the paint; if brake fluid do€s contast the paint, wash it off immediately with water. . Plug the end of the clutch line with a shop towel to prevcnt brake tluid from coming out.
3.
I n s t a l lt h e s l a v ec y l i n d e ri n t h e r e v e r s eo r d e r o t removal. NOTErMake sure the boot is installedon the slave cylinder. CLUTCH LINE 15N.m(i.Skgf.m,lt tbf.ftl
High Temp Urea crease (p/N 087989002). : BrakeAssemblyLube or equivalentrubber grease.
.6|l,Super
1.
SLAVECYLINDER
Disconnect the clutchline from the slavecvlinder.
.-lG
(P/N08798- 90021
E x 1.25mm 22 N.m (2.2kgt.m, 16 tbtft)
(BrakeAssembly Lube) Bleed the clutch hydraulic system.
2.
Removethe slavecylinderfrom the clutchhousing.
Attacha hoseto the bleederscrew,and suspend the hosein a containerof brakefluid. Makesurethere is an adequatesupplyof fluid at the clutchmastercylinder,then slowly pump the clutchpedaluntil no more bubblesappearat the bleederhose. Refillthe clutch mastercylinderwith fluid when qone. A l w a y s u s e G e n u i n eH o n d aD O T 3B r a k eF l u i d . Using a non Hondabrakefluid can causecorrosion and decreasethe life of the system. Confirm clutch operation,and checkfor leaking fluid.
BLEEDER SCREW 7.8 N.m (0.8 kgf.m.5.8 lbt.ft)
12-6
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PressurePlate Removal/lnspection 1 . Checkthe diaphragmspringfingersfor heightusing the specialtools and a feelergauge. StandardlNewl: 0.6 mm {0.02in) max. ServiceLimit: 0.8 mm (0.03in)
4.
Inspectthe pressureplate surfacefor wear, cracks, a n db u r n i n g .
5.
Inspectthe fingersof the diaphragmspringfor wear at the releasebearingcontactarea.
HANDLE 07936- 3710100 CLUTCHALIGNMENTDISC - PM7O11A OTJAF CI.UTCHALIGNMENTSHAFT 07NAF- PR30100
FEELER GAUGE
PRESSURE PLATE
lf the height is more than the servicelimit, replace the pressurePlate. 2.
6.
l n s t a l lt h e s D e c i a l l o o l sa s s h o w n .
Inspectfor warpageusinga straightedge and feeler gauge.Measureacrossthe pressureplate. in) max. StandardlNew):0.03mm 10.001 ServiceLimit: 0.15mm (0.006inl
PLATE PRESSURE
RINGGEARHOLDER ADJUSTERNUT
ADJUSTER BOLT
ENGINEBLOCK
GAUGE FEELER
BOLT NUT
WASHER
T o p r e v e n tw a r p i n g ,u n s c r e wt h e p r e s s u r ep l a t e mounting bolts in a crisscrosspattern in several steps.then removethe pressureplate.
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lf the warpage is more than the service limit, replace the pressure plate.
12-7
GlutchDisc Removal/lnspection '1. Removethe clutchdiscand specialtools.
4.
Measurethe rivet depth from the lining surfaceto the rivets,on both sides. Standard(New):1.2- 1.7mm 10.05- 0.07in) min. Service Limit: 0.2 mm {0.008inl
CLUTCHDISC
Inspectthe lining of the clutchdisc for signsof slipping or oil. lf the clutch disc is burned blackor oil soaked,replaceit. Measurethe clutchdiscthickness. Standard(New):8.,1-9.1 mm (0.33- 0.36in) ServiceLimh: 6.0 mm (0.2,1in)
LINI G SURFACE
CLUTCHDISC
l f t h e r i v e t d e p t h i s l e s s t h a n t h e s e r v i c el i m i t , replacethe clutchdisc.
lf the thicknessis lessthan the servicelimit, reDlace the clutchdisc.
12-8
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Flywheel Replacement
Inspection L
lnspectthe ring gearteethfor wear and damage.
L
Installthespecialtool as shown.
2.
Inspectthe clutch disc mating surfaceon the flywheelfor wear,cracks,and burning
2.
Removethe flywheelmountingbolts in a crisscross patternin severalsteps,and removethe flywheel.
3.
Measurethe flywheel runout using a dial indicator through at leasttwo full turns. Pushagainstthe flywheel each time you turn it to take up the crankshaftthrustwasherclearance.
MOUNNNG BOLTS
N O T E :T h e r u n o u tc a n b e m e a s u r e dw i t h e n g i n e installed. Standard (Newl: 0.05 mm (0.002in) max. ServiceLimit: 0.15mm {0.006inl lf the runout is more than the servicelimit, replace the flywheeland recheckthe runout FLYWHEEL
FLYWHEEL
RINGGEARHOLDER 07LAB- PV00r00 ol
07924 - PD20003
3.
Removethe ball bearingfrom the flywheel.
RINGGEAR
Turnthe innerraceot the flywheelbearingwith your finger.The bearingshould turn smoothly and quietly. Checkthat the bearingouter racefits tightly in the tlywheel.lf the racedoes not turn smoothly,quietly,or fit tight in the flywheel,replacethe bearing.
FLYWHEEL
BALLBEARING
(cont'd)
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12-9
Flywheel Replacement(cont'dl Drive the new bearing into the flywheel using the specialtools. HANOLEDRIVER 07749-
Clutch Disc,PressurePlate Installation 1.
Installthe ring gear holder. CLUTCHALIGNMENTSHAFT 07NAF- PR30100
ATTACHMET{T32x35mm 07746-O010100
FLYWHECI-
CLUTCHDISC
RINGGEARHOLDER 07LAB_ pvoot(x)or 07924_ PD20003
Align the hole in the flywheel with the crankshaft d o w e l p i n , a n d i n s t a l lt h e f l y w h e e l .I n s t a l lt h e mountingboltsfinger-tight. I n s t a l lt h e s p e c i a lt o o l , t h e n t o r q u e t h e f l y w h e e l mounting bolts in a crisscrosspattern in several stepsas shown.
Apply greaseto the spline of the clutch disc,then installthe clutchdisc usingthe specialtools. N O T E :U s e o n l y S u p e rH i g h T e m p U r e aG r e a s e (P/N08798- 9002).
Torque: 12x 1.0mm r03 N.m(10.5kgl.ln, 75.9tbtftl
lnstallthe pressureplate.
PRESSURE PLATE
12-10
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ReleaseBearing Removal/lnspection 4.
Torquethe mountingbolts in a crisscrosspatternas shown.Tightenthe bolts in severalstepsto prevent warpingthe diaphragmspring.
1.
Removethe releasefork boot from the clutchhousIng. RELEASE BEABING
8 x 1.25mm 25 N.m (2.6kgf.m,19lbfft) RELEASE FORK BOOT
\
RELEASEFORK
Removethe releasefork and releasebearingfrom the clutchhousing. Checkthe releasebearingfor play by spinningit by h an d . NOTE:The releasebearingis packedwith grease. Do not wash it in solvent. 5.
Removethe specialtools.
6.
Checkthe diaphragmspring fingersfor height (see page 12-7]'.
lf there is excessiveplay, replacethe releasebearing with a new one.
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12-11
ReleaseBearing lnstallation NOTE: Use only Super High Temp Urea Grease(P/N 08798- 9002).
3.
Move the releaselork right and left to make sure that it tits properly againstthe releasebear'rng.and that the releasebearingslidessmoothlY.
the releasebear1. With the releasefork slid bet\iveen ing pawls. installthe releasebearingon the mains h a f tw h i l e i n s e r t i n gt h e r e l e a s et o r k t h r o u g ht h e hole in the clutchhousing.
-6.l
(P/N08798-
r iz]))
lPlN 08798- 9002) 0.,1-1.0I (0.01- 0 04 ozl
(P/N08798 9002)
| (,4\1t1t
/\[w
RELEASE FORK BOOT
4.
(P/N08798 9002) 1 . 0- 1 . 6g {0.0,1- 0,06 ozl
Align the detentof the releasefork with the release f o r k b o l t , t h e n p r e s s t h e r e l e a s ef o r k o v e r t h e releasefork bolt sequarelv.
12-12
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Install the releasetork boot; make sure the boot sealsaroundthe releasefork and clutchhousing.
ManualTransmission Diff€rential l n d e x. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .3 - 3 8 BacklashInspestion..,....,.,.....................,......, 13-38 FinalDrivenGearReplacement.................... 13-39 TaperedRoller Bearing Replacement ............. 13-39 BearingOuterRaceReplacement......,.,........ 13-i10 TaperedRoller Bearing Preload Adiustment ............... 13-il1 Oil SealReolacement.................................... 13-/l:} TransferAssembly lllustratedIndex ............. 13-il4 Inspection ..,....,.,......,...... 13-46 Disassembly ................... 13-47 Transfer Drive Gear Bearing Replacement ...,..................,....................... 13-ilg Transfer Driven Gear Shaft Bearing Replacement.............................................. 13-ilg TransferShaft Disassembly/ Reassembly .............. 13-50 Transler Cover A Bearing Outer Race Rep1acement.........,.,.,..........,....,...,.........,., 13-50 Transter Housing Bearing Outer Race R e D 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 3. .-.5. .1. . . . . . . . . . . . Reassembly 13-52 ..-............,... Mainshaft Bearing/OilSeal Beplacement .................. 13-62 CountershaftBearing Replacement.,,.,.,., ..,...... 13-63 Mainshaft Thrust Clearance Adiustment .................... 13-6,1 TransmissionAssembly Reassembly 13-67 .,.,.,.,..,.,....,., fnstaffation 13-72 .,.,.............,... Gearshift Mechanism O v e r h a u.l. . . . . . . . . . . . . . . .........13-17
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SpecialTools SpecialTools Ref. No.
I
o o
Dsscription
1 1 1 'l
@ @
DriverAttachment MainshaftHolder MainshaftBase PreloadInspectionTool AdjustableBearingRemoverSet Driver Attachment Pilot,28 x 30 mm Attachment,40 x 50 mm CompanionFlangeHolder Attachment,32x 35 mm Attachment,42 x 47 mm Attachment,52 x 55 mm Attachment,62 x 68 mm
@ @
07746- 0010600 07746- 0030100
Attachment,72 x 75 mm Driver,40 mm l.D.
1 1
@ @ @
07746- 0030300 07746- 0030400 07749- 0010000
Attachment.30 mm l.D. Attachment,35 mm l.D. Handle
@ @
07947- SD90200 07979- PJ40001
@ -o \9'
a @ 6r
@
o
,d,
I A
a5-z
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1 1
Page Roterence 13-43 13-66 13-66 13-41 13-62.63 13-43,53 13-43 13-39,49 13-48,54,57,58 13-18,68 13-27,34,62 13-40.51 't3-40,50.51,61, oz, oJ 13-40 13-27,34,35, 49, tJ-5C
13-66
ta\
o@(9
o
1 1 1 1 1 1 'I
I
13-27,34 13-14,27.34,40, 43, 49, 50, 51, 53, 61,62,63,68 '13-49
Attachment MagnetStandBase * Must be usedwith commerciallyavailable3/8" - 16SlideHammer.
. A
Oty
07GAD- PG40100 07GAJ- PG20110 07GAJ- PG20130 07HAJ - PK40201 07JAC- PH80000 07JAD- PH80101 07JAD - PH80400 07LAD- PW50601 07RAB- 0020000 07746- 0010100 07746- 0010300 07746- 0010400 07746- 0010500
,6)
ll
Tool Number
G)
(oo@(9(}
@
o
@
Back-upLight Switch
Maintenance Fluid Transmission
Test/Replacement
NOTE:Checkthe fluid with the engineOFFand vehicle on levelground.
1.
1.
the connectorsfrom the switch. Disconnect
R e m o v et h e f i l l e r p l u g . t h e n c h e c kt h e l e v e l a n d conditionof the fluid. PLUG FILLER 44 N.m{4.5kgf.m.33 lbfftl \
TerminalsideoI malelerminals
PtopetLevel
ll
/ \--ril HllllllTl / Hllllrlll / _rf-F{--rno."." l l | |
BACK.UP LIGHTSWTTCH r 25 N.m 12.5kgt m, 18 lbf.ftl
Replaco.
The fluid level must be up to the filler hole. lf it is belowthe hole,add fluid until it runs out. then reinstallthe tiller plug with a new washer.
WASHER Replace.
lf the transmissionfluid is diny, removethe drain plug and drainthe fluid. PLUG FILLEB a,aN.m 14.5kgf..n.33 lbt'ftl
Checkfor continuity betweenthe No. 1 and No. 2 terminals. There should be continuitywhen the shift lever tnto reverse. . T h e r e s h o u l d b e n o c o n t i n u i t yw h e n t h e s h i f t leverin positionexceptreverse,
.
lf necessary,replacethe switch.
DRAINPLUG 39 N m (4.0 kgf.m,29 lbf'ft)
WASHER Replace.
R e i n s t a ltl h e d r a i n p l u g w i t h a n e w w a s h e r .a n d refillthe transmissionfluid to the properlevel. NOTE:The drain plug washershouldbe replacedat everyfluid change. Reinstallthe filler plug with a new washer. Fluid Capacity 1.7/ {1.8US qt, 1.5lmp qtl at oil change 2.1 ! 12.2US qt, 1.Almp qtl at overhaul Alwavs use GenuineHonda Manual Transmission Fluid (MTF).Using motor oil can causestiffershiftind becauseit doesnot containthe properadditives.
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13-3
TransferAssembly lnspection Make sure tifts, iacks, and satety stands @ are placed properly (seesection 1). L
Raisethe front of the vehicle,and support it with safetystands(seesection1).
2.
Set the parkingbrake,and block both rear wheels securely.
3.
Shiftto neutraloosition.
4.
Make a referencemark acrossthe DroDellershaft and the transferassemblyflanges, REFERENCE
6.
STANDARD:0.06- 0.16 mm (0.002- 0.006in)
COMPAf{IONFI-ANGE
1.
8 x 1.25mm 32N.m(3.3kg{.m. 24 rbf.ftl Replace. 5.
S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r assemDty.
13-4
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Set a dial indicatoron the transferassemblyflange, then measurethe transfergear backlash.
lf the measurementis out of specification, remove the transferassemblyand adjusttransfergear backlash(seepage13-44thru '13-61). C h e c kt h e t r a n s f e ro i l s e a l f o r d a m a g ea n d f l u i d teaKs. lf oil sealreplacement is required,removethe transfer assembly,replacethe oil seal, and adjust the total startingtorque (seepage 13-44thru 13-61). NOTE:Do not replacethe oil sealwhen the transfer assemblyis installedon the transmission.
Removal Make sure the lifts, i8cks. and safety stands !@@ properly placed are {seesection 1}. 1.
Raisethe front of the vehicle,and support it with safety stands (seesection 1).
2.
Set the parkingbrake,and block both rear wheels securely.
3.
D r a i nt h e m a n u a lt r a n s m i s s i o fnl u i d R e i n s t a ltlh e drain plug with a new sealingwasher.
4.
Disconnectthe heatedoxygen sensor (HO2S)connector.
6.
Make referencemarks across the propeller shaft and the transferassemblyflanges' REFEREI{CEi'ARKS
Replace.
7.
S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r assemblyflanges, Removethe rear stiffener, then remove the transfer assembly.
SELF.L(rcKNG NUT Replace. SELF-LOCKI'{G NUT Replac€.
5.
NOTE: While servicingthe transfer assembly,do not allow dust or otherforeignparticlesto enterthe transmission.
RemoveexhaustoipeA.
Replace.
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13-5
TransferAssembly lnstallation 1.
Installa new O-ringon the transferassembly. 8 x 1.25mm 24 N.m (2.4 kgt m, 17 rbt.ftl
6.
Installthe exhaustpipeA,
10 x 1.25mm 44 N.m (4.5 kgJ.m, GASKET
EXHAUSTPIPEA
HO2SCONNECTOR
DOWELPIN
TRANSFEB ASSEMBLY
Replace.
2.
Cleanthe areaswhere the transferassemblycon tacts the transmissionwith solvent or carburetor cleaner,and dry with compressedair. Then apply MTFto the contactareas.
10 x 1.25 mm 54 N.m (5.5 kgt m, 40 tbtftt Replace. SELF.LOCKING
NUT 8 x 1.25mm 16 N.m {1.6kgf.m, 12 tbt.ft) Replace.
8 x 1.25mm zzN.m l2.2kg!-m, 16rbf.trt Replace.
Installthetransferassemblyon the transmission. N O T E :W h i l e i n s t a l l i n gt h e t r a n s f e ra s s e m b l yo n the transmission,do not allow dust or other foreign particlesto enterthe transmission. lnstallthe rearstiffener. Installthe propellershaft to the transferassembly by aligningthe referencemarks, 8 x1.25mm 32 N.m 13.3kg{.m, 24 tbf.ftl
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REFERENCE MARKS
7.
Connectthe heatedoxygensensor(HO2S)connector.
8.
Relillthe transmissionwith MTF(seepage 13-3).
9.
Startthe engine,and run it to normaloperatingtemp e r a t u r e( t h e r a d i a t o r t a n c o m e s o n ) . T u r n t h e engineoff. and checkfluid level.
TransmissionAssemblY Removal
@ FMak.
sw. iack" and safety stands are placed propelly, and hoist bracketsare attached to collect position on the engine, . Apply parking brake and block rear wheels so vehicle will not roll off stands and lall on you while working under it.
4.
D i s c o n n e c t h e s t a r t e r c a b l e sa n d t r a n s m i s s i o n groundcable.
CAUTION:Use fender coversto avoid damaging painted surfaces. 1.
the negative{-) cablefirst,then the posDisconnect itive(+)cablefrom the batterY.
2.
Removethe intakeair duct and air cleanerhouslng (seesection5).
3.
Removethe slavecylinderand clutchhosebracket' NOTE: . Do not operatethe clutch pedal once lhe slave cvlinderhas beenremoved. . Takecarenot to bendthe clutchline.
TRANSMISSION GROUNDCABLE
Disconnectthe back-uplight switch connectorand wire harnessclamP.
WIREHARNESSCLAMP
(cont'd)
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13-7
TransmissionAssembly Removal(cont'dl 6.
R e m o v et h e c o t t e r p i n s , t h e n r e m o v e t h e s t e e l w a s h e r s ,p l a s t i cw a s h e r s .s h i f t c a b l e ,a n d s e l e c t cablefrom the levers.
9 . R e m o v et h e f o u r u p p e r t r a n s m i s s i o nm o un t i n g bolts.
MOUNNNG BOLTS
1 0 . Draintransmissionfluid (seepage '13-3). 1.
Removethe cablebracketfrom the clutchhousing.
8.
Disconnectthe vehiclespeedsensor(VSS)connector. -------------.2
13-8
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1 1 . Removethe guardbar and the splashshield.
12. Disconnectthe heatedoxygen sensor(HO2S)connector,then removethe exhaustpipe A.
15. Removethe cotter pins,and castlenuts.then separate the ball iointsfrom the lower arm (seesectlon 18). OAMPERPINCHBOLT
GASKET Replace. HO2SCONNECTOR
CASTLENUT NUT Replace.
NUT Replace.
DAMPERFORK
FOFK EOLT
Replace.
EXHAUST
SELF.LOCKING Replace.
GASKET Replace.
Mark referencemarks on the joint of the transfer and the propellershaft.
1 6 . Removethe right damper tork bolt, then separate right damperfork and damPer. 1 7 . Pry the right driveshaftout of the differential,and pry the left driveshaftout of the intermediateshaft (seesection18). 1 8 . Pull out the inboardioint, and removethe right and left driveshaft(seesection18). 1 9 . Tie plastic bags over the driveshattends. Coat all precisionfinishedsurfaceswith cleanengineoil
MABKS REFERENCE
\
8 x 1.25mm Replace. 1 4 . S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r assemDly.
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{cont'd}
13-9
TransmissionAssembly Removal(cont'd) 20. Removethe intermediate shaft.
2 1 . Tie plasticbagsoverthe both endsof the intermediate shaft. Coat all precisionfinished surfaceswith cleanengineoil. Removethe rear engine stiffene.and clutch housIng cover.
23. Removethe right front mounvbracket.
RIGHTFRONT MOUNT/BRACKET P l a c ea j a c k u n d e r t h e t r a n s m i s s i o nr,a i s e i t j u s t enough to take it off of the mounts, then remove the transmissionmount bracketand transmission mount. TRANSMISSIONMOUNT
MOUNT BRACKET
13-10
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25. Removethe transmissionmounting bolts and the rearenginemountingbolts.
REARENGINEMOUNTINGBOLTS Replace.
28. Removethe releasetork boot. releasebearing,and releasefork from the clutchhousing RELEASE BEANING
TRANSMISSION
Pull the transmissionaway from the engine until it clearsthe mainshaft,then lower it on the transmission jack. NOTE:Takecarenot to bendthe clutchline. Removethe startermotor and hose clampfrom the transmissionhousing.
STARTER MOTOR
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1 3 - 11
TransmissionAssembly lllustrated Index Referto the drawingbelowfor the transmissiondisassembly/reassembly. Cleanall the pans thoroughlyin solvent,and drv with comoressedair. I
LuUri""r"uttthe partswith MTFbeforereassembly.
NOTE: t This transmissionusesno gasketsbetweenthe major housings;use liquid gasket(p/N 0g718- 0001or oE7l8 - 0003) (seepage 13-69,71). . Alwayscleanthe magnet@ wheneverthe transmissjonhousingis disassembled. . Inspectall the bearingsfor wear and operation.
C) sHrFr FoRKASSEMBLY . I n d e xp a g e l, 3 - 2 1 (a MAINSHAFTASSEMBLY . I n d e xp a g e 1 , 3-23 (9 28 mm WASHER €) 28 mm SPRTNG WASHER O BALLBEARING a6)OIL SEALReDlace. (D 14 x 20 mm DOWELptN G) couNTERSHAFTASSEMBLY .lndex page,13-28
13 -1 2
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aol NEEDLESET PLATE
@ NEEDLEBEARING
o OILGUIOEC PLATE
@ MAGNET @ DIFFERENTIAL ASSEMBLY .lndex page,13-38
(DO-nlNGBeplace. i9 TRANSFERASSEMBLY '13,44 .Index page,
@ OILSEALReplace. @ VEHICLESPEEDSENSOR @ CLUTCHHOUSING (9 REVERSELOCKCAM @ REVEESESHIFTHOLDER @ REVERSEIDLEGEAR @ REVERSEGEARSHAFT
e3THRUSTWASHER,20x 36 x 2 @ COLLER,15 x 20 x 20
C) TRANSMISSIONHANGER BOLT O INTERLOCK O 32 mm SEALINGBOLT @ STEELBALL{5/16 in.) 26.1mm {1.03in.l €) SPRING @ wasHER Replace. O sET BALLscREw @ WASHERReplace. €) FLANGEBOLT @ oll SEALReplace. @ DRAINPLUG @ WASHERReplace. @ FILLERPLUG @ WASHERReplace.
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(9 10 x 12 mm DOWELPIN (D SPRING in.l 25.6mm 11.01 €' THRUSTWASHER @} SHIFTARM C (3 CONICALSPRINGWASHER BOLT @ SPECTAL 8] SHIFTARM COVER @ OILSEALReplace. €! SHIFTLEVER CAP @I BREATHER (2! SHIFTARM SHAFTASSEMBLY PINReplace. @ SPRING O SELECTARM
€!} THRUSTWASHER SELECT @ sTH/REVERSE RETURNSPRING @ SELECTRETURNSPRING €) OIL GUTTERPLATE @ 78 mm SHIM @ OIL GUIOEM PLATE @ SELECTSPRINGBOLT @ OILSEALReplace. @ SELECTLEVER O BACK.UPLIGHTSWITCH @ WASHERReplace. HOUSING OOTRANSMISSION
13-13
TransmissionAssembly Disassembly 1.
Removethe transferassemblv.
3.
Removethe interlockbolt. SELECTARM
O-RING Replace.
SHIFTARMSHAFT Turn the selectlevercounterclockwise, then remove the shift arm A finger from the groove of the shift forks.
Removethe shift arm cover assembly,and wiDe it cleanof the sealant. 5.
T u r n t h e s h i f t a r m s h a f t c o u n t e r c l o c k w i s ea n d removethe selectarm fingerfrom the grooveof the shift arm A. then removethe shift arm shaft assemblv.
6.
Removethe vehiclespeedsensor(VSS).
SHIFTARM COVERASSEMBLY
10x 12 mm DOWELptN
13-14
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7.
Removethe set ball screws,washers,springs,steel balls.and back-uPlight switch.
9. Removethe transmissionhousing mounting bolts in a crisscrosspauernin severalsteps.
STEELBALL D. 5/16 in
LIGHTSWITCH
8.
Removethe flangebolt. drainplug, and filler plug
10. Removethe 32 mm sealingbolt
FILLERPLUG DRAINPLUG WASHER Replace.
WASHER Replace.
FLANGEBOLT
' It . Expandthe snap ring on the countershaftball bearing, and removeit from the groove using a pair of snap ring plier. Separatethe transmissionhousingfrom the clutch housing. R e m o v et h e d o w e l p i n s ,a n d w i p e i t c l e a no f t h e sealant. (cont'd)
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13-15
TransmissionAssembly Disassembly(cont'dl 1 4 . R e m o v et h e o i l g u t t e rp l a t e ,7 8 m m s h i m , a n d o i l guide M plate.
1 6 . Removethe spring pin using the pin punch and a pair of diagonalcutters.
OIL GUTTERPLATE
PIN PUNCH,5.0 mm
Replace. OIL GUIDEM PLATE
17. Removethe selectlever,springs,washer,and select arm. 15. Removethe selectspringbolt.
SEL€CTLEVER
SELECTSPRINGBOLT
{
V
OIL SEAL Replace.
THRUSTWASHER
SELECTARM
18. Removethe oil seal.
13-16
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23. Removethe mainshaftand countershaftassemblies with the shiftforksfrom the clutchhousing.
19. Removethe reverselockcam.
NOTE;Beforeremovingthe mainshaftand countershaft assemblies,tape the mainshaftsplineto protect it.
COUNTEBSHAFT ASSEMBLY
20. lf necessary,checkthe clearanceof the reverseshift holder(seepage13-20).
2 ' t . Removethe reverseshift holder. Tapethe main' shaftsplines.
WASHER
SPRINGWASHER
HOUSING
HOLOER
24. Removethe differential asssmbly.
22. '97 - 99 models: Removethe reversegear shaft and the reverseidler gear. '00 model: Remove the reverse gear shaft, reverse idler gear,thrustwasherand the coller.
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13-17
Shift Arm Cover/ShiftArm Shaft Assembly Disassembly/Reassembly Shift Arm CoverAss€mbly 1.
5.
Installthe oil seal in to the shift arm coverusinothe sDecialtools.
Removethe breathercap and set ball screw,washer, spring.and steelball.
HANOLE 07749- 0010000 ATTACHMENT, 32x35mm 077a6- 0010100
BREATHER CAP OIL SEAL Replace.
STEELBALL D. 5/16 in,
SPRING L,25.6mm (1.01in.l T BALLSCREW 22 N.m 12.2kgtm, 16lbf.ftl Remove the special bolt and conical spring washers.
6.
Reassemble the shift arm cover in the reve.seorder of disassembly.
Shift Arm Shaft Assembly 1.
Removethe specialbolts and conicalspring washers.
SHIFTARMA
SHIFT ARM COVER
SPCCIALBOLT 8x1.0mm 29 N.m (3.0kgf.m, 22IbI.ftI
CONICALSPRING
SHIFTLEVER
SHIFTARM SHAFT
THRUSTWASHER
SHIFI ARM C WASHER
8x1.0mft
29 N.m13.0kg{.m, z2 tbt.ftl R e m o v et h e s h i f t l e v e r , s h i f t a r m C , a n d t h r u s t washerfrom the shift arm cover.
SPECIALBOLT 8x1.0mm 29 N.m {3.0kgf.m,22 lbtft}
Removethe oil seal. NOTE: lnstallthe thrust washerwith the alloy surfacetoward shift arm cover.
13-18
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SPRING WASHER
2.
Remove the interlock, shift arm A, and shift arm B from the shift arm shaft.
3.
Installin the reverseorderof removal.
InsPection Clearance 1.
Measurethe clearancebetweenthe shift arm A and selectarm. 0.05- 0 25 mm (0.002- 0'01 inl Standard: ServiceLimit:0.5mm (0.02in)
3.
Measurethe clearancebetweenthe shift arm B and shift arm c. 0.05- 0.25 mm (0.002- 0.01 inl Standard: SeryiceLimit:0,5mm (0.02inl SHIFTARM C
SELECTARM
SHIFT ARM A
2.
SHIFTARM B
l f t h e c l e a r a n c ea r e m o r e t h a n t h e s e r v i c el i m i t , measurethe diameterof the selectarm pln
l f t h e c l e a r a n c ea r e m o r e t h a n t h e s e r v i c el i m i t , measurethe diameterof the shift arm C.
Standard:7.9- 8.0 mm (0.311- 0.315in)
Standard:12.9- 13.0mm (0 508- 0.512in)
SHIFTARM C
SELECT ARM lf the diameterof the selectarm pin is lessthan the service limit, replacethe select arm wrtn a new one. lf the diameterof the selectarm pin is within the servicelimit, replacethe shift arm A with a new one.
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lf the diameterof the shift arm C is lessthan the servicelimit, replacethe shift arm C with a new one. l f t h e d i a m e t e ro f r h e s h i f t a r m C i s w i t h i n t h e servicelimit, replacethe shift arm B with a new on e .
13-19
ReverseShift Holder ClearanceInspection 1.
Measurethe clearancesbetweenthe reverseshift holderand sth/reverse shift DieceDin. A: 0.05- 0.35mm (0.002- 0.014in) 8: 0.4 - 0.8 mm 10.02- 0.03 inl ServiceLimit:A: 0.5 mm (0.02in) B: 1.0mm 10.0,[ in] Standard:
3.
Measure the clearancebetween the reverseidler gearand reverseshift holder. Standard: 0.5- 1.1mm {0.02- 0.0i1in} ServiceLimit: 1.8mm (0.07in) REVERSE IDLER GEAR
PIECEPIN
2.
l f t h e c l e a r a n c ea s r e m o r e t h a n t h e s e r v i c el i m i t . measurethe widths of the groove in the reverse shift holder. Standard:A: 7.05- 7.25 mm {0.278- 0.285inl B: 7.4- 7.7 mm (0.29- 0.30inl
lf the clearanceis more than the servicelimit. measurethe width ot the reverseshift holder. Standard:13.0- 13.3mm (0.512-0521inl
REVERSE SHIFTHOLDER
lf the widths of the grooves are not within the standard,replacethe reverseshift holderwith a new one. lf the widths of the groovesare within the standard, replacethe sth/reverseshift piece with a new one.
13-20
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It the width is not within the standard,replace the reverseshift holderwith a new one. lf the width is within the standard,reolacethe reverseidler gearwith a new one.
Shift ForkAssembly Disassembly/ReassemblY I
cleanall the pans in solvent,dry them, and apply lubricantto any contactparts erior,o reassembling,
3RD/,|THSHIFTFoRK 1ST/2NDSHIFTFORK
5TH/REVERSE SHIFTPIECE
PIN PUNCH,5.0 mm
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13-21
Shift ForkAssembly ClearanceInspection NOTE:The synchrosleeveand synchrohub should be reolacedas a set. 1.
3.
Measurethe clearancebetweenthe shift fork and the shift arm A.
Measurethe clearancebetweeneach shift fork and its matchingsynchrosleeve.
Standard; 0.2- 0.5 mm (0.008-0.020 in) ServiceLimit: 0.6 mm (0.02i1in)
Standard: 0.35- 0.65 mm 10.01/t- 0.026inl ServiceLimit: 1,0 mm {0.039inl
sTH/REVERSE SHIFTPIECE
ran,rru
lST/2ND SI{IFTFORK
lf the clearanceexceedsthe servicelimit, measure the width of the shift arm A.
SHIFTFORK
2.
lf the clearanceexceedsthe servicelimit. measure the thicknessof the shiftfork fingers.
- 0.512inl Standard:12.9- 13.0mm 10.508
Standard: 3rd/4th shift fork 1sv2ndshiftfork 5th shift fork
7 . 4- 7 . 6m m (0.29- 0.30in) 6 . 2- 6 . 4m m (0.24- 0.25in)
lf the thicknessof the shift fork finger is lessthan the standard,replacethe shift fork with a new one. lf the thicknessof the shift fork tinger is within the standard,replacethe synchrosleevewith a new one.
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lf the width of the shift arm A is less than the standard,reDlace the shift arm A with a new one. lf the width of the shift arm A is within the standard, replacethe shift fork or shift piecewith a new ones.
MainshaftAssembly lndex Notethe Iollowingduringreassembly: . The 3rd/4th,and 5th synchrohubs,and the ball bearingare installedwith a press. . Installtheangularball bearingwith the thin-edgedouter racefacingthe stop ring prior to reassembling, clean all the parts in solvent,dry them, and apply lubricantto any contactsurfaces.The hubs,however,shouldbe installedwith a pressbeforelubricatingthem' 5th svnchro 3rd/4thand
SYNCHRORING page l3 37 Inspection,
ANGULAREALLBEARING Checkfor wear and operation. Note the direction of installation.
SYOPRING
SYNCHROHUB page13-36 lnspection, SYNCHROSLEEVE page13 36 Inspection,
TAPERRING BEARING CheckIor wear and operataon. COLLAR
SPRING
RING page13-37 Inspection,
SYNCHRO
SYNCHROSPRING
Inspection, page13-37
SYNCHROHUB page13_36 Inspection,
3RDGEAR Inspeclton, page13 24,37
SYNCHROSLEEVE page13 36 Inspection, SPFING
BEARING
RING page13_37 Inspection,
Checkfor wear ano operalton.
GEAR page13_25, 37 Inspection, page13 26 Inspection, COLLAR page13-24,25 Inspection, NEEDLEBEARING Checkfor wear and operat,on. GEAR I n s p e c t i o n ,p a g e 1 3 2 4 , 3 7
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13-23
MainshaftAssembly ClearanceInspection NOTE; lf replacementis required,always replacethe synchrosleeveand hub as a set. L
Support the bearing inner race with a socket.and Dushdown on the mainshaft.
2.
Measurethe clearancebetween2nd and 3rd oears.
4.
Measurethe clearancebetween 4th gear and the spacercoIar, Standard: 0.06- 0.21 mm {0.002- 0.008in) Servic€Limit: 0.3 mm {0.01inl
+
Siandard: 0.06- 0.21 mm 10.002- 0.008in) ServicaLimit: 0.3 mm (0.01in)
lf the clearanceis more than the servicelimit, measure distance@ on the spacercollar, Standard: 26.03- 26.08mm {1.025- 1.027inl ServiceLimit: 26.01mm {1.02,[in]
o[-l:-g;;em
lf the clearanceis more than the servicelimit, measurethe thicknessof 3rd gear. Standard: 34.92- 34.97mm {1.375- 1.377in) ServiceLimit 34.8 mm (1.37in) 3RD GEAR
fp-rro.ERcoLLAR 6.
tf distance@ is lessthan the servicelimit, replace the sDacercollarwith a new one. lf distance@ is within the service limit. measure the thicknessof 4th gear. - L239 inl Standard: 31.42- 31.'17mm 11.237 SarviccLimit:31.3mm {1.23in)
lf the thicknessof 3rd gear is lessthan the service limit, replace3rd gearwith a new one. lf the thicknessof 3rd gear is within the service limit, replacethe 3rd/4thsynchrohub with a new one.
13-24
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lf the thickness of 4th gear is less than the service limit, replace 4th gear with a new one. lf the thickness of 4th gear is within the service limit, replace the 3rd/4th synchro hub with a new one,
Disassembly 7.
Measurethe clearancebetweenthe spacer collar and 5th gear. 0.06- 0.21 mm {0.002- 0.008in) Standard: ServiceLimit: 0.3 mm {0.01in)
1.
S u p p o r t5 t h g e a r o n s t e e l b l o c k s ,a n d p r e s st h e mainshaftout of the 5th synchrohub, as shown.Do not use a jaw-type puller, becauseit can damage the gearteeth. PRESS
MAINSHAFT
I ACHMENT
SPACERCOLLAR
SOCKET
8.
5TH GEAR
lf the clearanceis more than the servicelimit, measuredistance@ on the spacercollar 26.03- 26.08mm 11.025- 1.027in) Standard: S€rvicoLimit: 26.01mm (1.024in) SPACER COLLAR
In the same manneras above,supportthe 3rd gear on steel blocks.and pressthe mainshaftout of the 3rd/4thsvnchrohub, as shown. PRESS
5TH GEAR SIDE
9.
I
lf distance@ is lessthan the servicelimit, replace the spacercollarwith a new one. lf distance@ is within the service limit, measure the thicknessof sth gear. Standard: 30.92- 30.97mm (1.217- 1.219in) ServiceLimit:30.8mm (1.21in)
gt
r--\
,,srH GEAR
Fq
I- l.J'-----!--\--J
lf the thicknessof 5th gear is less than the service limit, replace5th gearwith a new one. li the thicknessof sth gear is within the service l i m i t , r e p l a c et h e s t h s y n c h r oh u b w i t h a n e w one.
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BLOCKS
MainshaftAssembly Inspection 1.
I n s p e c t h e g e a r s u r f a c ea n d b e a r i n gs u r f a c ef o r wear and damage,then measurethe mainshaftat pointsA, B, and C. Standard: A (Ballbearingsurface): 27.987- 28.000mm 1 1 . 1 0 1- 81 . 1 0 2 4i n l B (Needlebearing surfacel:37.984- 38.000mm - 1.4961inl (1.4954 C {Baflbearingsurfacel: 27.977-27.990 mm ( 1 . 1 0 1-5 1 . 1 0 2 0 inl ServiceLimit:A:27.94mm (1.100in) B: 37.93mm (1.'193 inl C: 27.94mm 11.100 inl
2.
Inspectfor runout. Standard: 0.02mm (0.0008in) max. ServiceLimit: 0.05 mm 10.002inl N O T E : S u p p o r tt h e m a i n s h a f a t t both ends shown.
lf the runout is more than the servicelimit, reDlace the mainshaftwith a new one. I n s p e c t o i l p a s s a g e sI o r c l o g g i n g .
lf anv oart of the mainshaftis lessthan the service limit. reolaceit with a new one.
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Reassembly sequence. NOTE:Referto page13-23for reassembly 1.
3.
I n s t a l lt h e a n g u l a rb a l l b e a r i n gu s i n g t h e s p e c i a l tools and a oress.Notethe directionof installation.
Suppon 2nd gear on steel blocks as shown, then i n s t a l lt h e 3 r d / 4 t hs y n c h r oh u b u s i n g t h e s p e c i a l tools and a pressas shown.
PRESS
I
NOTE:After installing,inspectthe operationof the 3rd/ 4th synchrohub set. PRESS
3RD/4TH SYNCHROHUB
HANDLE 07749- 0010000
I DRIVER,,l(} mm l.O. 07746 - 0030'100 ATTACHMENT, /Vl x a7 mm
077a6- 0011x100
BALLBEARING Notethe diredion o{ installation.
2NO GEAR
2.
Installthe sth synchro hub using the specialtools and a press. PRESS
I DRlvER,40mm l.D. 077{6 - 00301(x)
ATTACHMENT, 35 mm l.D. 077i16- lx)3ollx)
sTH SYNCHBOHUB
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13-27
CountershaftAssembly Index NOTE:The 3rd, 4th.and sth gearare installedwith a press.
3
Priorto reassembling, cleanall the partsin solvent,dry them, and apply lubricantto any contactsurfaces.The 3rd, 4th,and sth gears,however.shouldbe installedwith a pressbeforelubricatingthem.
LOCKNUTReplace. 127-o-127N.m 113-0- 13kstmi 9.trbtft/ \94-0WASHER
IST/2ND SYNCHROHUB page13 36 Inspection, DAMPER Checklor wear and damage.
AEARING Checkfor wear and ooeration. BEARING Checkfor wear and operation. GEAR
SPNING 4TH GEAR DOUBI.f CONE page13-37 Inspection, 3RD GEAR 1STGEAR page13 29,37 Inspection,
BEARING Checktor wear and operation. THRUSTWASHER page13-29 Inspection,
GEAR page13-30,37 Inspection, NEEDLEBEARING Checkfor wear and oPeration SPACER page13-30 Selection, DAMPER C h e c kf o r w e a r a n d d a m a g e .
DOUBLECONE page13-37 Inspection,
SPRING
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ClearanceInspection NOTE: lf replacementus required,always replacethe synchrosleeveand hub as a set. 1.
M e a s u r et h e c l e a r a n c eb e t w e e nt h e l s t o e a r a n d thrustwasher.
3.
lf the thicknessis lessthan the standard,reDlacethe thrust washer with a new one. lf the thicknessis w i t h i n t h e s e r v i c el i m i t , m e a s u r et h e t h i c k n e s so f t h e 1 s tg e a r . Standard:26.95- 27.00mm (1.061- 1.063inl
Standard: 0.06- 0.18mm (0.@2- 0.007in) ServicaLimit:0.23 mm {0.009in)
THRUST WASHER
2.
lf the thicknessof 1st gear is lessthan the standard,replace1stgearwith a new one. lf the thicknessof lst gear is within the standard. replace1sv2ndsynchrohub with a new one.
lf the clearanceis more than the servicelimit, measurethe thicknessof the thrustwasher. Standsrd:1.95- 1.97mm (0.077- 0.078in)
{cont'd}
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13-29
CountershaftAssembly Clearance Inspection(cont'dl 4.
Measurethe clearancebetweenthe 2nd qear and 3rd gear. Standard: 0.07- 0.1,1mm (0.003- 0.006inl ServiceLimit:0.18mm (0.007inl
6.
lf the thicknessis lessthan the standard,reDlacethe spacerwrln a new one. lf the thicknessis within the standard,measurethe thicknessof the 2nd gear. Standald:28.92- 28.97mm (1.139- 1.141in)
FEET.ER GAUGE
t
!
. -]
lf the thicknessof 2nd gear is lessthan the standard,replace2nd gearwith a new one. lf the thicknessof lst gear is within the standard, replace1sv2ndsynchrohub with a new one.
lf the clearanceis more than the servicelimit. measurethe thicknessof the spacer. Standard:29.07- 29.09mm (l.14il- 1.145inl
13-30
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Disassembly 1.
S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n a benchvisewith wood blocks.
4.
Removethe Jrictiondamperfrom the spacerusinga pressand a socket. PRESS
CHISEL
t
SPRIiIGWASHEF BETICH
vtsE
W(X)DBLOCKS
2.
FRICTIONDAMPER Inspectlor wear and damage.
Raisethe locknuttab from the groove in the countershaft,then remove the locknut and the spring washer. Removethe ball bearingusinga pressas shown.
5.
S u p p o r t l s t g e a r o n s t e e l b l o c k s ,a n d p r e s st h e out of 3rd gear. countershaft PRESS
I
3RD GEAR
1STGEAR
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13-31
CountershaftAssembly Inspection 1.
I n s p e c t h e g e a r s u r f a c ea n d b e a r i n gs u r f a c eI o r wear and damage,then measurethe countershaft at pointsA, B, and C. A: 36.000- 36.015mm - f.ill79 inl 11.,1173 B: 36.98/t- 37.000mm {r.4561- 1.4567inl C: 24.987- 25.000mm - 0.9843inl {0.98:17 Limit: Servics A:35,95mm (1.'115 in) B: 36.93mm (1.454in) C: 24.94mm (0.982in)
2.
Inspectfor runout. Standard: 0.02 mm 10.0008inl max. ServiceLimit: 0.05 mm {0.002inl
Standa.d:
N O T E :S u p p o r tt h e c o u n t e r s h a fat t b o t h e n d s a s shown.
Rotatetwo completerevolutions.
lf the runout exceedsthe servicelimit, reDlacethe with a new one. countershaft lnspectfor wear and damage.
lf anv part of the countershaftis lessthan the service limit.reolaceit with a new one.
13-32
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Reassembly Notetheseitemsduring reassembly: . Pressthe 3rd, 4th, and sth gear on the countershaft without lubrication. . When installingthe 3rd, 4th. and sth gears,suppon the shaft on steelblocksand installthe gearsusinga press. . Referto page 13-28for reassemblysequence. 1.
2.
Installthe doublecone synchro.
OUTER
Installthe thrustshim, needlebearing,1stgear,and frictiondamper. NOTE: Reassemblythe friction damper on the lst gearbeforeinstallation.
----.-4O) orn,leen rnrcrroru lST GEAR
NEEDLEBEARING
3.
Installthe 1sv2ndsynchrohub by align the friction damperfingerswith 1svzndsynchrohub grooves.
THRUSTSHIM
lST/2ND
(cont'd)
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13-33
CountershaftAssembly (cont'dl Reassembly 4.
Reassembly the frictiondamperon the spacerusing the sDecialtoolsand a Dress.
6.
Supportthe countershafton a steel blockas shown and install 3rd gear using the specialtools and a press. PRESS
PRESS
I
t
ATTACHMENT, U2t 47 mfi 07716- 0010300
3ROGEAR FRICTIONDAMPER Inspectfor wear and damage.
7.
lnstall4th gear usingthe specialtools and a press.
Install the 2nd gear by align the synchrocone the fingers with 2nd gear grooves.
PRESS
t
ATTACHMENT, 35 mm LD. 07746- 0030,100 GROOVE
13-34
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Installsth gear usingthe specialtools and a press.
8.
PRESS
I
I
DRIVER,40 mm l.D. 07715- 0030300
DRIVER.40 mm LD. 07746- 0030100 ATTACHMENT, 30 mm LD. 077a6- 0030300
ATTACHMENT, 30 mm LD. 077,16- 0030300
L
10. Installthe ball bearingusingthe specialtools and a press. PRESS
I n s t a l lt h e n e e d l eb e a r i n gu s i n g t h e s p e c i a tl o o l s and a press,then installthebearingouter race PRESS
1 1 .S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n benchvisewith wood blocks. LOCKNUT Replace.
I DRIVER.40 mm l.D. 077{6 - 0030100
ATTACHMENT, 30 mm l.D. 07746- 0030300
NEEDLE BEASING
wooD slocKs 12. Installthe springwasher. Installthe new locknutto the correcttorque, then stakethe locknuttab into the groove. Torque:127+ 0 + 127N.m 113- 0 +13 kgf.m, 94+0-94|bf.ft)
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13-35
SynchroSleeve,SynchroHub Inspection 1.
Installation
Inspectgear teeth on all synchrohubs and synchro s l e e v e sf o r r o u n d e d o f f c o r n e r s ,w h i c h i n d i c a t e
I n s t a l le a c h s y n c h r oh u b i n i t s m a t i n gs y n c h r o sleeve,and checkfor freedomof movement.
When assemblingthe synchrosleeveand synchrohub, b e s u r e t o m a t c h t h e t h r e e s e t s o f l o n g e rt e e t h ( ' 1 2 0 degreesapart)on the synchrosleevewith the three sets of deepergroovesin the synchrohub. Do not installthe synchrosleevewith its longerteeth in the lsv2nd synchro hub slotsbecauseit will damagethe springring.
N O T E :l f r e p l a c e m e ni ts r e q u i r e d a, l w a y sr e p l a c e the synchrosleeveand synchrohub as a set.
SYNCHRO SLEEVE
SYNCHRO
SYNCHBO HUB SYNCHBO SI.EEVE
13-36
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LONGER?EETH
SynchroRing,Gear Inspection 1.
SYNCHROSPRING
Inspectthe synchroring and gear. Ar lnspectthe insideof the synchroring for wear. B: lnspectthe synchro sleeveteeth and matching teeth on the synchroring for wear (roundedof0.
SYNCHRO
CC
GOOOWORN teeth and matching sleeve Cr Inspectthe synchro teethon the geartor wear (roundedoff).
,,\n
(-l u WORN GOOO D: Inspectthe gear hub thrustsurfacefor wear. E: Inspectthe conesurfacelor wear and roughness. F: Inspectthe teeth on all gearsfor unevenwear, scoring,galling,and cracks. 2.
Coatthe cone surfaceof the gearwith oil, and place the synchro ring on the matchinggear. Rotatethe synchroring, makingsurethat it does not slip. Measurethe clearancebetween the synchro ring a n dg e a ra l l t h ew a y a r o u n d . NOTE:Holdthe synchroring againstthe gearevenly while measuringthe clearance. Synchro Ring-to-GearClearance 0.85- 1.10mm (0.033- 0.0,lil in) Standard: ServiceLimit: 0.,1mm 10.02inl Double Cone Synchro-lo-GoarClearance Standard: @: {Outer Synchro Ring to Synchto Conel 0.5- 1.0mm (0.02- 0.04in) €): {synchro cone to Geal) 0.5- 1.0mm (0.02- 0.0i1inl @: louter Synchro Ring to Gearl 0.95- 1.68mm (0.037- 0.056inl ServiceLimit: @: 0.3 mm (0.01inl @: 0.3 mm {0.01in} @: 0.6 mm {0.02in)
OUTERSYNCHRORING
lf the clearanceis lessthan the servicelimit, replace the synchroring and synchrocone.
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13-37
Differential lndex
BacklashInspection
NOTE: lf the * mark parts were replaced,the tapered roller bearing preloadmust be adjusted(see page 1341).
1.
*THRUSTSHIM Adiustment,Page13'41
P l a c e t h e d i f f e r e n t i a l a s s e m b l yo n V - b l o c k sa n d install both axles.
PINIONGEARS
+BEARINGOUTERRACE page13 40 Beplacement, Inspectfor wear and damage. *TAPEREDROLLER BEARING pagel3-39 Replacement, Inspectfor wear and damage.
1 0x 1 . 0m m 103N.m {10.5kgf m, 75.9lbf.ft} Left-handthreads
CARRIER page13 38 Backlash inspection, lnspectfor cracks.
V-BLOCK
FINALDRIVENGEAR page13-39 Replacement, Inspectfor wear and damage
TRANSFERDRIVENGEAR page13-39 Replacement, Inspect{or wear and damage.
,,4\
W-
*TAPEREDROLLERBEARING page13'39 Beplacement, Inspectfor wear and damage. IEEARINGOUTERRACE page13-40 Replacement, Inspectfor wear and damage. .75 mm SHIM
13-38
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2.
Measurethe backlashot both piniongears. Standard(Newl:0.05- 0.15mm (0.002- 0.006inl lf the backlashis not within the standard,reolace the differentialcarrier.
FinalDrivenGearRePlacement L
Removethe bolts in a crisscrosspatternin several steps,and removethe final drivengearfrom the differentialcarrier. NOTE: The final driven gear bolts have left-hand threads.
TaperedRollerBearing Replacement Notetheseitems: . T h e t a p e r e dr o l l e r b e a r i n ga n d b e a r i n go u t e r r a c e shouldbe replacedas a set. . Inspectand adiustthe taperedroller bearingpreload wheneverthe taperedrollerbearingis replaced' . Checkthe taperedrollerbearingsfor wear and rough rotation.lf the taperedrollerbearingsare OK, removal is not necessary. 1.
1 0x 1 . 0m m 103N.m (10.5kgf m,75.9lbf'ftl Left'handthreads
Removethe taperedroller bearingsusing a bearing pullerand a bearingseparatoras shown.
BEARING BEARING SEPAFATOB {Commercially
FINALDRIVENGEAR lnsoect{or weal and damage
TRANSFERORIVENGEAR Inspectfor wear and damage.
Installnew taperedroller bearingsusingthe special tool as shown. N O T E :D r i v et h e t a p e r e dr o l l e r b e a r i n g so n u n t i l they bottomagainstthe differentialcarrter. PRESS
Installthe final driven gear by tighteningthe bolts in a crisscrosspatternin severalsteps.
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IJ
ATTACHMENT, ,10x 50 mm 07LAD - PWs060l
13-39
Differential BearingOuter RaceReplacement Notetheseitems: . The bearing outer race and tapered roller bearing shouldbe replacedas a set. . lnspectand adjustthe taperedroller bearingpreload wheneverthe taperedrollerbearingis replaced. '1.
2.
3.
Notetheseitemsduringbearingreplacement: . Installthe bearingouter racesquarely. . Check that there is no clearancebetween the bearingouter race,thrust shim or 75 mm shim and housing.
Removethe oil sealsfrom the transmissionhousing and clutchhousing(seepagej3-43). Drivethe bearingouter raceand thrust shim out of the transmissionhousing, or remove the bearing outer raceand 75 mm shim from the clutchhousing b y h e a t i n gt h e c l u t c h h o u s i n gt o a b o u t 2 1 2 " F (100"C)with a heat gun. Do not reuse the thrust shim if the outer racewas drivenout.
Installthe thrust shim or 75 mm shim and the beari n g o u t e r r a c e i n t h e t r a n s m i s s i o nh o u s i n g a n d clutchhousingusingthe specialtools.
TRANSMISSION HOUSING:
HANDI-E 07749 - 00 xxto
TRANSMISSION HOUSING:
ATTACHMENT, 62x68mm 077ir6- 0010500 ATTACHMENT 52x55mm 07746- 0010400
THRUSTSHIM
BEARING OUTERRACE
BEARING OUIER RACE
THRUSTSHIM
CLUTCH HOUSING:
HANDLE 07749 - 001tXX)o
CLUTCH HOUSING:
ATTACHMENT. 72xt5mm 07745 - 00106{x)
OUTERRACE 75 mm SHIM
4,
13-40
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lnstalltheoil seal(seepage13-43).
TaperedRollerBearingPreloadAdiustment After installingthe thrust shim, installthe bearing outer race in the transmissionhousing (see page 13-40).
the tapered lf any oJthe itemslistedbelowwere replaced, be adjusted. preload must rollerbearing . . . o . .
Transmissionhousing Clutchhousing carrier Differential Taperedrollerbearingand bearingouter race Thrustshim 75mm sham
1.
Do not use more than one thrust shim to adjustthe t a p e r e db e a r i n gp r e l o a d .F i r s tt r y t h e s a m e s i z e thrust shim that was removed.There are no shims usedon the clutchhousingside
W i t h t h e m a i n s h a f ta n d c o u n t e r s h a f tr e m o v e d , i n s t a l lt h e d i f f e r e n t i a al s s e m b l y ,a n d t o r q u e t h e clutchhousingand transmissionhousing. NOTE:lt is not necessaryto use sealingagent betweenthe housings.
R e m o v et h e b e a r i n go u t e r r a c e a n d t h r u s t s h i m from the transmissionhousing(seepage 13-40)' NOTE: . Do not reusethe thrust shim if the bearingouter racewas drivenout. . Let the transmissioncool to room temperatureil the bearingouter race was removedby heating the clutchhousing.
2.
4.
TOBOUE;8 x 1.25mm: 27 N'm (2.8kgf'm, 20 lbt'ftl 5.
Rotatethe differentialassemblyin both directions to seatthe taperedrollerbearings. Measurethe taperedroller bearingpreloadat normal room temperature.Measurethe startingtorque of the differentialassemblyin both directionswith the specialtool and a torquewrench. STANDAFD:1.4- 2.5 N'm {1/r- 26 kgf'cm, 12 - 23 lbf in)
THRUSTSHIM
/A
07HAJ- PK4020'1
(cont'd)
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13-41
Differential TaperedRollerBearingPreloadAdjustment(cont'd) 7.
lf the tapered roller bearing preload is not within the standard,selectthe thrust shim which will give the correcttaperedroller bearingpreloadfrom the followingtable. N O T E :C h a n g i n gt h e t h r u s t s h i m t o t h e n e x l s i z e w i l l i n c r e a s eo r d e c r e a s et a p e r e d r o l l e r b e a r i n g p r e l o a da b o u t 0 . 3 - 0 . 4 N . m ( 3 - 4 k g f . c m ,2 . 6 3.5 lbf.in).
9.
How to selectthe correctthrustshim: - 1 ) C o m p a r et h e t a p e r e dr o l l e r b e a r i n gp r e l o a d you get with the thrustshim that was removed, w i t h t h e s p e c i f i e dp r e l o a do f 1 . 4 - 2 . 5 N . m (14-- 26 kgfcm, 12-23lbtinl. -2) lf your measuredtaperedrollerbearingpreload is less than specified.subtractyours from the specified, l f y o u r s i s m o r e t h a n s p e c i f i e ds, u b t r a c tt h e specifiedfrom your measurement.
THRUSTSHIM Part Numbe. 41381- PX5 000
Thickness 1 . 9 0m m ( 0 . 0 7 4 i8n )
B
41382- PX5 000
c
41383-PX5-000
1 . 9 3m m { 0 . 0 7 6 i0n ) '1.96mm (0.0772 in)
n
41384-PX5-000
1 . 9 9m m ( 0 . 0 7 8 i3n )
E
41385-PX5-000
2 . 0 2m m ( 0 . 0 7 9 i5n )
F
41386-PXs-000
2.05mm (0.0807in)
G
41387-PXs-000
2 . 0 8m m ( 0 . 0 8 1 i9n )
n
41388-PX5-000
2 . 1 1m m ( 0 . 0 8 3 i1n )
41389-PX5-000
2 . 1 4m m ( 0 . 0 8 4 i3n )
J
41390-PXs-000
2.'17mm (0,0854in)
K
41391- PX5- 000
2.20mm (0.0866in)
4'1392-PX5-000
2.23mm (0.0878in)
M
41393-PX5-000
2.26mm (0.0890in)
N
41394-PX5-000
2.29mm (0.0902in)
o
4 1 3 9 5P , X s- 0 0 0
2.32mm (0.09'13 in)
P
41396-PX5-000
2.35mm (0.0925in)
o
41397-PX5-000
2.38mm (0.0937in)
4' t398-PXs-000
2.41mm (0.0949in)
S
41399-PXs-000
2.44mm (0.0961in)
T
41400-PXs-000
2.47mm (0.0972in)
41873-P16-000
1 . 6 6m m ( 0 . 0 6 5 i4n )
AC
41874-Pl6-000 41875 P16- 000
1 . 6 9m m ( 0 , 0 6 6 i5n ) '1.72mm (0.0677 in)
AD
41876-P16-000
1 . 7 5m m ( 0 . 0 6 8 i9n )
AE
41877-P16-000
1 . 7 8m m ( 0 . 0 7 0 1i n )
AF
41878-P16-000 41879-P16-000
3) 1 . 8 1m m ( 0 . 0 7 ' 1i n '1.84 mm (0.0724in)
41880-P16-000
1.87mm {0.0736in)
AB
AH 8.
Recheckthe taperedrollerbearingpreload.
13-42
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For examplewith a 2.17 mm (0.0854in) thrust shiml 2.5 N.m (26 kgf.cm,23lbiin) @ specified - you measure0.6 N.m (6 kgf.cm,5lbf.in) 1.9N.m(20kgicm, 18 tbt.in)tess @ you measure3.3 N.m (34 kgf.cm,30lbf.in) - specified 2.5 N.m (26 kgncm,23lbf.in) 0.8 N.m (8 kgf.cm,7lbt.in)more E a c hs h i m s i z e u p o r d o w n f r o m s t a n d a r d m a k e sa b o u t 0 . 3 - 0 . 4 N . . ( 3 - 4 k g f ' c m , 2.6- 3.5 lbf.in)differencein taperedrollerbearingpreload. I n e x a m p l e@ , y o u r m e a s u r e dt a p e r e dr o l l e r b e a r i n gp r e l o a dw a s 1 . 9 N . m ( 2 0 k g f . c m , 1 8 l b f . i n ) l e s s t h a n s t a n d a r ds o y o u n e e d a thrust shim five sizesthickerthan standard{try t h e 2 . 3 2 m m ( 0 . 0 9 1 3i n ) t h r u s r s h i m . a n d recheck). ln example@, your measurementwas 0,8 N.m {8 kgf.cm,7 lbf.in)more than standard,so you need a thrust shim two sizesthinner (try the 2.1'l mm {0.0831in) thrustshim,and recheck).
Oil Seal Replacement Clutch Housing:
TransmissionHousing: 1.
Removethe oil sealfrom the transmissionhousing
1.
Removethe oil sealfrom the clutchhousing.
OIL SEAL
Replace.
lnstallthe new oil seal into the clutchhousingusing the specialtools. 2.
lnstallthe new oil seal into the transmissionhousing usingthe specialtools.
NOTE:Installoil seal up to t0.5 mm (t0.02 in) from transmissionhousingend surface
jn) NOTE:Installoil sealup to i0.5 mm (10.02 from transmissionhousingend surface.
CLUTCH HOUSING
TRANSMISSION HOUSING
PRESS
PRESS
f
HANOLE - @1OCIO0 .--.'/'01119 DRIVERATTACHMENT
- PG4()r00
OIL SEAL Replace. PILOT,28x 30 mm 07JAO- PH80400
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I
HANDLE 07749 - tx)l(xxto DRIVERATTACHMENT OTJAD- PHM1Ol
PILOT,28 x 30 mm 07JAD - PH8oaU)
13-43
TransferAssembly lllustrated Index
E
ea/ g B
e
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,AC
O TRANSFERHOUSING @ O-RINGReplace. O DAMPERHUB G) NEEDLEBEARING G) TRANSFERDRIVENGEAR G) TRANSFERSHAFT O TAPEREDROLLERBEARINGOUTERRACE @ TAPEREDROLLERBEARING €) TRANSFERSHAFTCOLLAR @ THRUSTSHIM,25 mm selectivepart 6D TRANSFERDRIVEGEAR(HYPOIDGEAR) @ CONICALSPRINGWASHERRePlace SHAFTLOCKNUT.22x 1.25mm Left-handthreads,replace' GDTRANSFER BEARING ROLLER TAPERED E) BEARINGOUTERRACE ROLLER TAPERED @ @ THRUSTsHlM. 68 mm selectivepart O o.RlNG Replace. @ TRANSFERCOVERA GDTRANSFERCOVERB @ O-RINGReplace. €) TRANSFERDRIVENGEARSHAFT(HYPOIDGEAR} @ THRUSTSHIM,35 mm SelectivePart @ TAPEREDROLLERBEARING @ TRANSFEBSPACEBRepIace. @ TAPEREDROLLERBEARINGOUTERRACE @ TAPEREDROLLERBEARINGOUTERRACE @)TAPEREDROLLERBEARING @ olL SEALReplace. @ COMPANIONFLANGE @ O-RINGReplace. @ BACK-UPRING @ coNtcAL SPRINGWASHEBReplace. (o TRANSFERDRIVENGEARSHAFTLOCKNUT,22x 1.25mm Replace.
TOROUESPECIFICATIONS Boh/Nut No.
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Torque Value
Size
6A 8C 22L
12 N.m (1.2kgf.m.8.7lbf.ft) 24 N.m {2.4kgf.m,17 lbf'ft) 118N.m (12.0kgf.m,86.8lbf'ftl
6x1.0mm 8 x 1 . 2 5m m 2 2 x 1, 2 5m m
22H
1 3 2- 2 1 6N . m( 1 3 . 5- 2 2 . 0k g f ' m , 97.6- 159lbf.ft)
2 2 x 1. 2 5m m
Remarks
Transfershaftlocknut: Lett-handthreads Transferdriven gear shaft locknut Tighteningtorque:dePendingon TotalStartingTorquevaiue
13-45
TransferAssembly Inspection N O T E : T o p r e v e n t d a m a g e t o t h e t r a n s f e rh o u s i n g , always use soft jaws or equivalentmaterialsbetween the transferhousingand the vise.
TransferGear lHypoid gearl Tooth Contaqt Insp€ction 5.
Transter Gaar (Hypoid goar) BacklsshM€asurement 1.
Removetransfercover B, then apply PrussianBlue to both sides of the translergear teeth lightly and evenlv.
S e t a d i a l i n d i c a t o ro n t h e c o m p a n i o nf l a n g e a s shown.
DIALINDICATOR
TRANSFERDRIVEGEAR COMPANIONFLANGE
2.
Rotatethe companionflangein both directionsuntil the transfergear rotatesone full tuln in both directions.
Measurethe transfergear backlash. STANDARD:0.06- 0.16 mm {0.002- 0.006in}
7.
Checkthe transfer gear tooth contact pattern.
Total Sta.ting Torquo Msasuremont 3.
Rotatethe companionflange severaltimes to seat the taperedrollerbearing.
4.
M e a s u r et h e s t a r t i n gt o r q u e ( c o m p a n i o nf l a n g e side)usinga torquewrench. STANDARD: 2.68- 3.47 N.m {27.3- 35.4 kgf.cm.23.7- 30.7 tbt.in) lf the measurementsor the tooth contact Dattern are not within the standard.disassemblethe transfer assembly,replaceworn or damagedparts,and reassembleit.
1 3 -4 6
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Disassembly 1.
3.
Removethe transfercoversA and B.
Hold the transfershaft with a 14 mm Allen wrench clampedin a benchvise.
TRANSFER
TRANSFEF
Replace.
14 mm ALLENWRENCH
Loosenthe transter shaft locknut.The transfer shaft locknuthaslett-handthreads. Removethe transfershaft assembly,transferdrive gear,25 mm thrust shim. transfershaft collar.and taperedrollerbearingfrom the transferhousing. TRANSFERSHAFT ASSEMBLY
Cutthe locktabsofthe locknutusinga chisel.Keepa t l of the chiseledparticlesout of the transferhousing
TAPEREDROLLER BEARING TRANSFERSHAFT COLLAR
THRUSTSHIM, 25 mm pan Selective
TRANSFERDRIVE GEAR
LOCKNUT
LOCKTAB
(cont'd)
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13-47
TransferAssembly Disassembly(cont'd) Secure the transfer housing in a bench vise with soft jaws.
9. Removethe transferdrivengear shaft,then remove the transfer spacer from the transfer driven gear shaft.
COMPANION FLANGE HOLDER 07RAA-
7.
TRANSFER ORIVEN GEARSHAFT
I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g e , then loosenthe transferdrivengearshaft locknut. Removethe transferdrivengear shaft locknut,conical spring washer, back-upring, O-ring,and compsnionflange.
Removethe oil seal and the taperedroller bearing from the transferhousing,
OIL SEAL Replace.
TAPEREOROLIIR AEARING
TRANSFERHOUSING
TRANSFERDRIVEN GEARSHAFTLOCKNUT Reolace,
13-4 8
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Replacement
TransferDrivenGearShaft BearingReplacement
NOTE:Coatall partswith MTFduring reassembly.
NOTE:Coatall partswith MTFduring reassembly.
TransferDriveGearBearing
1.
Removethe taperedrollerbearingfrom the transfer drive gear usingthe specialtools and a press.
1.
Removethe taDeredrollerbearingfrom the transfer drivengear shaftusinga pressand a collar.
ATTACHMENT, 37x/Omm 07746- 0010200
SEPARATOR, BEARING o - 1112"
GEAR
SEPARATOR, BEARING 0 - 1112' available) lCommercially
{ C o m m e r c i a l l ya v a i l a b l e )
Installthe new taperedrollerbearingin the transfer drive gear usingthe specialtools and a press
lnstallthe 35 mm thrust shim on the transterdriven gear shaft. Installthe new taperedrollerbearingon the transfer drivengearshaftusingthe specialtoolsand a press. NOTE:Use old transferspacerfor bearinginstallation, then discardit. DRIVER40 mm l.D. 07746- 0030r00
ATTACHMENT, 40x50mm 07LAD - PW5lr601
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13-49
TransferAssembly TransferShaft Disassembly/ Reassembly 1.
Support the transfer driven gear on steel blocks, then pressthe transfershaftout of damperhub,
TransferGoverA BearingOuter RaceReplacement
NOTE:Coatall partswith MTFduring reassembly. 1.
Bemovethe taperedroller bearingouter racefrom t r a n s f e rc o v e r A b y h e a t i n gt h e c o v e r t o a l m o s t 2 1 2 " F( 1 0 0 o Cu) s i n g a h e a t g u n . D o n o t h e a t t h e coverover 212"F(100'C),
BEARINGOUTERRACE
2.
Installthe 68 mm thrustshim in transfercoverA.
Align the damper hub groovesand transferdriven gear teeth,and reassemble the damperhub. needle bearing,and transferdrivengear. Installthe transfershaftusinga press.
BEARINGOUTERRACE TRANSFERCOVERA ATTACXMCNT, 52x68mft 07746- tD,t0500
Install the tapered roller bearing outer race u sI n g the special tools and a press.
13-50
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TransferHousingBearingOuterRaceReplacement NOTE:Coatall partswith MTFduring reassembly. 1.
Bealing Outer RaceLocations and SpecialTool APP|ications
Removethe taperedroller bearingouter racefrom the transferhousing. HOUSING TRANSFER SectionalView
ATTACHMENT, 62x68mm 07746- 0010500
ATTACHMENT, 62x68mm 07?a6- 0010500 ATTACHMENT, 52x55mm 07715- 0010400
TBANSFERHOUSING
I n s t a l lt h e n e w t a p e r e dr o l l e r b e a r i n go u t e r r a c e usingthe specialtools and a press
DRIVER 07749- 0o1(xD0
J i= \ l
TRANSFERHOUSING DRIVERATTACHMENT
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BEARINGOUTER RACE
13-51
TransferAssembly Reassembly Notetheseitemsduring reassembly: . While reassembling the transferassembly: - Checkand adjustthe transfergeartooth contact. - Measureand adjustthe transfergear backlash. - Checkand adjustthe taperedroller bearingstartIng rorque. . Coatall partswith MTFduring reassembly. . R e p l a c et h e t a p e r e dr o l l e rb e a r i n ga n d t h e b e a r i n g outer raceas a set if eitherpart is replaced. . Replacethe transferdrive gear and the transferdriven gear shaftas a set if eitherpart is replaced,
EXAMPLE: C: EXISTING35 mm THRUSTSHIM Thicknoss:C=1.05mm
X: REPLACEMET{T35 mm THRUSTSHIM Thickness:X=??mm
Number: A=+2
Number: B-l
Outlineof Assembly 1.
Selectthe 35 mm thrustshim. Performthis procedureif the transler driven gear shaft or the tapered roller bearingon the transfer drivengearshaft is replaced.
2.
Preassemble the parts to checkand adjust transfer gear backlashand transfergeartooth contact.
3.
Disassemblethe parts,then assemblethe transfer drivengear shaftand its relatedparts.
4.
Measureand adjustthe staningtorque of the transfer drivengear shafttaperedrollerbearing.
5.
Assemblethe transfershaftand jts relatedparts.
6.
Measureand adjustthe total startingtorque.
35 mm Thrust Shim Seleqtion 1.
Selectthe 35 mm thrust shim if the transferdriven gearshaftor the taperedrollerbearingon the transfer drivengear shaft is replaced.
A: EXISTINGTRANSFER DRIVENGEARSHAFT
B: REPLACEMENT TRANSFER DRIVENGEAFSHAFT
'x- = A - B - .100 100 2 - 1 '100 100 = 0.02+ 0.01+ 1.05 -'1.08(mm) S e l e c t3 5 m m t h r u s t s h i m t h i c k n e s so t ' 1 . 0 8m m (0.043in). lf the taperedrollerbearingon the transfer drivengear shaftis replaced. M e a s u r et h e t h i c k n e s so f t h e r e p l a c e m e nbt e a r i n g and the existingbearing,and calculatethe difference of the bearingthickness.Adjust the thicknessof the existing35 mm thrust shim by the amount of differencein bearingthickness.and selectthe replacement 35 mm thrustshim. Do not use more than one 35 mm thrustshim to adjustthe transfergear backlash, THRUSTSHIM.35 mm
C a l c u l a t teh e t h i c k n e s so f t h e 3 5 m m t h r u s ts h i m usingthe formulabelow.
ronrvruu:fi--fr-+c=x A: Numberon the existingtransferdrivengearshaft B: Numberon the replacement transferdriven gear shaft C: Thicknessofthe existing35 mm thrustshim X : T h i c k n e s sn e e d e df o r t h e r e p l a c e m e n3t 5 m m thrustshim
Shim No.
B
c E F n
N O T E : T h e n u m b e r o n t h e t r a n s f e rd r i v e n g e a r shaft is shown in 1/100mm.
13-52
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Part Number 41361- PS3- 000 41362-PS3-000 41363-PS3-000 41364-PS3-000
Thickness 0.72 mm (0.028in) 0.75 mm (0.030in)
0.78 mm (0.031in) 0.81 mm (0.032in) 41365-PS3-000 0.84 mm (0.033in) 4 r 3 6 6 - P S 3 - 0 0 0 0.87 mm (0.034in) 41367-PS3-000 0.90 mm (0.035in)
4 1 3 6 8 - P S 3 - 0 0 0 0.93 mm (0.037in) 4 1 3 6 9 - P S 3 - 0 0 0 0.96 mm {0.038in) 4 1 3 7 0 - P S 3 - 0 0 0 0.99 mm (0.039in) 41371- PS3- 000
1.02mm (0.040in)
L
4 1 3 7 2 - P S 3 - 0 0 0 1 . 0 5m m ( 0 . 0 4 1i n ) 4 1 3 7 3 - P S 3 - 0 0 0 1.08mm (0.043in)
N
41374-PS3-000
1 . 1 1m m ( 0 . 0 4 4i n )
TransterGear BacklashInspectionand TransferGear Tooth Contaqt Inspection
5.
Installthe transferdriven gear shaft in the transfer housing. Do not install the transfer spacer on the transferdrivengear shaftin this step.
lnstallthe 35 mm thrust shim on the transferdriven g e a r s h a f t ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g usingthe specialtools and a press.
2.
TRANSFER HOUSING
NOTE:Use old lransferspacerfor bearinginstallation, then discardit.
6, DRIVEN TRANSFER G€ARSHAFT
Installthecompanionflange.conicalspringwasher, and locknut on the transfer driven gear shaft. Do n o t i n s t a l lt h e O - r i n ga n d t h e b a c k - u pr i n g o n t h e transfergearshaft in this step. TRANSFERHOUSING
3.
Installthe bearingouter race,then the taperedbeari n g o n t h e c o m p a n i o nf l a n g e s i d e o t t h e t r a n s f e r housing.
DRIVER 077/tg - 001qt00
OIL SEALDRIVER ATTACHMENT 07JAD- PH80101 CONICALSPRING WASHER direction.
COMPANION FLANGE
Replace.
TAPEREDROLLER BEARING
I n s t a l lt h e n e w o i l s e a l o n t h e t r a n s f e r h o u s i n g usingthe specialtools.
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(cont'd)
13-53
TransferAssembly (cont'd) Reassembly 7.
S e c u r et h e t r a n s f e rh o u s i n gi n a b e n c hv i s e w i t h soft jaws, then installthe specialtool on the companion flange. To preventdamageto the transfer housing,alwaysuse soft jaws or equivalentmaterials betweenthe transferhousingand the vise. COMPANION FLANGE HOLDER 07RAB- 0020000
9.
Installthe transfer shaft assembly in the transfer h o u s i n g ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g , t r a n s f e rs h a f t c o l l a r , 2 5m m t h r u s t s h i m , t r a n s f e r drive gear, conical spring washer, and locknut on the transfershaft. NOTE: . C o a t t h e t h r e a d so f t h e l o c k n u t ,a n d t h e s h a f t with MTFbeforeinstallingthe locknut. . Do not stakethe locknutin this step. TRANSFERSHAFT ASSEMBLY
TRANSFER
WRENCH
8.
T i g h t e nt h e l o c k n u tw h i l e m e a s u r i n gt h e s t a r t i n g torque so the starting torque is within 0.98 - 1.39 N.m {10.0- 14.2kgf.cm.8.68- 12.3lbf.in).
THRUSTSHIM. 25 mm Selectivepart COLLAR
NOTE: . C o a t t h e t h r e a d so f t h e l o c k n u t ,a n d t h e s h a f t with MTFbeforeinstallingthe locknut. . Do not stakethe locknutin this step. STARTINGTOROUE: 0.98- 1.39N.m (10.0- 14.2kgf.cm,8.68- 12.3lbf.in)
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TRANSFERDRIVE GEAR
Replace.
CONICALSPRING WASHER Replace.
Rotatethe companionflange severaltimes to seat the taperedrollerbearing.
10. Hold the transfershaft with a 14 mm Allen wrench clampedin a benchvise. TOROUEWRENCH
'14.
Set a dial indicatoron the companionflange,then measurethe transfergear backlash. - 0.006in) STANDARD: 0.06- 0.15mm 10.002 DIALINDICATOR
FLANGE COMPANION
lil mm ALLENWRENCH
NOTE: . The transfershaft locknuthasleft-handthreads, . Do not stakethe locknutin this step.
l f t h e m e a s u r e m e n ti s n o t w i t h i n t h e s t a n d a r d , removethe transfershaft locknutand replacethe 25 m m t h r u s t s h i m . S e l e c ta n d i n s t a l la n e w 2 5 m m Do not thrust shim. then recheckthe measurement. use more than one 25 mm thrust shim to adjustthe transfergear backlash,
TOROUE:118 N.m (12.0kgf.m,86.8 lbf.ft)
THRUSTSHlM,25mm
1 1 .Tightenthe transfershaftlocknut.
Temporarilyinstallthe transfercover A without the O-ring.
rl0ustNG
Shim No.
Thickness
5
6
29416-PlC-000
2 3
7 8
'10 11 TRANSFERCOVERA
Part Numbel
in 2 9 4 1 r- P 1 C- 0 0 0 1.70mm 10.067 'L73 mm (0.068in 29412-PlC-000 2 9 4 1 3 - P 1 C - 0 0 0 1.76mm (0.069in 2 9 4 1 4 - P l C - 0 0 0 1.79mm (0.070in 2 9 4 1 5 - P 1 C - 0 0 0 1.82mm (0.072in
I
12 13 l4 16 17
'18 19
1.85mm (0.073in 2 9 4 ' 1 7 - P r C - 0 0 0 1.88mm (0.074in 2 9 4 ' 1 8 - P 1 C - 0 0 01 . 9 1m m ( 0 . 0 7 5i n )
2 9 4 1 9 - P l C - 0 0 0 1.94mm (0.076in) 2 9 4 2 0 - P 1 C - 0 0 0 1.97mm 10.078in) 29421- P1C- 000 2.00mm (0.079in) 29422-P1C - 000 2.03mm (0.080in) 2 9 4 2 3 - P 1 C - 0 0 0 2.06mm (0.081in) 2 9 4 2 4 - P 1 C - 0 0 0 2.09 mm (0.082in) 29425-P'tC-000 2 . 1 2m m ( 0 . 0 8 3i n ) 2 9 4 2 6 - P 1 C - 0 0 0 2 . 1 5m m ( 0 . 0 8 5i n ) 29427-P1C-000 2 . 1 8m m { 0 . 0 8 6i n ) 2 9 4 2 8 - P 1 C - 0 0 0 2.21 mm {0.087in) 2 9 4 2 9 - P 1 C - 0 0 0 2.24 mm 10.088in)
8xL25mm 24 N.m (2.4kgt.m. 17 lbnftl
(cont'd)
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13-55
TransferAssembly (cont'dl Reassembly 16. Apply PrussianBlue to both sides of the transfer gearteeth lightlyand evenly.
19. lf the transfergear tooth contactis incorrect,adjust the transfergear tooth contactwith a 35 mm or 25 m m t h r u s ts h i m . NOTE: . To selecta 35 mm thrust shim, referto page '13.
Do not use more than one 35 mm shim to adjust the transfergeartooth contact. . To selectthe 25 mm thrust shim, refer to page 13-55. a Do not use more than one 25 mm shim to adjust the transfergeartooth contact.
TRANSFERDRIVEGEAR
1 7 . Rotatethe companionflangein both directionsuntil the transfergear rotatesone full turn in both directions. 1 8 . Checkthe transfergeartooth contactpattern. CORREST TOOTHCONTACT PATTERN
INCORRECT IOOTH CONTACTPATTERN
TOECONTACT
Toe Contact U s e a t h i c k e r3 5 m m t h r u s t s h i m t o m o v e t h e transferdriven gear shaft toward the transferdrive gear. Becausethis movement causesthe transfer gear backlashto change,move the transfer drive gear away from the transfer driven gear shaft to adjustthe transfergearbacklash asiollows; . I n c r e a s et h e t h i c k n e s so f t h e 2 5 m m t h r u s t shim. . R e d u c et h e t h i c k n e s so f t h e 6 8 m m t h r u s t shim bv the amount of increasedthicknessof the 25 mm thrustshim. Heol Contact Use a thinner 35 mm thrust shim to move the transfer driven gear shaft away from the transfer drive gear. Becausethis movement causesthe transfer gear backlashto change,move the transfer drive gear toward the transferdriven gear shaft to adjustthe transfergear backlashas follows: . R e d u c et h e t h i c k n e s so f t h e 2 5 m m t h r u s t s hi m . a I n c r e a s et h e t h i c k n e s so f t h e 6 8 m m t h r u s t shim by the amount of reducedthicknessof t h e 2 5 m m t h r u s ts h i m .
HEELCONTACT
FLANKCONTACT
FACECONTACT
13-56
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Flank Contact Use a thinner thrust shim to move the transfer drive gear toward the transferdriven gear shaft. Flankcontactmust be adtustedwithin the limits o f t h e t r a n s f e rg e a r b a c k l a s h l. f t h e b a c k l a s h e x c e e d st h e l i m i t s , a d j u s t a s d e s c r i b e du n d e r HeelContact. FaceContsct Use a thickerthrust shim to move the transfer drive gear away from the transfer driven gear shaft. Facecontactmust be adjustedwithin the limits of the transjergear backlash.lf the backl a s h e x c e e d st h e l i m i t s , a d j u s t a s d e s c r i b e d underToe Contact.
20. Removethe partson the transfershaft,and remove the transfershattfrom the transferhousinq. TRANSFERSHAFT
Removethe transterdrivengear shaftand the companionflange. Installthe new transferspaceron the transferdriv e n g e a r s h a f t ,t h e n i n s t a l lt h e m i n t h e t r a n s f e r housing.
TRANSFERDRIVEN TRANSFERHOUSING GEARSHAFT
TRANSFERSPACER Installin this direction.
TRANSFER
TAPEREDROLLER BEARING TRANSFERSHAFT COLLAR TMNSFER DRIVE GEAR
THRUSTSHIM,25 mm Selectivepart CONICALSPRING WASHER Replace.
LOCKNUT Replace. Transter Driven Gear Shaft Starting Torque Inspection and Adlustment 21. Securethe transfer housing in a bench vise with soft iaws. COMPANIONFLANGEHOLDER
25. Installthe companionflange,O-ring,back-upring, conical spring washer and locknut on the transfer drivengear shaft. NOTE: . Coatthe threadsof the locknut,O-ringand transfer shaftwith MTFbeforeinstallingthe locknut. . Installthe conicalspring washer in the direction shown. TRANSFER HOUSING
O.RING COMPANION FLANGE CONICALSPRING WASHER Replace. BACK.UP
22. I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g € ,
LOCKNUT Replace.
then removethe transferdriven gear shaft locknut and the conicalspringwasher. (cont'd)
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13-57
TransferAssembly (cont'dl Reassembly 26. Securethe transfer housing in a bench vise with soft jaws.
28. Stakethe locknutinto the transferdriven oear shaft u s i n ga 3 . 5m m p u n c h .
COMPANION FLANGE HOLDER 07RAB- 002tD00
0.7- 1.2mm (0.03- 0.05 inl PUNCH 3 . 0 - 3 . 5m m - 0.1ainl 10.12
Point to be staked.
29. Installthe transfer shaft assemblv in the transfer h o u s i n g ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g , transfer shaft collar, 25 mm thrust shim, transfer drive gear,conicalspringwasher,and transfershaft locknuton the transfershaft. 2 7 . I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g e . then tighten the transferdriven gear shaft locknut while measuringthe startingtorque of the transfer drivengearshaft.
NOTE: . Coatthe threadsof the locknutand transfershaft with MTFbeforeinstallingthe locknut. . lnstallthe conicalspringwasher in the direction snown.
STARTINGTOROUE: 0.98- 1.39N.m {10.0- 1i1.2kgf.cm,8.68- 12.3lbf in} TIGHTENINGTOROUE: 132- 216 N.m (13.5- 22.0kgf.m,97.6- 159lbf.ft) NOTE: . R o t a t et h e c o m p a n i o nf l a n g e s e v e r a lt i m e s t o seatthe taperedrollerbearing,then measurethe startrngtorque. . l f t h e s t a r t i n gt o r q u e e x c e e d s1 . 3 9 N . m ( 1 4 . 2 kgf.cm, 12.3 lbf.in), .eplacethe transfer spacer a n d r e a s s e m b l et h e p a r t s . D o n o t a d j u s t t h e torquewith the locknutloose. . l f t h e t i g h t e n i n gt o r q u ee x c e e d s2 1 6 N . m ( 2 2 . 0 kgf.m,159 lbf'ft),replacethe transferspacerand reassemble the parts. . W r i t e d o w n t h e m e a s u r e m e no t f the starting torque: it is used to measurethe total starting torque.
TMNSFER SHAFT ASSEMBLY
TRANSFERHOUSING
TAPEREDROLLER BEARING TRANSFERSHAFT COLLAR TRANSFERDRIVE GEAR
THRUSTSHIM,25 mm Selectivepart
CONICALSPRING WASHEB Replace. LOCKNUT Replace.
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30. Hold the transfershaft with a 14 mm Allen wrench clamDedin a benchvise. NOTE:The locknuthas left-handthreads.
Totsl Starting Torquo Inspoctionand Adiustment 32. Temoorarilvinstalltransfercover A without the Oring. TRANSFER HOUSING
TOROUE:118N.m (12.0kgt'm,86.8lbf'ft)
TRANSFERCOVERA
o
E
l
€ l E /Eh
v 14 mm ALLENWRENCH 5t.
c
/E\ \g
8 x 1.25 mm 24 N.m (2.4kg{ m, 17 lbtftl
Securethe transfer housing in a bench vise with soft jaws. then rotatethe companionflange several times to fit the taperedrollerbearing,
31. Stakethe locknuton the transfershaft using a 3.5 mm Dunch.
PUNCH 3.0- 3.5 mm {0.12- 0.14inl
TOROUEWR€NCH
34. Measurethe total startingtorque. TOTALSTARNNGTOROUE: - 21.2kgf.cm,15.0- 18.i1lbf inl 1.70- 2.08N.m 117.3 + Transter Driven Gear Shaft Starting Torque Value (wrot€ down in step 27).
(cont'd)
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13-59
TransferAssembly (cont'd) Reassembly 3 5 . RemovetransfercoverA.
37. Selectthe 68 mm thrustshim.
36. lf the measurementis out of specification,remove t h e 6 8 m m t h r u s t s h i m f r o m t r a n s f e rc o v e r A b y h e a t i n gt h e c o v e rt o a l m o s t2 1 2 ' F( 1 0 0 ' C )u s i n ga heat gun. Do not heat the cover higher than 212F ( 1 0 0 " C )L. e t t h e c o v e r c o o l t o r o o m t e m p e r a t u r e beforeadjustingthe startingtorque. go to lI the measurementis within the specification, step 40.
THRUSTSHIM,68 mm Shim No.
Part Number
Thickne3s
zv
23914-P1C-020
zw
23975-P1C-020 23916 PlC -020 23917-P1C-O20
1.41mm (0.056in) '1.44mm in) 10.057 '1.47mm (0.058in) 1.50mm (0.059in) 1.53mm (0.060in)
zx ZI
zz
23978-PlC-020 23941- PW5 000
E
1.56mm {0.061in) 1.59mm (0.063in) 2 3 9 4 3 - P W 5 - 0 0 0 't.62mm (0.064in) 23944 PW5- 000 1.65mm (0.065in) 2 3 9 4 5 - P W s - 0 0 0 1.68mm (0.066in)
F
23946-PW5-000
G
23947-PW5-000
23942-PWs-000
c D
HEAT GUN
K
1.71mm 10.067 in) '1.74mm in) 10.069 23948-PWs-000 1.77mm (0.070in) 2 3 9 4 9 - P W s - 0 0 0 1.80mm (0.071in) 2 3 9 s 0 - P W 5 - 0 0 0 1.83mm (0.072in) 23951- PW5- 000 1.86mm (0.073in)
L
23952-PWs-000
COVERA
1.89mm {0.074in)
2 3 9 s 3 - P W s - 0 0 0 1.92mm {0.076ini N
23954-PW5-000
o
23955-PW5-000 23956- PW5, 000
P
o R
T U
2.01mm (0.079in)
2 3 9 5 7 - P W s - 0 0 0 2.04mm (0.080in) 2 3 9 5 8 - P W s - 0 0 0 2.07mm (0.081in) 23959-PW5-000
BEARINGOUTERRACE
1.95mm (0.077in) 1.98mm (0.078in)
23960-PW5-000 23961- PW5- 000 23962-PW5-000
2.10mm (0.083in) 2.13mm (0.084in) 2.16mm (0.085in) 2.19mm (0.086n)
2 3 9 6 3 - P W s - 0 0 0 2.22 mm (0.087 n) X
23964-PWs-000
2.25mm (0.089n)
2 3 9 6 5 , P W s - 0 0 0 2.28mm 10.090n ) 23966-PW5-000
2.31mm {0.091in)
2 3 9 6 7 - P W s - 0 0 0 2.34mm (0.092in) 23968-PWs-000
AC AD
2 3 9 6 9 - P W s - 0 0 0 2.40mm {0.094in}
M BZ
cz
13-60
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2.37mm (0.093in)
AB
23970-PW5-000 23941- PW8- 000 23942-PW8-000
DZ
23943-PW8-000 23944-PW8-000
EZ
23945-PW8-000
2.43mm (0.096in) 2.46mm {0.097'n} 2.49mm (0.098in) 2.52mm {0.099ini 2.55mm (0.100in) 2 . 5 8m m ( 0 . 1 0 i2n i
3 8 . I n s t a l lt h e 6 8 m m t h r u s t s h i m u s i n g t h e s p e c i a l tools.
DRIVER 077€ - 001(xno
4 0 . C o a t t h e n e w O - r i n g sw i t h M T F , i n s t a l lt h e m o n transfercoversA and B, then installthe coverson the transferhousing.
6x1.0mm 12 N.m 11.2kgf.m, 8.7 tbt.ft)
TRANSFERCOVERB
TRANSFER
THRUSTS1{IM, 68 mm Selectivepart BEARINGOUTERBACE ATTACHMENT. 62x68mm 077a6 - (x)10500
O.RING Replace.
O.BING Replace.
39. After replacingthe 68 mm thrust shim, recheckand m a k e s u r e t h e t o t a l s t a r t i n gt o r q u e i s w i t h i n t h e soecification.
TRANSFER COVERA
8 r 1.25mm 2,r N.m (2.4 kgl.m. 17 lbtft)
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13-61
MainshaftBearing/OilSeal Replacement 1.
Removethe ball bearingusingthe specialtool.
3.
Drivethe new oil seal in from the transmissionside usingthe specialtools.
3/8" -16 SLIDEHAMMER (Commercially available)
ATTACHMENT, 12x 17 .nfi
07746- 0010300
- ,10mm PULLER.25 07736- A01000A
Drivethe new bali bearingin from the transmission side usingthe specialtools. 2.
Removethe oil sealfrom the clutchhousing.
ATTACHMENT. 62x68mm 07746- 0010500
BALLBEARING
13-62
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GountershaftBearing Replacement 1.
Removethe retainingplatefrom the clutchhousing.
Positionthe oil guide plate. Drivethe needlebearingusingthe specialtools.
Replace.
CLUTCHHOUSING HETAININGPLATE
Removethe needlebearingusing the specialtool, then removethe oil guide plate.
3/8" -16 SLIDEHAMMER (Commercially available)
ATTACHMENT, 62x88mm 07746- 0t!105q)
NEEDII AEARING
CLUTCHTIOUSING
Installthe retainingplate,and stakethe bolt heads into the groovein the retainingplate
^'
ADJUSTABI.fBEARING PULLER,25- 40 mm 07736- A01(x)04
6x1.0mm 12 N.m (1.2 kgt m,8.7 lbtftl
NEEDLEBEARING
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13-63
MainshaftThrustClearance Adjustment l.
Removethe 78 mm shim and oil guide plate from the transmissionhousing.
5,
Measuredistance@ betweenthe end of the clutch housingand bearinginner race. NOTE: . Usea straightedgeand depthgauge. . Measureat three locationsand avoragethe readIngs.
78 mm SHIM
END ot CLUTCHHOUSING
BEARING
Installthe 3rd/4th synchro hub, spacer collar, sth synchrohub, spacer,and ball bearingon the mainshaft.then installthe above assemblyin the transmissionhousing. lnstallthewasheron the mainshaft. 4.
Measuredistance@ betweenthe end of the transmissionhousingand washer,
Selectthe proper 78 mm shim from the chan by usingthe formulabelow. Shim S€lection Formula:
NOTE: . Usea straightedgeand verniercaliper. . Measureat three locationsand averagethe readIng.
you made in steps4 and 5: Fromthe measurements -1. Add distance@ (step5) to distance@ (step4). -2. From this number. subtract0.93 (which is the midpointof the flex rangeof the clutchhousing bearingspringwasher).
ENDot TRANSMISSION MAINSHAFT
-3. Takethis number and compareit to the availableshim sizesin the chart. WASHER
(Forexample)
3RD/4THSYNCHROHUB SPACERCOLLAR sTH SYNCHROHUB SPACER BALLBEARING
13-64
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A: 2.39 + Bi O.22
2.61 - 0.93
=
= 1.68
2.61
Try the 1.68mm (0.0661in) shim.
7,
78 mm SHIM
c u F G H
K L M N
o
T
X z AB AD AE
AH AI AJ
AK
AN
Part Numbor 23941- P16- 000 23942-P16-000 23943-P16-000 23944-Pt6-000 23945-P16-000 2 3 9 4 6 -P 1 6- 0 0 0 23947-P16-000 23948-P16-000 23949-P16-000 23950-P16-000 23951- P16- 000 23952-Pl6-000 23953-P16-000 23954-P16-000 23955-P15-000 23956- P16- 000 23957-P16-000 2 3 9 5 8 -P 1 6- 0 0 0 23959-P16-000 23960-P16-000 23961- P16- 000 23962-P16-000 23963-P16-000 23964-P16-000 23965-P16-000 23966-Pl6-000 23967-Pl6-000 23968-P16-000 23969-Pl6-000 2 3 9 7 -0 P l 6 - 0 0 0 23971- P16- 000 23972-P16-000 23973-P16-000 23974-P16-000 23975-P16-000 23976-Pl6-000 23977-P16-000 23978-Pl6-000 23979-Pl6-000 23980-P16-000
Checkthe thrust clearancein the mannerdescribed Delow.
Thickness 1.20mm (0.0472in) 1.23mm (0.0484in) '1.26mm (0.0496in)
in) 1.29mm (0.0508 1.32mm (0.0520n ) 1.35mm (0.0531n ) 1.38mm {0.0543n ) 1.41mm (0.0555n ) 1.44mm (0.0567in) 1.47mm (0.0579in)
N O T E : M e a s u r e m e nst h o u l d b e m a d e a t n o r m a l room temperature. -1. Installthe 78 mm shim selectedand oil guide platein the transmissionhousing. 78 mm SHIM OIL GUIDEPLATE
1.50mm {0.0591in}
in) 1.53mm (0.0602 1.56mm (0.0614in) 1.59mm (0.0626in)
in) 1.62mm (0.0638 1.65mm (0.0650in) 1.68mm (0.066'tin) 1 . 7 1m m ( 0 . 0 6 7 i3n )
- 2 . I n s t a l lt h e s p r i n g w a s h e ra n d w a s h e ro n t h e
1.74mm {0.0685in) 1.77mm {0.0697inl
ball bearing.
in) 1.80mm (0.0709 in) 1.83mm (0.0720 '1.86mm (0.0732 in)
NOTE: . Cleanthe spring washer,washerand thrust shim thoroughlybeforeinstallation. . Installthe spring washer,washerand thrust shim properly.
1.89mm (0.0744in) 1.92mm (0.0756in) 1.95mm (0.0768in)
in) 1.98mm (0.0780 in) 2.01mm (0.0791 in) 2.04mm (0.0803 n) 2 . 0 7m m { 0 . 0 8 1i 5
g
2.10 mm {0.0827in}
in) 2.13mm (0.0839
WASHER
SPRTNG*ASHER
,-g
2.16 mm (0.0850in)
in) 2.19mm (0.0862 4 inl 2.22mm 10.087 in} 2.25mm {0.0886 2.28mm {0.0898 in) in) 2.31mm (0.0909 2.34mm (0.0921 in) 2.37mm (0.0933 in)
Installthe mainshaftin the clutchhousing. Placethe transmissionhousingover the mainshaftand onto the clutchhousing. - 5 . Tightenthe clutch and transmissionhousings with several8 mm bolts. NOTE:lt is not necessaryto use sealingagent betweenthe housings. Tap the mainshaftwith a plastichammer. (cont'd)
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13-65
MainshaftThrustClearance Adjustment(cont'dl -7. Slidethe mainshaftbaseoverthe mainshaft.
-12. Turn the mainshaftholder bolt clockwise;stop t u r n i n gw h e n t h e d i a l g a u g e h a s r e a c h e di t s maximum movement,The readingon the dial gaugeis the amountof mainshaftend play. NOTE:Turningthe mainshaftholderbolt more t h a n 6 0 d e g r e e sa f t e r t h e n e e d l eo f t h e d i a l gaugestopsmoving may damagethe transmission. MAGNETSTANDAASE 07979- PJ40001
DIALGAUGE
07GAJ- PG20130
-8. Attachthe mainshaftholderto the mainshaftas follows: NOTE: . B a c k - o u t h e m a i n s h a f th o l d e r b o l t a n d loosenthe two hex bolts. . Fit the holderover the mainshaftso its lip is towardsthe transmission. . Align the mainshaftholder'slip around the groove at the insideof the mainshaft splines,then tightenthe hex bolts. HOLDER MAINSHAFT BOLT
-13. lf the readingis within the standard,the clearancers correct. l f t h e r e a d i n gi s n o t w i t h i n t h e s t a n d a r d , recheckthe shim thickness. Standard:0.11- 0.18mm (0.00i1-0.007inl
t--E-H lf\f,A\ l\.
xex
l"\y I aors t____=__)"n-____"8 \ MAINSHAFT HOLDER 07GAJ- PG20110
MAINSHAFT EASE 07GAJ- PG20130 -9. Seatthe mainshaftfully by tappingits end with a plastichammer. -10. Threadthe mainshaftholder bolt in until it just c o n t a c t st h e w i d e s u r f a c eo f t h e m a i n s h a f t base. - 1 1 . Z e r oa d i a lg a u g eo n t h e e n d o f t h e m a i n s h a i t .
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MAINSHAFTHOLDER 07cru - PG20110
TransmissionAssembly Reassembly 1.
Installthe differentialassemblyin the clutch housIng.
4.
ASSEMBLY DIFFERENTIAL
'97 - 99 models: Installthe reverseidle gaar and reverse gear shaft in the clutch housing. '00 model: Installthe coller,thrust washer,reverse idler gear and the reversegear shaft in the clutchhousing.
model
THRUSTWASHER
Installthe springwasherand washerwith the angle againstthe clutchhousingas shown.
COLLER
Tape the mainshaft splines. insert the mainshaft and countershaft into the shift forks, and install them as an assemblv.
NOTE:Installthe reversegear shaft ('00 model) in the directionshown. 5.
Installthe reverseshift holderin the clutch housing with the sth/reverseshift piecepin positionedin the slot of the reverseshift fork.
5x1.0mm 15 N'm 11.5kgt.m, 11 lbf.ftl
Tapethe mainshatt splines.
REVERSE SHIFTHOLDER
(cont'd)
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13-67
TransmissionAssembly Reassembly(cont'dl 6.
Installthereverselockcam on the clutchhousing. 6x1.0mm 15 N.m (1.5kgf.m, 11 lbf.ftl
10. Apply liquid gasket (P/N 08718- 0001 or 087180003)to the selectspring bolt threads,then install the selectspringbolt. SELECTSPRINGBOLT 39 N.m la.o kgf'm,29lbtft)
LOCKCAM REVERSE
7.
l n s t a ltl h e o i l s e a l . HANDLE 07749- 001mO ATTACHMENT, 32x35mm 07745- 0010100
'I1. I n s t a l tl h e o i l g u i d e M p l a t e . 7 8m m s h i m , and oil guner platein the transmissionhousing. N O T E : S e l e c tt h e 7 8 m m s h i m a c c o r d i n gt o t h e measurements madeon page13-64,
OIL SEAL Replace.
Installthe selectlever,spring washer,and springs on the selectarm. SELECT LEVER
SELECTBETURN SPRING 5TH/REVERSE SELECTRETURN
SPRINGPIN Replace.
OIL GUIDEM PLATE
SELECT ARM 9.
Installthe s e l e ca t r m a n ds p r i n gp i n .
13-68
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12. Apply liquid gasketto the surfaceof the transmission housingas shown.
15. Lowerthe transmissionhousingwith the snap ring pliers.and set the snap ring into the groove of the countershaftbearing.
Notetheseitems: . Use liquid gasket(P/N 08718- 0001 or 087180003). . Removethe dirty fluid from the sealingsurface. . Sealthe entirecircumterence of the bolt holesto preventfluid leakage. . lf 20 minutes have passedafter applying liquid gasket,reapplyit and assemblethe housings. a Allow it to cure at least20 minutesafter assembly betorefillingthe transmissionwith MTF.
SNAPRINGPLIERS
DOWELPINS
r3. Installthe 14 x 20 mm dowel pins. 1 4 . Set the stopperring as shown. Placethe transmis-
sion housingover the clutchhousing,being careful to line up the shafts.Be sure to align the stop ring with the 5th shift fork fingertip. TRANSMISSIONHOUSING
1 6 . Checkthat the snap ring is securelyseatedin the grooveof the countershaftbearing. DimensionA as installod:3.6 - 6.3 mm (0.142- 0.2/8 in) 32 mm SEALINGBOLT 25 N m 12.5kgf.m, 18 lbf.ftl
SNAPRING
vk..*, SHIFTFORK Align point
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1 7 . A p p l y l i q u i d g a s k e t( P / N0 8 7 1 8- 0 0 0 1o r 0 8 7 1 80003)to the 32 mm sealingbolt threads,then install (cont'd) the 32 mm sealingbolt.
13-69
TransmissionAssembly Reassembly lcont'd) 18. Installtransmission hanger,then tightenthe bolts in a crisscrosspatternin severalstepsas shown. 8 x 1.25mm bolis: 27 N.m 12.8kgf.m,20 lbf'ft}
2 0 . I n s t a l lt h e s t e e l b a l l s ,s p r i n g s .w a s h e r s ,s e t b a l l screws,back-uplight switch. WASHER Replace. STEELBALL D,5/16 in
TRANSMISSION HANGER
SPRINGL.26.1mm 11.03inl
1 9 . Install flange bolt, w a s h e r s d , rainplug.and filler plug. 21. Installthevehiclespeedsensor(VSS). FILLERPLUG 4,r N.m (a.5 kgl.m,33lbtftl
VEHICI."ESPEEDSENSOR
DRAINPLUG 39 N.m {4.0kg{.m,29lbtftl WASHER Replace.
13-70
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8 x 1.25mm 22 N.m 12.2kgl.m, 16 lbt.ftl WASHER
22. Turn the selectlever and shift arm shaft counterclockwise,then insertthe shift arm shaft. EOLT INTERLOCK 39 N.m (4.0kqt ft, 29 lbf ft)
26. Installthe shift arm coverassembly.
SELECTARM SHIFTARM COVERASSEMBLY
-->.-
(
10 x 12 mft DOWELPIN SHIFTARM A
I x 1.25mm 27 N m 12.8kgtm,20 lbf'ft)
SHIFTARM SHAFT
23. Align the shift arm A groove and selectarm finger by turn the shift arm shaft and select lever clockwise.then installtheshift arm shaftassembly. Apply liquid gasket (P/N 08718- 0001 or 08718 bolt' interlock to the threads,then installthe OO03)
t1
Installthe transferassemblY. N O T E : L u b r i c a t eM T F t o t h e O - r i n g a n d c o n t a c t areas.
Apply liquid gasketto the surfaceof the shift arm coveras snown. Notetheseitems: . Use liquid gasket(P/N 08718- 0001 or 087180003). . Removethe dirtv oilfrom the sealingsurface. of the bolt holesto . Sealthe entirecircumference preventoil leakage. . lf 20 minutes have passedafter applying liquid gasket.reapplyit and assemblethe housings. a Allow it to cure at least20 minutesafter assembly betorefillingthe transmissionwith MTF.
10x 1.25mm 44 N.m 14.5kgf.m,33 lbl.ftl
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13-71
TransmissionAssembly Installation 1.
Checkthat the dowel pins are installedin the clutch housing.
5.
P l a c et h e t r a n s m i s s i o no n t h e t r a n s m i s s i o nj a c k , and raiseit to the enginelevel.
Apply greaseto the releasefork and releasebearing.
6.
Installthe transmissionmountingboltsand the rear enginemountingbolts.
{P/N 08798- 90021
{P/N 08798- 9002) 0.{ - 1.0g {0.0'l- 0.04ozl
TRANSMISSION MOUNTINGEOLT 12x 1.25mn 64 N.m {6.5 47 tbt.ft)
REARENGINEMOUNNNG BOLTS Replace. Itl x 1.5mm 8:l N.m 18.5kgt m, 61 lbf.ft)
RELEASE BEARING
(P/N 087989002)
7. RELEASE FORK BOOT
.
(P/N08798- 9002) '1.0 - 1.6g {0.0,10.06o2l ?
Installthe releasebearing,releasefork, and release fork boot to the clutchhousing. Installthe startermotor and hoseclamp. HOSE
10x 1.25mm 4{ N'm (4.5 kgf.m, 32 tbf.ftl
13-72
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Risethe transmission,then installthe transmission mount bracketand transmissionmount. T o r q u et h e m o u n t i n g b o l t s a n d n u t s i n t h e sequenceshown. . Checkthat the bushingare not twistedor offset. O . @ : 1 2x 1 . 2 5m m 64 N.m (6.5 kgf.m, 47 lbf'ft) Temporarytightening O: 1 2x 1 . 2 5m m @: 74 N.m (7.5kgf'm,54lbf.ft)
8.
Installtheright front mounvbracket. 12 x 1.25mm 64 N.m (6.5 kgf'm, 47 tbf.ftl Replace.
10. Pourtransmissionfluid of 1 literfrom the driveshaft insertedhole. 11. lnstallthe intermediateshaft {seesection18).While installingthe intermediateshaft in the differential. be sure not to allow dust and other foreignparticles to enterthe transmission.
RIGHTFRONT MOUNT/BBACKET
10r 1.25mm 39 ttm 14.0kgf.m, 29 tbt ftl
SETRING Replace.
10 x 1.25mm 4,aN.m (4.5kgf m, 33 tbf ftl Install the clutch housing cover and rear engine stiffener.
SHAFT INTERMEOIATE
1 2 . l n s t a l l t h e d r i v e s h a f t s( s e e s e c t i o n 1 8 ) . W h i l e in the differential,be sure installingthe driveshaft(s) not to allow dust and otherforeignpaniclesto enter the transmission. DRIVESHAFT
6xl0mm 12 N.m 11.2kgt.m. 8.7 tbf.ft)
HOUSING '12x 1.25mm 29 N.m 13.0kgf.m.22 lbf'ft)
8 x 1.25mm 24 N.m {2.5 kgf'm' 18 tbl.ft)
SET RING Replace.
10 x 'l .25 mm 44 N.m {4.5kgf m,33 lbf ftl
(cont'd)
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13-73
TransmissionAssembly Installation(cont'dl 13. Installthe balljoints onto the lower arms.
Installthe exhaustpipe A, then connectthe heated oxygensensor(HO2S)connector.
DAMPERPINCHBOLT 10 x 1.25mm 43 N.m {a.a kgf.m, 32 rbfft)
GASKETS Replace.
HO2SCONNECTOR
SELF.LOCKINGNUT '12x 1.25|nm 6il N'm 16.5kgtin, 47 lbtftl Reolace.
Replace.
10 x 1.25mm 5,1N.m15.5kgtm. () tbt fil Replace.
12x 1.25mm ,19- 59 N.m (5.0- 6.0kgi.m,36 - € lbfttl
SELF.LOCKING 8 x 1.25rr|ln 22 N.m (2.2 tgf.m, 16 lbl.ftl Replac6.
NUT SELF.LOCKING 8 x 1.25mm 16 N.rn 11.6kg{.m, 12lbtfr) Replace.
GASKET Replace.
1 4 . Installthe right damperfork bolt. 1 5 . Installthe propellershaft to the transferassembly by aligningthe referencemarks.
'17.
Installthe guard bar and the splash shield.
REFERENCEMARKS
E x 1.25mr'|
32 N.m 13.3kst m, 2a lbf.ftl
SPLASHSHIEI.I) I x 1.25mm 24 N.m l2.a kgf.m. 17 tbtft)
GUARDBAR
6x1.0mm 9.8 N.m (1.0 kgf.m,7.2 lbf.ft)
PROPELI"ER SHAFT
13-74
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TRANSFER
1 8 . Refillthe transmissionfluid (seepage 13-3)
21, Installthe cablebracketfrom the clutchhousing.
1 9 . Installthe four uppertransmissionmountingbolts.
8 x 1.25mm 27 N.m (2.8 kgt'm. 20 lbtftl
COTTERPIN
R€place. STEEL WASHER COTTENPIN Replace.
STEEL WASHER PLASTIC WASHER
12 x 1.25mm 6it N.m 16.5kgf m, il7 lbf.ftl
20. Connectthe vehiclespeedsensor(VSS)connector.
SELECT CABLE
22. lnstallthe shift cableand selectcableto the levers, then installplasticwashers,steelwashers,and cotter prns, )a
------------,-
Connectthe back-up light switch connector.and installthe wire harnessclamP. 6x1.0mm 9.8N.m{1.0kgf.m,
VSS CONNECTOR
HARNESSCLAMP
(cont'd)
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13-75
TransmissionAssembly (cont'dl Installation 24. Connectthe startercablesand transmissionground caore.
26. Turn the breathercap so that the "F" mark pointsat the right side of the vehicleas shown.
6x1.0mm 9.8 N.m (1.0kg{.m, 7.2 tbt.ttl
TRANSMISSION GROUND CABLE
Apply greaseto the push rod on the slavecylinder, then installthe slavecylinderand clutchhosebracket,
2 7 . I n s t a l lt h e i n t a k ea i r d u c t a n d a i r c l e a n e rh o u s i n g (seesection5),
NOTE:Use only SuperHigh Temp Urea Grease {P/N08798- 9002).
28. Connectthe positive(+) cablefirst. then the negative (-) cableto the battery.
8 x 1.25mm 22 N.m 12.2kgi-m, 16 tbr.f0
CI-UTCHHOSE BRACKET
29. Checkthe levelof the transmissionf luid. 30. Checkthe clutchoperation. 31. Shift the transmissionand checkfor smooth operation. 32. Checkthe front wheelalignment(seesectionl8).
6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 rbf.ftt
_G1
(P/N 08798- 9002)
13-76
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GearshiftMechanism Overhaul Notetheseitemsl . InsDectrubberpartsfor wear and damagewhen disassembling' . Checkthat the new cotterpin is seatedfirmly. . Be carelulnot to damagethe guide pipe when removingthe cables'
CHANGELEVERKNOS 8 N.m (0.8kgl.m, 5.8 lbf.ft)
COTTEFPIN
CABLE SELECT PLATES Replace.
WASHEB (PlN
I I
curur I
\ \"1I a,I ?-@ -.4'
-( I
Guidepipe in the
\ GUIDEPIPES
DOOI,
SHIFTCABLE PLASTICWASHER 6 x 'l.0mm 9.8 N.m {1.0 kgf.m, 7.2 lbf.ftl
(stLlcoNE GREASEI LEVERASSEMBLY 8 x 1.25mm 13 N.m 11.3kgt'm,9.4lbfft) FLOATING COLLAR
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13-77
AutomaticTransmission 14'2 . S p e c i a lT o o l s Oescription . .... 143 G e n e r aO l peration '14_6 . . .. Power Flow . . . 1 4 _15 . . . . . . S y s t e m E l e c t r o n iC control .. 14 24 H y d r a u l i cC o n t r o l .. .. . 14_29 H y d r a u l i cF l o w . . . . - . . . . . . . . . . . . .'t4'39 .. Lock'upSyslem Electrical System 14 45 ComponenlLocdlrons P C M C i r c u i l D r a g r a m( A / T C o n t r o l S v s t e m ) '97 .14-46 - . ... M o d e l . . . . . . . . . . . . . . . . . . . . . ... . . ' 9 8 M o d e .l . . . . . . . . . . . . .. . . . . . . .1450 .. .. '99 00Models.... .... 1452 . . . P C M T e r m i n a l V o l t a g e / M e a s u r i n gC o n d i t i o n s ..14'48 ...... A"/T C o n t r oSl y s t e m - ' 9 7 M o d e l 14 54 00 Models . . .. . . A , / TC o n t r o l S y s t e m - ' 9 8 ... - 14_56 ..... T r o u b l e s h o o t i nPgr o c e d u r e s. . Svmotom to comoonent Charl 14 60 . E i e c t r , c aS l yslem -'97 Model . 14_62 E l e c t r i c aS l y s t e m - ' 9 8 - O OM o d e l s . . . . . E l e c t r i c aTl r o u b l e s h o o t i n g( ' 9 7 M o d e l ) T r o u b l e s h o o t i nFgl o w a h a r t s. . . . . . . . . . . . . . 1 4 _ 6 4 E l e c t r i c aT l r o u b l e s h o o t i n g( ' 9 8 - 0 0 M o d e l s ) T r o u b l e s h o o t i nFql o w c l t " n " . . . . . . . . . - . . 1 4 - 9 3 ElectricalTroublesliooting('99 00Models) T r o u b l e s h o o t i n oF l o w c h a r t 14 131 O / D O F F I n d i c a t o rL i g h t D o e s N o t C o m e O n O / D O F F I n d i c a t o rL i a h t O n C o n s t a n t l Y . . . . 1 ! - 1 3 2 O / D O F F I n d i c a t o rL i g h t D o e s N o t C o m e O n EvenThough O/D Switch ls Pressed . .... - 14_133 L o c k u p C o n t r o l S o l e n o i dV a l v e A , / BA s s e m b l y . .14-135 Test....................-......... .ll_135 . Replacement S h i f r C o n t r o l S o l e n o i dV a l v e A y ' BA s s e m b l , . .. 14-136 T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14'136 Replacement..............L i n e a rS o l e n o i dA s s e m b l Y T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . .. .. .. .. . . . . .. . . .1 4 _ 1 3 7 14138 .. . Replacement M a r n s h a f t l c o u n t e r s h a fSl p e e d S e n s o r s 14_138 ...-... Replacement A/T Gear Position Switch . .. 14-139 T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . .1. .4. .- .1. 4 0 Replacement A/T Gear Position l n d i c a t o r '97 .. 9 8 M o d e l s . . . . . . . . . . . . . . . _ . . . . . . .t.4. .1. .4. 2 Input Test'99 0 0 M o d e l s . . . . . . . . . . . . . . . . . . . . . . . .1. .4. -. 1. .4. .3. . Input Test I n t e r l o c kS y s t e m I n t e r l o cC k o n t r o l U n i tl n p u t T e s t .- . . . . . - . . . . . . . - 1 4 1 4 4 * K e y I n t e r l o c kS o l e n o i dT e s t . - . . . . . - . . . . . . . . 1 4 _ 1 4 6 * S h i f t L o c k S o l e n o i dT e s t . . . . . . . . . . . . . . -. ..-... . . . . . . . 1 4 1 4 7 * S h i f t L o c k S o l e n o i d R e p l a c e m e n t . . . . .. . . . . . 1 4 1 4 8 * park pin Switch Test . . . . . . . .1. 4 1 1 9 ' Park Pin Switch Replacement - '97 - 98 Models . . . . . . .1 4 - 1 5 0 * Park Pin Swirch/Over Drive (O/Di Switch '99-00Models 14_151 . .. Replacemenl o v e r - D r i v e ( O / D )S w i t c h { ' 9 9 0 0 [ 4 o d e l s ] .......14-152 Test........_..................... Hydr.ulic System Symptom to-Component Chart H y d r a u l i cS y s t e m . . . . . . . . . . . . . . . 14 157 R o a d T e s t . . . . . . . . . . . . . -. . . . . . . .
StallSpeed T e s t. . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . FluidLevel Checking
. . . . .1 . .4 - 1 5 9 . . . . . . _ . . . . . . . . . . .1. .4. '.1. .6. 0.
Transmigrion
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14 164 I n s p e c l r o n. . . . ..,. . . . . . . . . . T r a n s f e rA s s e m b l y 14-165 Remova1,.,,,.............., 14,167 l n s t a l l a l i o n. . . . . . . . . . . . . Transmission 14-169 Removal ..., l l l u s t r a t e dI n d e x ( 4 W D ) 14'174 . End Cover/Transmissio ... .. . . .... .. 14-176 T r a n s m i s s i oH n o u s i n g. . . . T o r q u e C o n v e r t e rH o u s i n g l y ' a l v eB o d y . . - . . . - . 1 4 1 7 8 lllustrated lndex (2WD) . . . . . . .1 4 1 8 0 End Cover/Transmissio T r a n s m i s s i oH n ousing . . ... . .. .... ... 14'182 14-184 T o r q u eC o n v e n e rH o u s i n g / r ' a l vBeo d y . . . . . . End Covef . . . . . .1. 4 ' 1 8 6 R e m o v a t. . . . . . . . . . . . . . . . . . . . . . T r a n s m i s s i o nH o u s i n g .. 14_188 R e m o v a l. . . . . . . . . . . . . . . . . . . . . . Torque Convener HousingA/alve BodY . - . . . .1. 4 - 1 9 0 R e m o v a t. . . . . . . . . . . . . . . . - . . . . .
ValveEody n e p a i r. . . . . . . . . . . . . . . . . . . . . . ........... ... .. . . - . . . . . . 1 4 1 9 2 .. 1{_193 A s s e m b l .y. . . . . . . . . . . . . . . . . . . ValveCaps D e s c i i p t i o n . . . . - . . . . . . . . . . . . . . . . . . . . .. .. .. .. . . 1 4 1 9 4 . . 1 4 1' 9 5 ................... tnspeition ValveBody N4ain - ...... .. 14_196 Disassembly/lnspection/Reassemblv ValveBodY Secondarv 14 198 .. . Disassemblv4nspectron/ReassemblY Reoulator ValveBodv . 14199 bisassembtv,lnspiction/Reassemblv ServoEodv ....14'200 ... Disassembly/lnspection/Reassembly Lock'uoValveBodY . 14_201 .... Dis;ssembly/lnspection/Reassembly Mainshaft .. .. .. ..14'202 Disassembly/lnspection/Reassembly ..11_203 I n s p e c t i o.n. . . - . . . . . . . . . . . . . . SealingRings ...... ..... . 14'204 Reilaceient Countershaft .. . . . . . 11-205 Disassembly/lnspection/Reassembly D i s a s s e m b l y / R e a s s e. .m.b. .|.y. . . . . . . . . . . . . 1 4 _ 2 0 6 1 42 0 7 .... . I n s p e d r o .n. . . . . . . . . . . . . . . Onewav Clutch 11_209 Disassembly/lnspection/ReassemblY... Sub-shaft ... . .. . 14-210 Disassembly/lnspection/Reassembly o i s a s s e m b l y / R e 6 s s e.m b. l.y. . . - . . . . . . . . . . 1 4 - 2 1 1 Bearings Sub-shaft .......14'212 Replacement Clutch . . .14-213 Index.......... llfustrated .... .. .....14-216 Disassembly .... . .. .. . 14'218 Reassembfy Differential 14-222 " llfustratedIndex . ..... .14'223 Inspection Backlash .. 11-223 BearingRepiacement .. .. . . . .. ..11-2?4 CarrierReplacement Differe-ntial . .. 14'225 OifSealReplacement. lnspection. . - .. ... . - ....... .. 11'226 SideClearance HousingBearings Transmission Eearings MainshaJVCountershaft .......14221 Repfacement . . . . . . . . . ..11'224 Sub'siraltEearingReplacement HousingBearings ToroueConverter .. l4229 . MainshattEearing/OilSe6lReplacement Bfet a ; i n R g e p l a c e m e n t..... . . . . . 1 4 - 2 3 0 Countersha ControlLeverAssembly . . . . . . . .1. .4 - 2 3 0 R 6 p l a c e m e n t. . . . . . , . , R e v e r s el d l e r G e a r
............... 1 n s t a 1 | a t.i .o. n ParkStop Inspeclion/Adjustmenl TransferAssemblY lllustrated lndex
......... Disessembly T r a n s f e rD r i v e G e a r B e a r i n g Replacement T r a n s { e rD r i v e n G e s f S h a f t B e a r i n g Replacement T r a n s f e rH o u s i n g R o l l e r B e a r i n g Replacement T r a n s f e rC o v € r A B e a r i n gO u t e r R a c e Replacement T r a n s f e r H o u s i n g B e a r i n gO u t e r R a c e R e p l a c e m e n t. . . . . . - . . , , , , , . . . . .
1 42 3 1 11-231 .......14.232 ........... 14-235 11-237 11-237 14-238 $-234
11-239 14-240 Reassemblv Transmassaon ...-.. .... .14250 Beassembly C o n v e r i e r / D rPi vl a e t e. . - . . . . . . . . . . . . . . . . 1 4 _ 2 5 8 Torque Transmission .......14'259 .................. lnstatlation . . ......11-261 C o o l eFr l u s h i n g ATFCoolerHoses .......14-266 Connection.................. I Shift Lever . .. 14'261 Removal/lnstallation - '97 - 98 Models . . 14_264 Disassemblv/Reassemblv -'99 00 Models. 14-269 Disassembli/Reassemblv (O/D)SwitchWire Over'Orive C l e a r a n c e A d j u s t m -e n.t... . . . . . . . . 1 4 ' 2 7 0 ... .14'271 D e t e nSt p r i n R g e p l s c e m e. n .t - . . *ShiftCable 14'272 ....... Adiustment . 11'273 Repfacement..............
Ref.No. ^
Tool Number
Description
Oty I
BackprobeSet lVT Oil PressureGaugeSetw/Panel A,/TLow PressureGaugew/Panel AdjustableBearingPuller,25 - 40 mm
2 1 'l
@ @ @ @
07GAB- PF50101 or 07GAB- PF50100 07GAE- PG40200 or _ PG4O2OA OTGAE 07HAC- PK40102 07JAB- 001020A 07JAD- PH80101 07LAD- PW50601 07LAE- PX40100 OTMAJ- PY4O114 07MAJ- PY40120 07PAZ- 0010100 07RAB- TB4010Aor 07RAB.TB40lOB 07sAz - 001000A 07406- 0020400 07406- 0070300 07736- 4010008or 07736- A010004 07746- 0010100 07746- 0010200 07746- 0010400 07746- 0010500
Anachment,32 x 35 mm Attachment,37 x 40 mm Attachment.52 x 55 mm Attachment.62 x 68 mm
I 1 1 1
@ @ @ @
07746077460774607749-
Attachment,72 x 75 mm Driver40 mm l.D. Attachment,35 mm LD. Driver
1 1 1 I
@
07947- SD90200
tl)
@ *rar
@ @
,-o @
o
@ @ @ @ @ .--@
0010600 0030100 0030400 0010000
MainshaftHolder
PagoReferonc€ 14-181, 254
ClutchSpringCompressorBoltAssembly
1
14-216,219
HousingPuller HolderHandle Oil SealDriverAftachment Attachment,40 x 50 mm ClutchSpringCompressorAttachment Ay'TPressureHose,2210mm IVT PressureHoseAdapter SCSServiceConnector CompanionFlangeHolder
1 1 1 ,l
14-189 't4-236,242,245,246 't 4-225, 241 14-237 14-216,2't9 14-161 1 4 -1 6 1 14-57 14-236,242,245,246
1 I
1
SealDriverAftachment lf the top arm is too short,replaceit with 07SAC- pOZ01OO1. 07HAE- PL50101may be usedto substituteone of thesetools. Must be usedwith commerciallyavailable3/8"-16slide hammer.
1
14-58,157 14-161 14-161 '14-229,230 14-211, 2't2 14-231 14-239 14-212,227, 228,229,230, 238, 14-239,249 14-221,229 't 4-207 , 223,226, 237, 241 14-237,241 1+21 1, 2't2, 225,227, 228, 229, 14-230,237, 238, 239,24't, 249 't4-225
E----G
@
tvj @@@@@
14-2
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\r'
@)
@
@
Description GeneralOperation controlledunit which provides4 The Automatictransmissionis a 3-elementtorqueconverterand triple-shaftelectronically positioned with the engine' in line is The unit speedsforwardand 1 reversespeed ('97- 00)' and the front-wheel Thereare two tvoes of automatictransmissionon CR-V;the four-wheeldrive (4WD)model drive (2WD)model ('98- 00). Toroue Converter,G€ars,and Clutches The torqueconverterconsistsof a pump.turbine.and statorassemblyin a singleunit.The torqueconverteris connectedto Thesepartsturn togetheras a unit as the engineturns.Aroundthe outsideof the torqueconverteris the enginecrankshatt. a ring gearwhich mesheswith the starterpinionwhen the engineis started.The torqueconverterassemblyservesas a flywheelwhile transmittingpowerto the transmissionmainshaft. The mainshaftis in line with and the sub-shaft. The transmissionhasthree parallelshafts:the mainshaft.the countershaft, reverseand 1st gears lor 3rd,2nd,4th. and 4th clutches, 1st, 2nd. and the includes The mainshaft crankshaft. the engine the 3rd gear). includes The countershaft (3rdgear is integralwith the mainshaft,while reversegear is integralwith the 4th at its cencountershaft gears locked to the be 4th can clutchand gearsfor 3rd,2nd,4th, reverse,1st,and park.Reverseand the lst-hold includes The sub-shaft is moved. way the selector which ter, providing4th gear or reverse,dependingon clutchand gearsfor lst and 4th. Whencertaincombinations and sub-shaft. The gearson the mainshaftare in constantmeshwith thoseon the countershaft to provideE, D!, tr, tr, of gearsare engagedby the ctutches,power is transmittedfrom the mainshaftto the countershaft ('99 position models)' 00 and E position('97 98 models).and E. E, E, and E Electlonic Control The electroniccontrot system consistsof the PowenrainControl Module (PCM),sensors,a linear solenoid,and four controlledfor comfortabledrivingunderall conditions.The PCMis solenoidvalves.Shiftingand lock-upare electronically panel side. on the passenger's locatedbelowthe dashboard,underthe kick HydraulicControl The valve bodiesincludethe main valve body, the secondaryvalve body, the regulatorvalve body, the servo body, and the lock up valve body.They are boltedto the torque converterhousing.The main valvebody containsthe manualvalve, the 1-2 shift valve,the 2nd orificecontrolvalve.the CPB{ClutchPressureBack-up)valve,the modulatorvalve,the servo controlvalve.the reliefvalve,and ATF pump gears.The secondaryvalve body containsthe 2-3 shift valve,the 3-4 shift valve,the 3,4 orificecontrolvalve.the 4th exhaustvalveand the CPC(ClutchPressureControl)valve.The regulatorvalve bodv containsthe pressureregulatorvalve,the torque convertercheckvalve,the coolerreliefvalve,and the lock-upcontrol valve.The servo body containsthe servovalvewhich is integratedwith the reverseshift tork, and the accumulators The lock-upvalve body containsthe lock-upshift valveand the lock-uptiming valve.The linearsolenoidand the shift control solenoidvalveAy'Bare boltedto the outsideof the transmissionhousing,and the lock-upcontrolsolenoidvalveAy'Bis boltedto the outsideof the torque converterhousing.Fluid trom the regulatorpassesthrough the manualvalve to the feed pipesor internalhydrauliccircuit variouscontrolvalves.The clutchesreceivefluid from their respective ShiftControl Mechanism input from varioussensorslocatedthroughoutthe vehicledetermineswhich shift controlsolenoidvalvethe PCMwill actipressurizes vate.Activatinga shift controlsolenoidvalvechangesmodulatorpressure,causinga shiftvalveto move.This A and B are valves gear. solenoid The shift control a lineto one of the clutches.engagingthat clutchand its corresponding controlledby the PCM. Lock-up Mechanism ('97- 98 tn E! position(,97- 98 modets)and in E position('99 - O0models),in 3rd and 4th, and in Delpositionin 3rd ('99 pressurized models), 00 (by in 3rd (O/D) pressing O/D switchl rhe is OFF models)and in El positionwith Over,Drive fluid is drainedfrom the back of the torque converterthrough a fluid passage,causingthe lock-uppiston to be held againstthe torque convertercover,As this takesplace,the mainshaftrotatesat the same speedas the enginecrankshaft. Togetherwith hydrauliccontrol,the PcM optimizesthe timing of the lock-upmechanismThe lock-upvalvescontrolthe range of lock-upaccordingto lock-upcontrol solenoidvalves A and B, and the linear solenoid.When lock-upcontrol solenoidvalvesA and B activate,the modulatorpressurechanges.The lock-upcontrol solenoidvalvesA and B and the linearsolenoidare controlledby the PCM. {cont'd)
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14-3
Description GeneralOperation(cont'dl Gsar Selection '97 - 98 Models The shift lever has sevenpositions;El PARK,ts REVERSE, N NEUTRAL,Ell 1st through 4th ranges,lpq 1stth.ough 3rd ranges,P 2nd gear,and [ 1stgear '99 - 00 Models ,lst through The shitt lever has six positions;El PARK,E REVERSE, 4th ranges,and 1st through 3rd E NEUTRAL.E (whenOver-Drive(O/D)is OFF)ranges.@ 2nd gear,and E 1stgear. Position
Description
tll PARK t!!l l|EvEn>E
Reverse;reverseselectorengagedwith countershaftreversegear and 4th clutch locked.
E NEUTRAL
Allclutches released.
('97- sB) Ell DRrvE ('ss- oo) E DRrvE (1stthrough 4th)
Generaldriving;startsoff in 1st,shifts automaticallyto 2nd, 3rd, then 4th, dependingon vehiclespeed and throftle position.Downshiftsthrough 3rd,2nd, and lst on decelerationto stop. The lock-upmechanismoperates;n3rd and 4th gear.
E DRrvE {'97- s8) with overO DRTVE Drive(O/D) isOFF ('99- 00)
used for rapid €ccelerationat highway speeds and general driving; stans off in 1st, shifts automaticallyto 2nd_then 3rd, dejending on vehiclespeedand throttleposition.Downshiftsthroughlower gearson decelerationto stop.The lock-upmechanismcomesinto operationin 3rd gear.
E SECOND
Driving in 2nd_gear;stays in 2nd gear,does not shift up and down. For engine brakingor bettertrac_ tion startingoff on loose or slipperysurfaces.
E FIRST
Driving in 1st gear;stays in 1st gear,does not shift up. For engine braking.
(1stthrough3rd)
Startingis possibleonly in @ and @ positions.usinga slide-type.neutral-safety switch. Automatic Transaxle(A/T) Gear Position Indicator This indicatorin the instrumentpanelshowswhich gear has beenselected. Transler Mochanism {4WD} The transfermechanismconsistsof the transfershaftdrivegear.the transfershaft.the transferdrivegear,the transferdriven gear shaft,and the companionflange,The transfermechanismassemblyis on the rearside ot the transmission. beside the differential. The transfershaftdrivegearon the final drivengeardrivesthe transfershaftdrivenqear.poweris transmitted to the reardifferentialvia the transfershaftand the Drooellershaft. Clutches The four-speedautomatictransmissionuses hydraulically-actuated clutchesto engageor disengagethe transmissiongears. When the hydraulicpressureis introducedinto the clutch drum, the clutch piston moves.This pressesthe friction discs and steel platestogether,lockingthem so they don't slip. Power is then transmiftedthrough the engagedclutch pack to its hu$ mountedgear.When hydraulicpressureis bled from the clutchpack,the piston releasesthe friction discsand steelplates,and they are free to slide pasteachother.This allowsthe gearto spin independentlyon its shaft,transmittingno power. lst Clutch The 1stclutchengages/disengages lst gear,and is locatedat the end ofthe mainshaft,just behindthe end cover. The 1stclutchis suppliedhydraulicpressureby its ATFfeed pipewithin the mainshaft. lst-hold Clutch The 1st-holdclutchengages/disengages 1st-holdor E position,and is locatedat the middleof the sub-shaft.The 1st-hold clutchis suppliedhydraulicpressureby its ATF feed pipewithin the sub-shaft. 2nd Clutch The znd ciutchengages/disengages 2nd gear,and is locatedat the middleof the mainshaft.The 2nd clutchis joined backto-backto the 4th clutch.The 2nd clutchis suppliedhydraulicpressurethroughthe mainshaftby a circuitconnectedto the internalhydrauliccircuit.
14-4
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3rd Clutch oppositethe end cover.The 3rd 3rd gear,and is locatedat the end of the countershaft, The 3rd clutchengages/disengages clutchis suppliedhydraulicpressureby its ATFfeed pipewithin the countershaft. ilth Clutch 4th gear,as well as reversegear,and is locatedat the middleof the mainshaft.The 4th The 4th clutchengages/disengages joined clutch.The 4th clutchis suppliedhydraulicpressureby its ATFfeed pipewithin the to the 2nd back-to-back clutchis mainshaft. One-way Clutch The one-wayclutchis positionedbetweenthe parkgear and the countershaft1stgear,with the parkgear splinedto the countershaft.The countershaft1st gear providesthe outer race surface,and the park gear providesthe inner racesurface The one,way clutch locks up when power is transmittedfrom the mainshaftlst gear to the countershaft1st gear. The 1st pt, E, or E position The one-way clutchand gearsremainengagedin the 1st,2nd, 3rd, and 4th gear rangesin the lo], in the or E position' applied are [d, E, or 4th clutches/gears lor, clutchdisengageswhen the 2nd, 3rd, the locking"speedrange" of the gears over-ride on the countershaft of the rotational speed increased because the This is one-wavclutch.The one-wavclutchfree-wheelswhen the lst clutchis engaged 2NOCLUTCH
lST.HOLD CLUTCH
4TH CLUTCH
1STCLUTCH
MAINSHAFT 3RDCLUTCH
COUNTERSHAFT
TRANSFER SHAFTDRIVE GEAR ONE.WAYCLUTCH TRANSFER ASSEMBLY
OUTSIDEOF ONE.WAY CLUTCH INSIDEOF ONE.WAY CLUTCH Splined with countershaft
N O T E :T h e i l l u s t r a t i o ns h o w s t h e 4 W D a u t o m a t i ct r a n s m i s s i o n{ s e c t i o n avl i e w ) t h e 2 W D t r a n s m i s s i o nd o e s n o t h a v e a transferassemblyand transfershaft drive gear on the differentialassembly. www.emanualpro.com
-
LOCKINGCONDITION
The sprags engage/ disengage outside and inside of the
OVER.RIOING LOCKINGSPEEDCONOITION
14-5,
Description PowerFlow
*N E E N 1ST
Fi
2ND
or
3RD
E
4TH
tr
TOROUE
1ST.
1STGEAR 2ND GEAR 3RDGEAR
4TH REVERSE PARK coNHOLD 1ST 2ND 3RD GEAR VERTER CLUTCH CLUTCH CLUTCH CLUTCH GEAR CLUTCH
o o o o o o o
o
o*, o*,
o o
o*1
o
o*1
'tsT
o
o"
2ND OverDrive (o/D) 3RD is OFF
o
o*1
o
o*r
o o
o*r
or
o
X
o
E
tr tr
o
o o o
o
O: Operates, x: Doesn'toperate. * 1:Althoughthe 1stclutchengages,drivingpower is not transmittedas the one_wayclutchslips. *2: The one-wayclutchengageswhen accelerating. and slipswhen deceleraung. NOTE:p! and Ipj positionsare on the '97 - '98 models;El positionis on the ,99- OOmodels.
14-6
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o
E Po3ition Hydraulicpressureis not appliedto the clutches.Poweris not transmittedto the countershaft. The countershaft is lockedby the parkpawl interlockingthe parkgear, E Position Enginepower transmittedfrom the torque converterdrivesthe mainshaft.but hydraulicpressureis not appliedto the The countershaft4th gear is engagedwith the reverseselectorhub clutches.Poweris not transmittedto the countershaft. and the countershaftby the reverseselector,when the shift lever is shiftedin E positionfrom E or E position.The countershaftreversegear is engagedwhen shiftedfrom E position. NOTE;The illustrationshows the 4WD automatictransmission;oower flow of the 2WD automatictransmissionis identical to the 4WD exceDtfor oarts relatedto the transfer assemblv.
PARKGEAR
SELECTOR
COUNTERSHAFT REVEBSEGEAR
(cont'd)
www.emanualpro.com
14-7
Description Power Flow (cont'dl E Position In E position,hydraulicpressureis appliedto the lst clutchand the lst-holdclutch. The powerflow when accelerating is as follows: 1. Hydraulicpressureis appliedto the lst clutchon the mainshaft,and power is transmittedvia the 1stclutchto the mainshaft 1stgear. Hydraulicpressureis also appliedto the lst-hold clutchon the sub-shaft.Powertransmittedto the mainshaft1st gear is conveyedvia the countershaft1st gear to the one-wayclutch,and via the sub-shaft1st gear to the 1st-holdclutch. The one-wayclutchis usedto drivethe countershaft, and the 1st-holdclutchdrivesthe countershaft via the 4th gears. Poweris transmittedto the final drive gear,which drivesthe final drivengear,and the transfershaftdrive gear (4WD), 4. The transfershaftdrive geardrivesthe transfershaftand the transferdrivengearshaft(4WD).
NOTE;The illustrationshowsthe 4WDautomatictransmissjon; powerflow ot the 2WDautomatictransmissionis identical to the 4WDexceptfor partsrelatedto the transferassembly. TOROUE CONVERTER
SUB.SHAFT4TH GEAR
SU8-SHAFT1STGEAR
lST.HOLDCLUTCH SUB.SHAFT
1STGEAR
lST CLUTCH
COUNTERSHAFT
ONE.WAYCLUTCH FINALDRIVE GEAR PARKGEAB
COUNTERSHAFT 4TH GEAR FINALDRIVENGEAR TRANSFERSHAFTORIVEGEAR{4WD} TRANSFERSHAFT{4WD}
14-8
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TRANSFERDRIVENGEARSHAFT{4WD)
E Position is as follows: The powerflow when decelerating trom the road surfacegoesthroughthe tront wheels(and rearwheels:4WD)to the final drive gear. L Rollingresistance then to the sub-shaftlst gearvia the 4th gear.and 1st-holdclutchwhich is appliedduringdeceleration. 2 . The one-wayclutchis free becausethe applicationof torque is reversed. J.
The counterforceconveyedto the countershaft4th gear turns the sub-shaft4th gear via the mainshaft4th gear.Since hydraulicpressureis also appliedto the 1st clutch.counterforceis also transmittedto the mainshaft.As a result, enginebrakingcan be obtainedwith'lst gear. powerflow of the 2WDautomatictransmissionis identiNOTE:The illustrationshowsthe 4WDautomatictransmission; cal to the 4WD excepttor parts relatedto the transfer assembly. lST.HOLDCLUTCH SUB.SHAFT1STGEAR TOROUECONVERTER
SUB.SHAFT {TH GEAR MAINSHAFT lST GEAR
lST CLUTCH MAINSHAFT
COUNTERSHAFT
FINALDRIVEGEAR HUB SELECTOR REVERSE
SELECTOR REVERSE COUNTERSHAFT IITHGEAR FINALORIVENGEAR TRANSFERSHAFTDRIVEGEAR{4WDI TRANSFEBSHAFT{{WD)
{cont'd}
TRANSFERDRIVENGEARSHAFT{,lWDl www.emanualpro.com
14-9
Description PowerFlow lcont'd) lst Gear(8. E or E positionl In E, E, or D position, the optimumgearis selected from 1st,2nd,3rd,and4thgears,according to conditions suchas the balancebetweenthrottle opening (engineload) and vehicle speed. 1. Hydraulicpressureis appliedto the 1st clutch,which rotatestogetherwith the mainshaft,and the mainshaft1st gear rotates. 2. Poweris transmittedto the countershaft1stgear.which drivesthe countershaft via the one-wayclutch. 3. Poweris transmittedto the final drive gear.whichdrivesthe final drivengearand the transfershaftdrive gear (4WD). 4. The transfershaftdrive geardrivesthe transfershaftand the transferdrivengearshaft(4WD). NOTE: o In @, @, @, or E position.hydraulicpressureis not appliedto the 1st-holdclutch. . The illustrationshowsthe 4WD automatictransmission;power flow of the 2WD automatictransmissionis identical to the 4WD exceptfor parts relatedto the transfer assembly. CONVERTER
MAIiISHAFT 1ST
CLUTCH
MAINSHAFT
COUNTERSHAFT FINALOBIVEGEAR ONE.WAYCLUTCH
PARKGEAR
FINALDRIVENGEAR TRANSFERSHAFTDRIVEGEAR{4WD}
14-10
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2nd cesr (8, E. E, or E positionl 1. Hydraulicpressureis appliedto the 2nd clutch,which rotatestogetherwith the mainshaft,and the mainshaft2nd gear rotales. 2. Power is transmitted to the countershaft2nd gear, which drives the countershaft 3. power is transmittedto the final drive gear,which drivesthefinald rivengearand the transfershaftdrive gear (4WD) 4. The transfershaftdrive gear drivesthe transfershaftand the transferdrivengearshaft(4WD). NOTE: . Hvdraulicpressureis also appliedto the 1stclutch,but sincethe rotationspeedof 2nd gear exceedsthat of lst gear. powerfrom 1stgear is cut off at the one-wayclutch. . The illustrationshowsthe 4WD automatictransmission;power flow of the 2WD automatictransmissionis identical to the 4WD exceptfor parts relatedto the transfer assembly. CLUICH
TOROUE
COUNTERSHAFT
FINALORIVEGEAR
2NO GEAR
FINALDRIVENGEAF TRANSFERSHAFTDBIVEGEAR{4WD} TRANSFERSHAFT{4WDI
(cont'd)
TMNSFER DRIVENGEARSHAFT(4WD) www.emanualpro.com
14-11
Description PowerFlow (cont'd) 3rd Gear {8. @, or @ position) 1. Hydraulicpressureis appliedto the 3rd clutch.Powerfrom the mainshaft3rd gear is transmittedto the countershaft 3rd gear. 2. Poweris transmiftedto the final d rive gear,wh ich d rivesthe f inal drivengearand the transfershaftdrive gear(4WD). 3, The transfershaftdrive geardrivesthe transtershaftand the transferdrivengearshaft (4WD). NOTE: . Hydraulicpressureis also appliedto the 1stclutch,but sincethe rotationspeedof 3rd gear exceedsthat of 1stgear, powerfrom lst gear is cut off at the one-wayclutch. . The illustrationshowsthe 4WD automatictransmission;Dowerflow of the 2WD automatictransmissionis identical to the 4WDexceptfor partsrelatedto the transferassembly. CONVERTEF MAINSHAFT3RDGEAR
COUNTERSHAFT
COUNTERSHAFT 3ROGEAR 3RDCLUTCH DRIVENGEAR SHAFTDRIVEGEAR(4WO) TRANSFERSHAFT(,lwDl TRANSFERORIVENGEANSHAFT(4WD)
14-12
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4th Goar (E or D positionl 1. Hydraulicpressureis appliedto the 4th clutch,which rotatestogetherwith the mainshaft,and the mainshaft4th gear rotates, 2. Poweris transmittedto the countershaft4th gear,which drivesthe countershaft. 3. Poweris transmiftedto the f inal d rive gear,which drivesthe finaI drivengearand the transfershaftdrive gear (4WD). 4. The transfershaftdrive gear drivesthe transfershaftand the transferdrivengearshaft {4WD). NOTE: . Hydraulicpressureis also appliedto the 1stclutch,but sincethe rotationspeedof 4th gear exceedsthat of 1stgear, powerfrom 1stgear is cut off at the one-wayclutch, . The illustrationshowsthe 4WOautomatictransmission;power flow of the 2WD automatictransmissionis identical to the 4WD except for parts relatedto the transfer assembly. ilTH GEAR
TOROUE CONVERTER .TH CLUTCH
COU'{TERSHAFT
HUB SELECTOR REVERSE
REVERSE SELECTOR
FINALDRIVENGEAR TRANSFEBSHAFT DRIVEGEAB I'WD) TNANSFERSHAFTI4WDI
{cont'd)
TMNSFER DRIVENGEARSHAFT(4WDI www.emanualpro.com
14-13
Description PowerFlow (cont'dl E position 1. Hydraulicpressureis switched by the manual valve to the servo valve, which movss the reverseshift fork to the reverseposition,The reverseshift fork engageswith the reverseselector,the reverseselectorhub, and the countershaft reversegear. 2. Hydraulicpressureis also appliedto the 4th clutch. Power is transmittedfrom the mainshaftreversegear via the reverseidler gear to the countershaftreversegear. 3. Rotationaldirectionofthe countershaftreversegear ischangedviathe reverseidlergear. 4. Poweris transmittedto the final drivegear,whichdrivesthefinald rivengear and the transfershaftdrive gesr (4WD). 5. The transfershaftdrive geardrivesthe transfershaftand the transferdrivengearshaft (4WD). NOTE:The illustrationshows the 4WD automatic.transmission; power flow of the 2wD automatictransmissionis identical to the 4WD exceptfor partsrelatedto the transferassembly. REVERSE MAINSHAFT
TOROUECONVERTER
COUNTERSHAFT REVERSE IDLER GEAR
FINALORIVE
COUNTERSHAFT REVERSE GEAR
REVERSESEITCTOR HUB REVERSESELECTOR FINALOBIVENGEAR
REVEBSC SHIFT FORK
TRANSFERSHAFTDRIVEGEAR {4WD) TRANSFERSHAFT{4WD) TRANSFERDRIVENGEARSHAFTI4WD}
14-14
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SERVOVAI-VE
ElectronicControlSystem The electroniccontrolsvstemconsistsof a PowertrainControlModule(PCM),sensors,a linearsolenoid,and four solenoid valves.Shiftingand lock-upare electronically controlledfor comfortabledriving under all conditions.The PCMis located side. belowthe dashboard,underthe kickpanelon the passenger's '97 - 98 Mod€ls
Throttl€ Poshion Sensor Signal
VehicleSp.ed Sensor Signal PGM.FI Control Sy3t6m
EnginoCoolantTampereture SonsorSignrl
ServiceCheckconnector
A/T Control Sy3tem INTERLOCK CONTROLUNIT
Shift Control Solenoidvalve A
r
R
Shift Cont.ol
Shift Control SolenoidValve B
N Linear Solenoid
Dr Ds Lock-upControl
2
Lock-upConirol Sol6noidvalvo B
1
M.inshaft SpoedSensor Signel
-D! Indicator Light
Selt-Oiagnosbsignel
Lock-upControl SolenoidValve A
Il -
Sell-Diagnosis Function
Count€rahaftSpeed sensorSignel
{cont'd)
www.emanualpro.com
14-15
Description ElectronicGontrolSystem(cont'd) '99 - 00 Models
PCM Throttle Position Sensor Signel
VehicleSpeedSensor Signal PGM.FI Control System
Engin€Coolsnt Tomperature Sen30rSignal
Service Ch€ck Connectol
A/T Control Svstem INTERLOCK CONTROLUNIT
Shift Conlrol SolenoidValve A
r
R
Shift Control
Shift Control SolenoidValve B
N Linear Solenoid
D 2 Lock-upControl
1
Lock-upControl SolenoidValve B
Over-Drive Switch Signal
Mainshaft SpeedSensor Signal
E Indicator Light
Selt-OiagnosisSignd
Lock-upControl Solenoidvalve A
Self-Diagnosis Func{ion
CountershaftSpeed SensorSigntl
O/D OFF Indicetor Light
14-16
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Shift Control The PCMdetermineswhich gear should be selectedby varioussignalssent from sensors,and actuatesthe shift control solenoidvalvesA and B to controlshifting.Also.a GradeLogicControlSystemhas beenadoptedto controlshiftingin E anOE ('gZ- gg),and E ('99- 00) positionwhile the vehicleis ascendingor descendinga slope,or reducingspeeo. Position
E, E, Or
E E orE
a
tr
Gear
Shift Control Solenoid Valve A
Shift Control Solonoid Valve B
'Ist
OFF
ON
2nd
ON
ON
3rd
ON
OFF
4th
OFF
OFF
2nd
ON
ON
1st
OFF
ON
Reverse ON E*See page 14-37for reverseinhibitorcontroldescription.
OFF
Lock-upControl From sensor input signals,the PCM determineswhether to turn the lock-upON or OFF,and activateslock-upcontrol solenoidvalveA and/orB accordingly.Lock-updoes not occur until the engineis warm. The combinationof driving signalsto lock-upcontrolsolenoidvalvesA and B and the linearsolenoidpressureis shown in the table below. Lock-upControl Solonoid Valve A
Lock-upControl Solenoid Valve B
LinearSolenoid Pressuro
LOCK-Up \Jrr
OFF
OFF
High
Lock-up,Half
ON
Dutyoperation OFF- ON
Lock-up,Full
ON
ON
Hish
Lock-up duringdeceleration
ON
Dutyoperation OFF- ON
Low
Lock-upConditions
(cont'd)
www.emanualpro.com
14-17
Description ElectronicControlSystem(cont'dl Grade Logic Control System How it works: The PCMcomparesactualdrivingconditionswith memorizeddrivingconditions,basedon the inputfrom the vehiclespeed sensor,the throttlepositionsensor,the barometricpressuresensor('98model).the enginecoolanttemperaturesensor,the brakeswitch signal,and the shift lever positionsignal,to controlshiftingwhile the vehicleis ascendingor descendinga slope,or reducingspeed.
SIGNALSDETECTED
Judgemont ot Controlling Aroa Driving Rcsisl.nce
. . . .
14-14
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Normal Modo {Flrt ro.d mode} AscendingMode DeacendingMode DecelerationMode
AscendingControl {37 Modol} When the PCMdeterminesthat the vehicleis climbinga hill in E] and E positions,the systemextendsthe engagement area of 2nd g€ar and 3rd gear to preventthe transmissionfrom frequentlyshifting between2nd and 3rd gears,and between 3rd and 4th gears,so the vehicle can run smooth and have more power when needed. NOTE: . Shift schedulesstored in ths PCM between 2nd and 3rd gears, and between 3rd and 4th gears. enable the PCM'sfuzzy logicto automaticallyselectthe most suitablegearaccordingto the magnitudeof 8 gradient. t Fuzzylogic is a form of artificialintslligencethat lets computersrespondto changingconditionsmuch like a human mind would. 2ND- 3RD
ASCENoINGMODE:UFhift Sch.dulc
3RD - tlTH
. FLATROADMODE
-
-----------. : GRADUAL ASCENDING MODE o 5 l )
- - - - - : STEEPASCENDING MODE SHIFTINGCHARACTERISTICS FN1NS : 2ND-3RD CONTROLAREA
F
SHIFTINGCHARACTER|SnCS 7,.,.7a | 3RD-aTH CONTROLAREA
62 mph 1100km/h)
Vehicle .o..d
AscondingConirol ('98 - 00 Mod.ls) When the PCMdeterminesthat the vohicleis climbinga hill in E] and E positions('98 model),and in E] position('9900 models),the system extendsthe engagementsrea of 2nd gear and 3rd gear to prevent the transmissionfrom frequently shifting between 2nd and 3rd gears, and between 3rd and 4th gears, so the vehicle can run smooth and have more power when needed. NOTE: Shift schedulssstored in the PCM between2nd and 3rd gears, and between3rd and 4th gears,enable to selsct the most suitablegear accordingto th6 magnitudeof a gradi€nt. 2ND + 3RD 3RD+ 4TH
ASCENDINGMODE:Up.hift Sch.dul.
8 5 0 : 2ND-3RDSXImNG CHARACTERISTICS GoNTRoLAREA VVVVVZ:IRD-ITHSHIFnNGCHARACTERISTICS cot{TRoL AREA NN -
o
6:l mph 11fl)km/hl
Vahicl. sDctd
(cont'd)
www.emanualpro.com
14-19
Description ElectronicControlSystem(cont'd) DescendingControl When the PCMdeterminesthat the vehicleis going down a hill in E and @ positions('97- 98 models).and in @ position {'99 - 00 models),the shitt-upspeedfrom 3rd to 4th gear and from 2nd to 3rd (whenthe throttleis closed)becomes fasterthan the set speedfor flat road drivingto widen the 3rd gear and 2nd gear drivingareas.This, in combinationwith engine brakingfrom the decelerationlock-up,achievessmooth drivingwhen the vehicleis descending.Thereare three descendingmodeswith different3rd gear drivingareasand 2nd geardrivingareasaccordingto the magnitudeof a gradient storedin the PCM.When the vehicleis in 4th gear,and you are decelerating when you are applyingthe brakeson a steep hill, the transmissionwill downshiftto 3rd gear,When you accelerate, the transmissionwill then returnto higher gear. 2ND - 3RD
3RD- 4TH
DESCENDING MODE:Downshift Schodule
-
: FLATROADMODE
----'-----' I GRADUALDESCENDING MODE o 5 0
- - - - - : MEDIUMOESC€NOING MODE .
F
62mph km/hl 1100
.
... : STEEPDESCENDING MODE
Vehiclesp€ed
DecelerationControl When the vehiclegoes arounda corner,and needsto deceleratefirst and then accelerate, the PCMsetsthe datafor deceleration control to reducethe number of times the transmissionshifts.When the vehicle is deceleratingfrom speedsabove 27 mph (4i| km,ih),the PCMshiftsthe transmissionfrom 4th to 2nd earlierthan normalto cope with upcomingacceleration,
14-20
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CircuitDiagramand TerminalLocationsr9TModel IGNITIONSWITCH
LOC( UPCONTROL
LOCK UPCONTROL B SOLEITOIDVALVE
sf Frc0|lltF0L SOLENOIDVALVE A
sHrFr c0r{TnoL
VALVEB SOLEI{OID
UNEASSOLINOID
www.emanualpro.com
14-21
Description ElectronicControl System (cont'd) CircuitDiagramand TerminalLocationsrgS Model
GNTIONSWITCN
LOCK-UPCONIFOL SOLEIIO D VALVEA
LOCK-UPCONTSOL SOLEI.IO 0 vALvEB
SBIFICONTROL A SOLEI€DVALVE
SHFTCONTFOL SOLEiDIDVALVE8
LIN€AASOL€iDID GNIION SWTCH tGr
14-22
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Circuil Diagram and Terminal Locations-'gg- 00 Models
GN'IONSWITCN
pG2
LOC(UPC,ONTROL SOLEIDD VALVEA
IGPI IGP2
vcc2
LOCK.UPCON'IFO! SOLENOIOVALVE B
SNIFTCONTAOT VALVEA SOL€NOID
SH]FTCONTROL
vArvE B solEtiroro
L NEAFSOLEI{OIO
rGNloNSWrlCH GI
PCM Conn€clor Tehrial Loaabm
www.emanualpro.com
14-23
Description HydraulicControl The hydrauliccontrolsystemis controlledby the ATF pump,valves,accumulators, and electronically controlledsolenoids. The ATF pump is driven by splineson the end of the torqueconverterwhich is aftachedto the engine.Fluidfrom the ATF pump flows throughthe regulatorvalveto maintainspecifiedpressure,throughthe main valve body,to the manualvalve, directingpressureto each clutch.The valve body includesthe main valve body, the regulatorvalve body, the lock-up valve body,the secondaryvalve body,the servo body,the linearsolenoid,the shift controlsolenoidvalveAy'Bassembly, a n d t h e l o c k - u pc o n t r o ls o l e n o i dv a l v e A / B a s s e m b l yT. h e s h i f t c o n t r o ls o l e n o i dv a l v eA , / Ba s s e m b l ya n d t h e l i n e a r solenoidare boltedon the outsideof the transmissionhousing.The lock-upcontrolsolenoidvalveA,/Bassemblyis bolted on the outsideof the torqueconverterhousing. SHIFTCONTROL SOLENOIDVALVEA/B ASSEMBLY
LINEAR
N
REGULATOR VALVEBOOY
VALVE SECONDARY BODY
VALVEBODY
SOLENOIDVALVEA/B ASSEMELY
14-24
www.emanualpro.com
ATF PUMPGEARS
Main Valve Sody The main valve body housesthe manualvalve,the 1-2shift valve.the 2nd orificecontrolvalve.the CPBvalve,the modulator valve.the servo controlvalve.and the reliefvalve.The primaryfunctionsof the main valve body are to switchfluid pressureon and off, and to controlthe hydraulicpressuregoing to the hydrauliccontrolsystem. CP8 VALVE
2ND ORIFICE CONTROL VALVE
MODULATORVALVE 1-2 SHIFTVALVE
RELIEFVALVE
MANUAL VALVE
MAIN VALVE BOOY
SERVOCONTROIVALVE
Secondaryvalve Body The secondaryvalve body is locatedon the main valvebody,The secondaryvalvebody housesthe 2-3 shift valve,the 3-4 shiftvalve,the 3-4 orificecontrolvalve,the 4th exhaustvalve,and the CPCvalve' 3.' SHIFTVALVE
2.3 SHIFTVALVE
.TH EXHAUSTVALVE
CPCVAL
3naORIFICECONTROL VALVE
VALVE
(cont'd)
www.emanualpro.com
14-25
Description HydraulicControl(cont'd) RegulatorValve Body The regulatorvalve body is locatedon the main valve body.The regulatorvalve body consistsof the regulatorvatve,the torqueconvertercheckvalve.the coolerreliefvalve,and the lock-upcontrolvalve.
COOLERRELIEFVALVE
Lock-upValve Body The lock-upvalvebody,with lock-upshift valveand lock-uptiming valve,is locatedon the regulatorvalvebody.
LOCK.UPSHIFTVALVE
NMINGVALVE
14-26
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RegulatorValve The regulatorvalve maintainsconstanthydraulicpressurefrom the ATF pump to the hydraullccontrolsystem,while also furnishingfluid to the lubricatingsystemand torque converter.Fluid from the ATF pump flows through B and B'. Fluid enteringfrom B flows throughthe valveorificeto the A cavity.This pressureof the A cavitypushesthe regulatorvalveto the right side. and this movementof the regulatorvalve uncoversthe fluid port to the torque converterand the relief valve. The fluid flows out to the torque converterand the relief valve, and the regulatorvalve moves to the left side. Accordingto the levelof the hydraulicpressurethrough B, the positionof the regulatorvalvechangesand the amountof fluid from B,throughthe torqueconverteralsochanges.This operationis continued,maintainingthe line pressure. "|eft" or "right" indicatesdirectionon the illustrationbelow. NOTE;When used, ENGINERUNNING
ENGINENOT RUNNING
To TOROUECONVERTER Lubtication STATORSHAFTABM
Stator ReactionHydraulic PressursControl in hydraulicpressureaccordingto torqueare performedby the regulatorvalve usingstatortorque reaction.The Increases statorshaft is splinedto the stator in the torque converter,and its arm end contactsthe regulatorspring cap When the or climbing(TorqueConverterRange),statortorque reactionactson the statorshaft,and the stator vehicleis accelerating pushes springcap in the directionof the arrow in proportionto the reaction.The statorreactionspring regulator the arm and the regulatorvalve movesto increasethe line pressure.Line pressurereachesits maximum when the compresses, statortorque reactionreachesits maximum. TOROUECONVERTER VALVE REGULATON
STATORREACTION
TOR SPRINGCAP
STATON
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STA
SHAFT
ATOF SHAFTARM
(cont'd)
14-27
Description HydraulicControl(cont'd) Servo Body The servo body is locatedon the secondaryvalve body.The servobody containsthe servovalve(whichis integratedwith the reverseshiftfork),and the accumulators.
2ND ACCUMULATOR
3RDSUB ACCUMULATOR
SERVOBODY
1STACCUMULATOR
SERVOVALVE/SHIFT FORKSHAFT
14-28
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HydraulicFlow GeneralChart of Hydraulic Pressure RegulatorValve -a ATFpump -
ModulatorPressureClutchPressure ToroueConverterPressure Pressure LUbrication LinePressure
| LL
5 -
LinearSolenoid
Distribution ol Hydraulic Pressure . RegulatorValve -"- TorqueConverterPressure LLubricationPressure I To regulateLinePressure .
ManualValve
To selectLinePressure -
.
ModulatorValve
ModulatorPressure --
. . .
--1-2ShiftValve 2-3 ShiftValve -t-I 3-4 Shift Valve
ClutchPressure
't' 2 3 3' 3"
MODULATE (SHIFT SOLENOIO CONTROL MODULATE VALVEA) (SHIFT SOLENOID CONTROL MODULATE VALVEB) (LOCK.UP SOLENOID CONTROL IVODULATE VALVEA) (LOCK-UP SOLENOID CONTROL MODUTATE VALVEB) (LOCK-UP SOLENOID CONTROL MODULATE VALVEB)
91
92
TOROUECONVERTER
93
ATF COOLER
94
TOROUECONVERTER
95
LUBRICATION
LIN E
97
LINE/CPC LINE 1STCLUTCH
99
LINE LINE LINE LINE LINE LINE LINE LINE LINE LINE
6D' 7
8 I 10
PORTNO, 15
17 18 20 20A 30 40 41
90
5 6A
---- ShiftControlSolenoidValves Lock-upControlSolenoidvalves fL LinearSolenoid
OFPRESSURE DESCRIPTION CLUTCH lST-HOLD CLUTCH 1ST-HOLD CLUTCH 1ST-HOLD 1ST-HOLDCLUTCH 2ND CLUTCH 2ND ACCUMULATOR 3RDCLUTCH 4TH CLUTCH 4THCLUTCH SOLENOID LINEAR TOROUECONVERTER TOROUECONVERTER
OFPRESSURE DESCRIPTION
PORTNO, 1
ClutchPressure
TOROUECONVERTER
x
TOROUECONVERTER SUCTION DRAIN
HIX
HIGHPOSITIONDRAIN
{cont'd)
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14-29
Description HydraulicFlow (cont'dl lll Position As the engine turns, the ATF pump starts to operate.Automatictransmissionfluid (ATF)is drawn from (99) and dischargedinto (1).Then,ATF flowing from the ATF pump becomesline pressure('l). Line pressure(1) js regulatedby the regulatorvalve.Torqueconverterinlet pressure{92)enters(94)of the torqueconveTter throughthe lock-upshift valveand dischargesinto (90) The torque convertercheckvalve preventstorque converterpressurefrom rising.Underthis condition, hydraulicpressureis not appliedto the clutches. NOTE; . When used."|eft" o. "right" indicatesdirectionon the hvdrauliccircutt. . The hydrauliccircuitshowsthe '97 - 98 models{7 positions};the '99 - 00 models(6 positions)is similar.
'lF'.j.l
14-30
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B Position pressure(1) changesto line pressure(4) and Line pressure{1) flows to the manualvalve and the modulatorvalve,Line pressure at the modulatorvalve Modulatorpres1st-holdclutchpressureat the manualvalve,and changesto modulator shift controlsolenoidvalveA is turned oFF because sure {6)flows to the left ends of the 1-2shift valve and 3-4 shift valve Line pressure(4) becomes1st clutch side. right to the moved are by the PcM. The 1-2 shift valve and the 3-4 shift valve 1st clutchis engaged lstpressure(10)at the 1-2 shift valve.1st clutchpressure(10)is appliedto the 1st clutch,and the Poweris transmitted valve shift 1-2 hold clutchpressure(18)flows to the lst-hol; clutchvia the 3-4 shift valve and the throughthe 1st-holdclutch. only duringdeceleration NOTE: "right" indicatesdirectionon the hydrauliccircuit' . When used,"left" or '99 - O0models(6 positions)is similar' . The hvdrauliccircuitshowsthe'97 - 98 models(7 positions);the
(cont'd)
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14-31
Description HydraulicFlow (cont'dl l?JPosition Line pressure{1) flows to the manualvalve and the modulatorvalve.Line pressure(1} changesto line pressure(4) at the manualvalve,and changesto modulatorpressureat the modulatorvalve.But modulatorpressure{6} does not flow to eachshift valvebecauseshift controlsolenoidvalvesA and B are turnedON by the PCM.Linepressure(4) passesthrough the CPBvalveand the CPCvalve,and changesto line pressure(5),then flows to the 'l-2shift valve.Line pressure(5)from the 1-2shift valvechangesto 2nd clutchpressure(20)at the 2-3 shift valve.The 2nd clutchpressure(20)is appliedto the 2nd clutch,and the 2nd clutchis engaged,Line pressure(4)passesthroughthe 1-2shiftvalveand the orifice,and changes to lst clutchpressure.The 1stclutchpressure{10)also flows to the 1stclutch.However,no power is transmittedbecause of the one-wayclutch. NOTE: . When used,"left" or "right" indicatesdirectionon the hvdrauliccircuit. . The hydrauliccircuitshowsthe '97 - 98 models(7 positions);the '99 - OOmodels(6 positions)issimilar.
14-32
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E] or E Position ('97 - 98 Models), and D Position ('99 - 00 Modelsl 1.
lst Gear Fluidflow throughthe torque convertercircuitis the same as in E] position.Line pressureflows to the manualvalve pressure and the modulatorvalve.Line pressurechangesto modulatorpressure(6) at the modulatorvalveand to line 3-4 shift valve and the 1-2 shift valve (6) of the left end pressure flows to the {4) at the manual valve. Modulator is moved to valve The 1-2 shift PcM. oN by the B is turned and is turned oFF valve A solenoid becauseshift control 'lst clutchpressure(10}at the 1-2shift valveand the orifice The 1stclutch the right side.Line pressure{4)changesto the vehiclewill move as the enginepower is transpressure(10)is appliedto the 1stclutchand the 1st accumulator; mitted. NOTE: . When used,"left" or "right" indicatesdirectionon the hydrauliccircuit. '97 - 98 models(7 positions); the '99 - 00 models{6 positions)issimilar. . The hvdraulic circuitshowsth e
(cont'dl
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14-33
Description HydraulicFlow (cont'dl 2nd Gsar As the speed of the vehiclereachesthe prescribedvalue.shift control solenoidvalve A is turned ON by the pCM. Modulatorpressure(6A) in the left end of the 1-2shift valveis releasedby turning shift controlsolenoidvalveA ON. The 1-2shift valve is movedto the left side and uncoversthe port to allow line pressure(5)to the 2-3 shift vatve.Line pressure(5) changesto 2nd clutch pressure(20)at the 2-3 shift valve,The 2nd clutch pressure {20)is appli€dto the 2nd clutch.and the 2nd clutchis engaged. Fluidflows by way of: - LinePressure(4)+ CPBValve- Line Pressure(5)* 1-2ShiftValveLinepressure(S)* 2-3 ShiftValve - 2nd ClutchPressure(20)- 2nd Clutch The hydraulicpressurealsoflows to the lst clutch.However,no power is transmittedbecauseof the one-wav ctutch. NOTE: . When used,"|eft" or "right" indicatesdirectionon the hydrauliccircurr_ ' The hydrauliccircuitshowsthe'97 - 98 models(7 positions);the '99 - 00 models(6 positions) is similar,
14-34
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3.
3rd Gear As the speedof the vehiclereachesthe prescribedvalue.shift control solenoidvalve B is turned OFF by the PCM. Shift controlsolenoidvalveA remainsON. Modulatorpressure(6)flows to the right end of the 1-2shift valveand the (68) The 2-3 shift left end of the 2-3 shift valve.The 2-3 shift valve is movedto the right side by modulatorpressure 2-3 shift valve as the (5) shift valve the 3-4 and uncovers prsssure 2nd clutch. to the valvecoversthe port to stop line (30) The 3rd clutch valve. pressure 3-4 shift (5) at the pressure 3rd clutch becomes side, Line is moved to the right pressure(30)is appliedto the 3rd clutch,and the 3rd clutchis engaged. Fluidflows by way of: - Line pressure(4)- CPBValve- LinePressure(5)* 1-2Shift Vaiv€- LinePressure(5)* 2-3 ShiftValve - Line Pressure(5)* 3-4 ShiftValve- 3rd ClutchPressure(30)* 3rd Clutch The hvdraulicDressurealsoflows to the 1stclutch.However,no power is trsnsmittedbecauseof the one-wayclutch. NOTE: . When used,"|eft" or "right" indicatesdirectionon ths hydrauliccircuit. . The hvdrauliccircuitshowsthe '97 - 98 models(7 positions);the'99 - 00 models(6 positions)is similar.
(cont'd)
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14-35
Description HydraulicFlow (cont'd) 4th Gear llQ! or E Posirion) As the speedof the vehiclereaches the prescribedvalue.shift controlsolenoidvalve A is turned OFF by the pCM, Shift controlsolenoidvalve B remainsOFF.Modulatorpressure(6)flows to the left end of the 1-2shift valveand the left end of the 3-4 shift valve.Modulatorpressure(64) in the left end of the 1-2shift valveequalsmodulatorpressure (68)in the right end of the 1-2shift valve.The 1-2shift valveremainsat left side by the tensionof the valvespring. The 3-4 shiftvalve is movedto the right side by modulatorpressure(6A).The 3-4 shift valvecoversthe pon to the 3rd clutch and uncoversthe port to the 4th clutchas this valve is moved to the right side,The 4th clutch pressure(41) from the 3-4 shift valve becomes4th clutchpressure(40)at the manualvalve.The 4th clutchpressure(40)is applied to the 4th clutch,and the 4th clutchis engaged. Fluidflows by way of: - Linepressure(4)+ CPBValve- Line Pressure(5)+ l-2 ShiftValve- LinePressure * 2-3 {5) Shift Valve - LinePressure(5)+ 3-4 ShiftValve- 4th ClutchPressure(41)+ ManualValve- 4th ClutchPressure(40) + 4th Clutch The hydraulicpressurealsoflows to the lst clutch.However,no power is transmittedbecauseof the one-wavclutch. NOTE: . When used,"lelt" or " tight" indicatesdirectionon the hydrauliccircuit. . The hydraulic circuitshowsthe '97 - 98 models(7 positions);the '99 - 0Omodels(6 oositions)issimilar.
14-36
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E Position (3) Fluidflow throughthe torque convertercircuitis the same as in N position.Line pressure(1)changesto line pressure (3') servo and flows to the pressure 1-2 shift valve (3) at the and flows to the 1-2shift valve.Line pressure changesto line (3") vaive.The servovalveis movedto the right side (Reverserangeposition)and uncoversthe port to allow line pressure valve and manual valve to the (3') through the servo valve flows pressure 1-2 shift from the Line manual valve. to the changesto 4th clutchpressure(40).The 4th clutchpressure(40)is appliedto the 4th clutch,and the 4th clutchis engaged. R€verseInhibitor Control Whenthe @ positionis selectedwhile the vehicleis movingforwardat speedsover 6 mph (10 km/h),the PCMoutputsthe 1stspeedsignalto shiftcontrolsolenoidvalvesA and B; shift controlsolenoidvalveA is turnedOFF,shift controlsolenoid (3') valve B is turned ON. The 1-2 shift valve is moved to the right side and coversthe port to stop line pressure to the (40} to the 4th pressure is not applied 4th clutch and valve, pressure to the servo servo valve. Line {3') is not applied power direction. the reverse not transmitted to is clutch,as a result, NOTE: . When used,"lelt" ot " right" indicatesdirectionon the hydrauliccircuit. '97 - 98 models(7 positions);the '99 - 00 models(6 positions)is similar' . The hvdrauliccircuitshowsthe
(cont'd)
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14-37
Description HydraulicFlow (cont'dl E Position Fluidflow throughthe torqueconvertercircuitis the same as in fl position.Linepressure( 1)changesto line pressure(3) and flows to the 1-2shift valve.Line pressure(3) changesto line pressure{3') at the 1-2shift valveand flows to the servo valve.The servovalveis movedto the right side (Reverserangeposition)and uncoversthe port to allow line pressure(3") to the manualvalveas in E position.Linepressure(3") from the servovalveis interceptedby the manualvalve.Hydraulic pressureis not suppliedto the clutches,and power is not transmitted. NOTE: . When used,"left" or "right" indicatesdirectionon the hydrauliccircuit. . The hydrauliccircuitshowsthe '97 - 98 models(7 positions);the '99 - 00 models(6 positions)issimilar.
14-38
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Lock-upSystem In E position('97- 98 models)and in E position('99OOmodels)(3rdand 4th),and E position('97- 98 models) and in E positionwith Over-Drive(O/D)is OFF(by pressingthe O/Dswitch)('99- 00 models)(3rd),pressurizedfluid is drainedfrom the backof the torque converter througha fluid passage,causingthe lock-uppistonto be held againstthe torqueconvertercover,As this takes Dlace,the mainshaftrotatesat the same speed as th8 engine crankshaft.Togetherwith the hydrauliccontrol, the PCM optimizesthe timing of the lock-up system. Under certaincondltions.the lock-upclutch is appli€d in 3rd and 4th gear. duringdeceleration,
CONVERTER TOROUE
LOCK.UPCONTROL ' VALVE
LOCK.UPCONTROL SOLENOIDVALVE A
B
The lock-upsystemcontrolsthe rangeof lock-upsccording to lock-upcontrol solenoidvalvesA and B, and ths linearsolenoid.When lock-upcontrol solenoidvalvesA and B activate.modulator pressurechanges.Lock-up controlsolenoidvalvesA and B are mountedon the outs i d e o f t h e t o r q u e c o n v e r t e rh o u s i n g ,a n d t h e l i n e a r solenoidis mountedon the transmissionhousing.They are controlledbv the PCM. The table belowshowsthe lock-upconditionsfor lock-up controlsolenoidvalvesand linearsolenoidpressure. Lock-upConirol Solenoid valve
B
Linaal Solenoid Prgssuls
OFF
OFF
High
Lock-up,Half
ON
Dutyoperation OFF- ON
Low
MAINSHAFT
Lock-up,Full
ON
ON
High
COUNTERSHAFT
Lock-up during deceleration
ON
Duty operation OFF- ON
Lock-up Conditions
A Lock-upOFF MODULATOR Pf,ESSURE RELIEFVALVE
LOCK'UPTIMING VALVE SUB.SHAFT
LINEARSOLENOIDPRESSURE COOLERRELIEFVALVE
ATF PUMP ATF COOLER
ATF STRAINER
(cont'd)
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14-39
Description Lock-upSystem(cont'dl Lock-upClutch L
Ooeration(clutchon) With the lock-upclutch on, the fluid in the chamber betweenthe torque convenercover and the lock-uDoiston is drained off, and the converterfluid exertspressurethrough the piston againstthe torque convertercover,As a result,the convener turbine is lockedto the convertercover.This bipassesthe converter,placingthe vehiclein directdrive. LOCK,UPPISTON
The power flows by way of: Engine
IOROUE COVER
+
Drive plate Torque convertercover I Lock-uppiston
t Damperspring { Turbine Mainshaft
MAIf{SHAFT
Operation(clutchoff) With the lock-upclutch off, the fluid flows in the reverseof "clutch on." As a result,the lock-uppiston moves away from the convertercover,and the torque converterlock-upis released.
TOROUE
Engine COVER I Driveplate { Torqueconvertercover { Pump I Turbine { Mainshaft
{(1 \\ n1
Jtl ort
MAII{SHAFT
14-40
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To ATF cooler INLET
t
No Lock-up . . .
TOROUECONVERTER
Lock-upControlSolenoidValveA: OFF Lock-upControlSolenoidValveB: OFF High LinearSolenoidPressure:
The pressurized fluid regulatedby the modulatorworks on both endsof the lock-upshift valve.Underthis condition, the pressuresworking on both ends of the lock-up s h i f t v a l v e a r e e q u a l . a n d t h e l o c k - u ps h i f t v a l v e i s m o v e d t o t h e r i g h t s i d e b y t h e t e n s i o no f t h e v a l v e spring. Fluid trom the ATF pump will flow through the left side of the lock-upclutchto the torqueconverter;the lock-upclutchis OFF. "|eft" and "right" indicatesdirection NOTE:When us€d, on the hydrauliccircuit.
LOCK.UPCONTROL SOI-ENOIDVALVE
MOOULATOR PRESSURE MAINSHAFT RELIEFVALVE
COUNTERSHAFT
TIMING LOCK-UP VALVE
+
LINEARSOLENOIDPRESSURE
i COOLERRELIEFVALVE
ATFPUMP ATF COOLER
ATF STRAINER
(cont'd)
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14-41
Description Lock-upSystem(cont'dl HalfLock-up a Lock-upControlSolenoidValveA: ON a Lock-upControlSolenoidValveB: DutyOperation
OFF- ON LinearSolenoidPressure: Low
TOFOUECONVERTER
L(rcK.UPCONTROL SOLENOID VALVE A
RELIEFVALVE
B
MODULATOR PNESSURE MAINSHAFT
The PCMswitchessolenoidvalveA on to releasemodulator pressurein the left cavityof the lock-upshift valve. Modulator pressure in the right cavity of the lock-up shift valve overcomesthe spring force,and the lock-up shiftvalveis movedto the left side. Line pressureis then separatedinto the two passagesto the torque converter;torque converterinner pressure entersinto right side to engagethe lock-upclutch,and torque convener back Dressureenters into left side to disengagethe lock-upclutch. Back pressure(F2) is regulatedby the lock-upcontrol valve,whereasthe positionof the lock-uptiming valve is determinedby linearsolenoidpressureand tensionof the valvespring.Also the positionof the lock-upcontrol valve is determinedby the back pressureof the lock-up control valve.torque converterpressure(regulatedby the torque convertercheckvalve),and modulatorpressure (determinedby the lock-upcontrol solenoidvalve B). The PCM switcheslock-upcontrol solenoidvalve B on and off rapidly(duty operation),undercertajnconditions,to regulatebackpressur€(F2)and lockthe torque convertef. NOTE:When used,"left" and "right" indicatesdirection on the hvdrauliccircuit.
COUNIERSHAFT
L(rcK-UP TIMING VALVE
+
LINEARSOLENOIDPRESSURE
COOLERRELIEFVALVE
ATFPUMP ATFCOOLER
14-42
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ATF STRAINER
FullLock-up . . .
TOROUECONVEFTER
LOCK-UPCONTROL SOLENOIDVALVE
Lock-upControlSolenoidValveA: ON Lock-upControlSolenoidValveB: ON LinearSolenoidPressure:High
W h e n t h e v e h i c l e s p e e d f u r t h e r i n c r e a s e s l,i n e a r solenoidpressureincreasesto high in accordancewith the linearsolenoidwhich is controlledby the PCM. T h e l o c k u p t i m i n g v a l v e o v e r c o m e st h e s p r i n gf o r c e and moves to the left side. Also, this valve closesthe fluid port leadingto the left side of the lock-upcontrol valve. Underthis condition,modulatorpressurein the left side of the lock-upcontrol valve had alreadybeen released by the lock-upcontrolsolenoidvalve B; the lock-upcontrol valve is moved to the left side. As this takes place, torqueconverterbackpressureis releasedfully, causing the lock-upclutchto be engagedfully. NOTE:When used."left" and "right" indicatesdirection on the hydrauliccircuit.
MODULATOR PRESSURE MAINSHAFT RELIEF VALVE
COUNTERSHAFT
TIMING LOCK.UP VALVE SUB-SHAFT
+ BELIEF VALVE COOLER
LINEARSOLENOIOPRESSURE
ATFPUMP ATF COOLER
ATF STRAINER
(cont'd)
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14-43
Description Lock-up System (cont'dl DecelelationLock-up a Lock-upControlSolenoidValveA: ON a Lock-upControlSolenoidValveB; DutyOperation
OFF- ON LinearSolenoidPressure: Low The PCM switchessolenoidvalve B on and off rapidly u n d e r c e r t a i nc o n d i t i o n sT . h e s l i g h t l o c k - u pa n d h a l f lock-upregionsare maintainedto lock the torque convener propeny. TOROUECONVERTER
NOTE:When used,"left" and "right" indicatesdirection on the hydrauliccircuit.
t
MOOULATOR PRESSURE MAINSHAFT RELIEFVALVE COUNTERSHAFT LOCK.UPTIMING VALVE SUB.SHAFT
+
LINEARSOLENOIDPRESSURE
COOLERRELIEFVALVE
ATFPUMP ATF COOLER
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14-44
ATF STBAINER
ComponentLocations
CONTBOLUN]T
POWERTRAIN CONTROL MODULE{PCMI
ASSEMBLY
COUNTERSHAFT SPEEDSENSOR
AUTOMAIIC TRANSAXI.E (A/T} GEAR POSITION
swtTcH \ SHIFTCONTROL SOLEM)IDVALVE ASSEMBLY
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SPEEDSCNSOR
14-45
PCMCircuitDiagram(A/T ControlSystem) '97 Model FUSAFELAY BOX UNDER.I]OOD EATTEFY
_YEL_ IGNITON SWITCH
UNDEF OASN FUSAFELAYSOX
T-l ,
-T Tl
t_ -: G101
oowEa-qar. MooLrE cor.lForpcMr
*1F
\
ATP NP
&
r*--'l_____O_=_ IO! lrNo
,ATP lR
. A T D, A - P , A - P , A - P 101 103 12 ll
UNDER DASN M 25(7.54)
'Fr-r.04 _a TMEALOC( BrK€ru-<< calTFoL
P- r.-or..u L P_ *+rr F- onmrx
f-"".>
CFUISE CONTFOL UNIT
pw
F_ P_ eLu F-- enN
|
I l,[-l; , III
Ar'TGEAR POS]TION
swtcN
14-46
www.emanualpro.com
["'"]
INTEFLOC( CONIFOL UNIT KEYLCICI( ACCPUSNSWSOLEIJOIO IGI
SHIFILOCX SOLEIOD
PPNSW
LI]
ATPF
GND
]' I
YEI]BLK
-[I l
YEITILX
t,
I l-f? POSrn0N PPOsITION
SEr!5OR
V
II
ENGINE CooL,ANT TEMPERATURE SENSOF
tr h. nf
I
I1",, II r I
l"
8nN
II
H I
SEFVICECHECK CONNECTON
BLX
{ G101
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PGMTerminal Voltage/MeasuringConditions A/T ControlSystem-'97 Model The PCMterminalvoltageand measuringconditionsare shownfor the connectorterminalsthat are relatedto the Ay'Tcontrol system.The other PCMterminalvoltageand measuringconditionsare describedin section11.
PCMTerminalLocations
A {32P}Connector
B (25P1Connectol
C {31PIConnector
D {16P}Connector
PCMCONNECTOR A {32P} Torminal Numbcr
Signsl
A9
LG1
G r o u n d( G 1 0 1 )
A10
PG1
G r o u n d{ G 1 0 1 )
At1
IGPl
Power supply system With ignitionswitchON (ll):Batteryvoltage (under-hoodFuse44 via main relav) With ignitionswitchOFF:0 V
422
Description
MeasuringConditions/TerminalVohage
Ground Ground
424
IGP2
Power supply system With ignitionswitchON (ll):Batteryvoltage (under-hood Fuse44via main relav) With ignitionswitchOFF:0 V
FCM CONNECTORB (25P)
Description
Terminal Number
Signal
B1
LSM
Linearsolenoidpowersupply negativeelectrode
lgnitionswitchON (ll):Pulsingsigna
82
LSP
Linearsolenoidpower supply positive electrode
lgnitionswitchON (lll: Pulsingsigna
B3
SHA
Shift controlsolenoidvalveA control
In @, @ position,in 2nd and 3rd gear in E, E position:Batteryvoltage In 1stgear in E. F! position,in 4th gear in E position:0 V
B4
LCB
Lock-upcontrolsolenoidvalve B control
With full lock-up:Batteryvoltage With half lock-up:Pulsingsignal With no lock-up:0 V
B5
LCA
Lock-upcontrolsolenoidvalveA control
When lock-upis ON: Bafteryvoltage With no lock-up:0 V
86 to 87 B8 89 to 810
14-48
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Measuring Conditions/TerminalVohage
Not used
ATPD3
,VT gear position switch E position signalinput Not used
In E position:0V In otherthan E position:Batteryvoltage
PCMCONNECTORB (25P)lcont'd) Signal
811
SHB
Shift controlsolenoidvalveB control
812
ILU
lnterlockcontrol
B13
D 4I N D
D4 Indicatorlight control
814
NMSG
Mainshaftspeedsensorground
815
NM
Mainshaftspeedsensorsignal InpuI
Dependingon enginespeed:Pulsingsignal When engineis stopped:0 V
816
ATP R
Ay'Tgear position switch E positionsignalinput
I n E p o s i t i o nO; V In otherthan E position:Batteryvoltage
817
ATP2
Ay'Tgear position switch E position signalinput
InEposition:0V In otherthan E position:Batteryvoltage
B18
ATP 1
A/T gear positionswitchEl posit i o n s i g n a il n p u t
InEposition:0V In otherthan E position:Batteryvoltage
NCSG
Countershaft speedsensorground
NC
Countershaft speedsensorsignal Inpur
Dependingon vehiclespeed:Pulsingsignal when vehicleis stooped:0 V
824
ATP D4
A/T gear position switch iql position signalinput
I n E p o s i t i o n0: V In other than lgalposition: Bafteryvoltage
825
ATP NP
Ay'Tgear positionswitchE and N positionsignalsinput
0V In E andE positions: V Inotherthan @ andffi positions:5
8 1 9t o 8 2 1
B22
Description
voltage MeasuringConditions/Terminal
TerminalNumbel
In E, E position,in 1stand 2nd gear in -q, Er position:Batteryvoltage In B position,in 3rd gear in qd, q:l,inatn gear in D. position:0 V When ignitionswitchis ON (ll),brakepedal deDressed and accelerator oedalreleased:0V When ignitionswitchis first turnedON (ll):6 V or more for tlvo seconds In lDllposition:6V or more
Not used
PCMCONNECTOR C {31PI TerminalNumber
c10
Signal
Description
Measuring Conditions/TerminalVoltage
SCS
Servicechecksignal
With ignitionswitchON (ll) and servicecheck connectoropen: 5 V With ignitionswitchON (ll) and servicecheck connectorconnectedwith specialtool: 0 V
VBU
Back-uppower system (under-hoodFuse47)
Alwaysbatteryvoltage
PCM CONNECTORD II6PI Terminal Number
Signal
STOPSW
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Description Brakeswitchsignalinput
Measuring Conditions/TerminalVoltage BrakepedalpressedrBatteryvoltage Brakepedalreleased:0 V
14-49
PCMCircuitDiagram(A/T GontrolSystem) '98 Model FUSAFELAY sox UNOEF-HOOO
_YEL_
rGD2
I ocr
ATP NP
I oG2
IDl lrND
,ATP lR
I CAs
, A T P, A - P , A T P, A _ P lD4 lD3 12 ll
PNK BLU
F
rronr
F_
GFNTBLX
*,',,,)83Hf'L
f-'r'------}-'er' F_
cRN_______]_f-
F_
gnN
f
PN(
*'-> 3111"?"
I
1*[-l
l l ,I I
I
sr{rTat
14-50
I SIOPSW
09 lD0 lDl,llDl5
UNOEF-DASH FUSE/BELAYBOX
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| V8 S0.
Gro]
NIEFIOCX T CONTAOLI]N KEYLOCX ACCPUSN SW SOLEIOLO 6]
SHFILOCK SOLENO1O
PPINSW
ILU
l ' l ' I'
YEUBLX
WNI/8LI< V
ATPP
GNO
II ' I
BLl(BLU
It_
I
___L
V
T-T l l
YEL]BLK
PosrTroN
VI
PPOSITON
WHTELK
l , l
,T
q** IH lF I l:$"." -T-
SPEED SENSOR
L
I s"'nLocr erx
v
tJFj
I
gLUA|/H'I
lS0LEN00 | 4 vrL
__t
;,
,l
Tl'
BLU/YELGFNAiI/N]
l
COTJNIEFSHAfI SPEEDSENSOA
LNEAFSOLEI€D
l*
BFN
I
-T-
--l
I
l
l
t*l I t ? t L
SERVCECHECX CONNECTOF
I SNFTCONTFOL I SOLENOIDVALVE
AssEM4Y
I I-:
BLK
T
I
I BqN€LK
I Gr01
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PCMCircuitDiagram(A/T ControlSystem) '99- 00 Models IJNOER'HOOD FUSE/FELAY EoX EATTERY
-]-
T
8LKryEL
l .
]T
I
BLX,'YEL
AIP,O,0,ATP,ArPlO/D 04 t5w t2 tr tN0
D 9 1 0 0 | 0 r 4| D r t I B t g
IJNOER DASII FUS'/FELAYBOX
GAUGEASSEMELY LTGRN BLKtsLU
f
+
Fffi[t** L'om {--1 sr&BrLr l-
F-lwr-i FED
|--FED----.1
YEL 8LU |-BFN-LI BLU
d
f-
Lr sLrJ-l
,-rI ,
G401
) { :-\ G4o1 POS]IION !r'TGEAF
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14-52
NIEFLOCX UNIT CONTROL
.'1" .l' I XEYLOCX ACCP1JSHSW SOLENOID 61
SHFILOCX SOLENO D
PPNSW
3
YEU8L(
T--[T
? I
YEUBLK
t,
rt--r
| tr-r I
t9il LJA LOCK 1SNTFl D SOTENO L YEL
LL]
A'PP
GND
l6 I
SLTBL!
l
Posti0N
SPEEO SENSOn
YL I
iJrl I
(PCM) POWEFTFALN CONTROL MODIJLE
0rr
012
i"']*
lDro
BFN
BLU/IEL
8FN
BLI]IEL
I t -tl Trt
SERVCE CHECK CONNECIOF
f7
nx^* ltfJ: I o coNNEcroR
LOC(,I]PCON'IBOL SOLENOIDVALVE
I
BLK
i
G10r
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PCMTerminalVoltage/MeasuringConditions A/T ControlSystem-'98 - 00 Models The PCMterminalvoltageand measuringconditionsare shownfor the connectorterminalsthat are relatedto the A"/Tcontrol system.The other PCMterminalvoltageand measuringconditionsare describedin section11. FCM ConnectorTerminalLocalions
NOTE:819 and C3terminals are appliedto'99 - 00 models.
o (16Pt
T6rminal Number
Signal
A5
CRS
Downshiftsignalinput from cruisecontrolunit
Whencruisecontrolis used;Pulsingsignal
A10
scs
Timing and adjustmentservice checksignal(5 V from PCM)
With ignitionswitchON (ll)and servicecheck connectoropen:5 V With ignitionswitchON (ll) and servicecheck connectorjumpedwith specialtool: 0 V
A14 ('98 model)
D4 IND
D4 indicatorlight control {Voltagefrom PCMturns D4 light
When ignitionswitchis firstturnedON (ll): Batteryvoltage for two seconds In E position: Batteryvoltage
Description
oN) A14 ('99- 00 models)
D IND
D indicatorlight control (Voltagefrom PCMturns D light
oN) 428
ILU
A.32
STOPSW
MeasuringConditions/TerminalVoltage
When ignitionswitchis firstturnedON (ll): Bafteryvoltage for two seconds ln E position:Batteryvoltage
Interlockcontrol (Voltagefrom PCM)
When ignitionswitchON {ll),brakepedal pedalreleased: depressed, and accelerator Batteryvoltage
Brakeswitchsignalinput
Brakepedalpressed;Batteryvoltage Brakepedalreleased:0 V
FCM CONNECTORB I25P} Terminal Number
Signal
B1
IGPl
Powersupplycircuitfrom main relayvia under-hoodFuse44
82
PG1
G r o u n d( G 1 0 1 )
B8
LSM
Linearsolenoidpower supply negativeelectrode
IGP2
Powersupplycircuitfrom main relay
PG2
G r o u n d( G 1 0 1 )
810 B17 819 ('99- 00 models)
O/DIND
s20
MeasuringConditions/TerminalVoltage With ignitionswitchON {ll):Batteryvoltage With ignitionswitchOFF:0 V
With ignitionswitchON (ll):Bafteryvoltage With ignitionswitchOFF:0 V
Linearsolenoidpower supply positiveelectrode
With ignitionswitchON (ll):Pulsingsignal
Over-Drive(O/D)OFFindicator light control
When ignitionswitchis first turnedON (ll): 0 V for two seconds O/DOFFindicatorlight ON:0 V O/DOFFindicatorlight OFF:Batteryvoltage
G r o u n d( G 1 0 1 )
B21
VBU
Back-uppowersupply (under-hoodFuse47)
B22
LG2
G r o u n d( G 1 0 1 )
14-54
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Description
Always battery voltage
PCMCONNECTORD (16P) Signal
D1
LCA
Lock-upcontrolsolenoidvalveA control
Duringlock-upconditions:Bafteryvoltage Duringno lock-upcondition:0 V
D2
SHB
ShiftcontrolsolenoidvalveB control
Batteryvoltagein followingpositions: . E, E and positions . E, -ql, and E positionsin lst and 2nd gear 0 V in followingpositions: . E, E;, and E positionsin 3rd gear . E and E positionsin 4th gear . E, El, and El positions
D3
LCB
Lock-upcontrolsolenoidvalveB control
Duringfull lock-upconditions:Batteryvoltage Duringhalf lock-upconditions;Pulsingsignal
D4
Not used Powersupplyfor solenoidvalves (Under-hoodFuse15)
With ignitionswitchON (ll);Batteryvoltage With ignitionswitchOFF:0 V
ATP R
Ay'Tgear position switch B positioninput
In E position:OV In otherthan E position:Bafteryvoltage
SHA
Shift controlsolenoidvalveA control
Batteryvoltagein followingpositions: . E position . E, E, and E positionsin 2nd and 3rd gear . E position 0 V in followingpositions: . E position . E. E, and E positionsin lst gear . Erl and E positionsin 4th gear .EandEpositions
ATPD3
Ay'Tgear position switch E positioninput
In E position: 0V voltage Baftery In otherthanE position:
O/DSW
Over-Drive(O/D)switch signal input
When Over-Drive{O/D)is OFF(O/DOFF indicatorlight is ON):0 V When Over-Drive{O/D)is ON {O/DOFF indicatorlight is oFF):Batteryvoltage
D9
ATP D4
A/f gear position switch E positioninput
I n E p o s i t i o n0: V In otherthan E position:5 V
D10
NC
Countershaft sDeedsensorinout
Dependingon vehiclespeed:Pulsingsignal when vehicleis stopped:Approx.0 V
Dl1
NM
Mainshaftspeedsensorinput
Dependingon vehiclespeed:Pulsingsignal When engineis stopped:Approx.0 V
D12
NMSG
Mainshaftspeedsensorground
D13
ATP NP
A,/Tgear position switch E and El positionsinput
I n E a n d E p o s i t i o n s 0: V In otherthan E and m position:5 V
D14
AlP 2
I n E p o s i t i o n0 ;V Battery voltage In otherthanE position:
D15
ATP 1
A/T gear position switch El positioninput A,/Tgear position switch E positioninput
D16
NCSG
D5
VB SOL
D6 D7
D8 {'98model} D8 ('99- 00 models)
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Description
Measuring Conditions/TerminalVoltage
Terminal Numbor
InEposition:0V ln otherthan El position:Batteryvoltage
Countershaft speedsensor grouno
14-55
TroubleshootingProcedures
Checkingths DiagnosticTrouble Code (DTC) with an O8D ll Scan tool or Honda PGM Tsster Whenthe PCMsensesan abnormalityin the input or outputsystems,the El ('97- 98) or E ('99- O0)indicatorlight in the gaugeass€mblywill blink.When the 16PData Link Connector(DLC){locatedunderthe dash on the passenger'sside) is connectedto the OBD ll ScanTool or Honda PGM Testeras shown, the scan tool or testerwill indicatethe Diagnostic TroubleCode(DTC)when the ignitionswitchis turnedON(ll).
DATA LINKCONNECTOR {16PI
[ -=.r, ili
,i
/i, v,., i
HONDAPGMTESTER ol OBDII SCANTOOL
lf the E or E indicatorlight or the MIL has been reportedon, or if a driveabilityproblemis suspected, follow this procedure: 1.
2. 3. 4.
5. 6. 7.
8.
Connectthe OBD ll ScanTool (conformingto SAEJ1978)or HondaPGMTesterto the 16PDLC.(Seethe OBD ll Scan Tool or HondaPGMTesteruser'smanualfor specificinstructions.lf you are usingthe HondaPGMTester,makesure it is set to the SAE DTCWpe). Turn the ignitionswitchON (ll),and observethe DTCon the screen Recordallfuel and emissionDTCS, A,,/T DTCS,and freezedata. lf there is a fuel and emissionsDTC,first checkthe fuel and emissionssystemas indicatedby the DTC(exceptfor DTC P0700).DTCP0700meansthere is one or more Ay'TDTC,and no Droblemswere detectedin the fuel and emissions circuitof the PCM. Wire down the radio station presets. Resetthe memorywith the PGMTestero. by removingthe BACKUP fuse in the under-hoodfuse/relaybox for more than 10seconds. Drive the vehicle for several minutes at speeds over 30 mph (50 km/hr), and then recheckfor DTCS.lf the A/T DTC returns,9o to the Symptom-toComponentCharton pages14-60and 14-61for the '97 models,and pages14-62and 14-63for '98 - 00 models.lf the OTCdoes not return,there was an intermittentproblemwithin the circuit.Makesure all pinsand terminalsin the circuitare tight, and then go to step8. Resetthe radioDresetstations,and setthe clock.
1 4 -5 6
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Checkingthe DiagnosticTrouble Code IDTCI with the Servic€CheckConnestoland SpecialTool ('97- 98) or E (gS - OO)indicatorlight in the when the PcM sensesan abnormalityin the input or outputsystems'the E gaugeassemblymay blink. the specialtool When the ServiceCheckConnector(2P)(locatedunderthe dash on the passengerside)is connectedwith is turned ON (DTC) switch the ignition when Trouble Code as shown,the E or E indicatorlight will blinkthe Diagnostic { ). (2P)to the specialtool when the E or E indicatorlight has beenreponedon, connectthe servicecheckconnector light' Thenturn ON (ll)the ignitionswitchand observethe E or E indicator
.AUGE AssEMaLY
'99 - O0models
$1,"^f:tT"'ff,
SCSSERVICECONNECTOR 07PAz- (x!l0100
'97 - 98 models
long and short codes 1 through9 are indicatedby individualshort blinks.codes 1o and aboveare indicatedby a seriesof After detercode. the to determine together blinks short long and Add the blinks. blinks.one long blink equals1o short '97 model, for the pages and 14-61 14-60 on chart symptom-to-component system electrical refer to the code, miningthe '98- 00 models. and pages14-62and 14-63tor the
Short blinl lonc.)
Sr. DTC1
S.. DTC2 Long blink
Shori blink! {fiv. timt
l
Sc. DTC 15
(cont'd)
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14-57
TroubleshootingProcedures (cont'dl L
Removethe kickpanelon the passenger's side (seesection2O),
2.
Removethe PCM,and turn it over.
KICK PANEL
Inspectthe circuiton the PCMaccordingto the troubleshooting flowchartwith the specialtools and a digitalmultimeter. How to Use the BackplobeSet Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multimeter.Usingthe wire insulationas a guide for the contouredtip of the backprobeadapter,gentlyslidethe tip into the connectorfrom the wire side until it comesin contactwith the terminalend of the wire.
BACKPROBE
EACKPROBE SET 07sAz- 001000a {tworequired)
DIGITALMULTIMETER (Commercially.v.ilablel KS-AHM-32-003 ot oquivalont
14-58
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PCMResetProcedure '1. Turn the ignitionswitchoff 2.
Removethe BACKUP fuse (7.5A) from the under-hoodfuse/relaybox for 10 secondsto resetthe PCM. NOTE: . Disconnecting the BACKUp fuse also cancelsthe radio presetstationsand clock setting Make note of the radio presetsbeforeremovingthe fuse so you can resetthem . The PCMmemorvcan also be clearedby usingthe OBD ll ScanTool or HondaPGMTester' BACKUP IRADIO}{7.5AI FUSE
UNDER.HOOD BOX FUSE/RELAY Final Proceduro This proceduremust be done after any troubleshooting. 1. Turn the ignitionswitchOFF. 2.
Resetthe PCM.
3.
the OBD ll ScanTool or HondaPGMTesterfrom the DataLinkConnector(16P),or removethe specialtool Disconnect from the ServiceCheckConnector(2P).
4.
Turnthe ignitionswitchON (ll),and set the radio presetsand clocksetting'
5,
To verifythat the problemis repaired.test-drivethe vehiclefor severalminutesat speedsover 30 mph
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(48 km/h).
14-59
Symptom-to-Component Chart ElectricalSystem-'97
Model
DTC*
E Indicatol Light
MIL
P1753 (1)
Blinks
ON
Lock up controlsolenoidvalveA
(seepage 14-64)
P1758 \21
Bl i n k s
ON
Lock-upcontrolsolenoidvalve B
(seepage14-66)
P1 7 0 5 (5)
Blinks
ON
A,/Tgear positionswitch(shortto ground)
(seepage14-68)
P1706 (6)
OFF
ON
A,/Tgear positionswitch{open)
(seepage14-70)
P0753 \11
Bl i n k s
ON
Shift controlsolenoidvalveA
(seepage 14-72)
P0758 (8)
Blinks
ON
Shift controlsolenoidvalveB
(seepage14-74)
P0720 (9)
Blinks
ON
Countershaft speedsensor
{seepage14-76)
P0715 (15)
Bl i n k s
ON
Mainshaftspeedsensor
(seepage l4-78)
P1768 (1 6 )
Blinks
ON
Linearsolenoid
(seepage 14-80)
P0740 {40)
OFF
ON
Lock-upcontrolsystem
(seepage14-82)
P0730 (41)
OFF
ON
Shift controlsystem
(seepage 14-84)
Detection ltem
DTC*:The DTc in parentheses is the codethe loaindicatorrightindicateswhen the DataLink Connectoris connectedto the HondapGM Tester.
14-60
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Page
NOTE:When the OBD ll ScanTool or HondaPGMTesterindicateDTC(s)for the automatictransmissioncontrolsystem' code P07oomeansa detectionof some automatictransmisthe scantool or testerindicatescode P0700simultaneously. sion problemin the PGM-Flcontrolsystem lf the self-diagnostic E indicatorlight does not blink,performan inspectionaccordingto the table below. Symptom E indicatorlight is on constantly(not blinking)wheneverthe ignition switchis ON (ll). E indicatorlight does not come on for two secondsafterignition switchis first turnedON (ll). Shift levercannotbe movedfrom @ positionwith the brakepedal Dressed, lgnitionkey cannotbe movedfrom ACC(l) positionto LOCK{0) posi tion with the shift leverin E position.
Inspection
Ref.page 14-86 't 4-41
Checkshift locksystem
14-89
CheckkeYinterlocksystem
14-91
NOTE: lf a customer describesthe symptom for code P1706(6), it will be necessaryto recreatethe symptom by test-driving, then recheckthe OTC.
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14-61
Symptom-to-Component Chart ElectricalSystem-'98 - 00 Models Et Indicatol Lighr (98) E Indicator Light ('99 - 00)
MIL
P1753 (1)
Blinks
ON
Lock-upcontrolsolenoidvalveA
{seepage14-93)
P1758 (21
Blinks
ON
Lock-upcontrolsolenoidvalveB
(seepage 14-96)
P1705 (5)
Blinks
ON
A,/Tgear positionswitch(shonto grounol
(seepage14-99)
P1706 (6)
OFF
ON
A,/Tgear positionswitch(open)
(seepage 14-103)
P0753 (71
Blinks
ON
ShiftcontrolsolenoidvalveA
(seepage14-106)
P0758 (8)
Blinks
ON
Shift controlsolenoidvalveB
(seepage14-109)
P0720 (9)
Blinks
ON
Countershaft speedsensor
{ s e ep a g e1 4 - 1 1 2 )
P0715 {15)
Blinks
ON
Mainshaftspeedsensor
( s e ep a g e1 4 - 1 1 4 )
P1768 (16)
Blinks
ON
Linearsolenoid
( s e ep a g e1 4 - 1 1 7 )
POl40 (40)
OFF
ON
Lock-upcontrol system
(seepage 14-119)
P0730 (41)
OFF
ON
Shiftcontrolsystem
( s e ep a g e1 4 - 1 2 1 )
DTC*
Detestion ltom
Page
DTC*;The DTCin the parentheses is the codethe E or E indicatorlight indicateswhen the DataLink Connectoris connectedto the HondapGM Tester.
14-62
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for the automatictransmissioncontrolsystem, NOTE:When the OBD ll ScanTool or HondaPGMTesterindicateDTC(S) means a detectionof some automatictransmisP0700 Code P0700 simultaneously. code indicates the scantool or tester sion problemin the PGM-Flcontrolsystem. lf the self-diagnostic E or E indicatorlight does not blink,performan inspectionaccordingto the table below. Symptom E or E indicatorlight does not come on for two secondsafterignition switchis first turnedON (ll). E or E] indicatorlight is on constantly(not blinking)wheneverthe ignitionswitchis oN {ll). Shift levercannotbe movedfrom E positionwith the brakepedal presseo. lgnitionkey cannotbe movedfrom ACC(l) positionto LOCK(0)position with the shift leverin E position.
Inspection
14-123 14-125 Checkshift locksystem
14-'t26
Checkkey interlocksystem
14-129
O/DOFFindicatorlight does not come on for two secondsafter ignition switchis first turnedON (ll).('99- 00 models) The O/DOFFindicatorlight is on constantlywheneverthe ignition switchis ON (ll).('99- 00 models) The O/DOFFindicatorlight does not come on eventhoughthe OverDrive(O/Dlswitchis pressedin E position.('99- 00 models)
Ref.page
14-131 14-132 CheckOver-Drive{O/D} switchcircuit
14-133
(6), it will be necessaryto recreatethe symptom by test-drivNOTE: lf a customer describesthe symptom for code P17OO ing.then recheckthe DTC.
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14-63
ElectricalTroubleshooting('97 Model) TroubleshootingFlowchart- Lock-upControlSolenoidValveA . OBD ll ScanTool indicatesCode P1753. . S e l f - d i a g n o s i si @ i n d i c a t o r light blinksonce.
PossibleCause . Disconnectedlock-up control solenoid valve A/B assembly . Short or open in lock-up control solenoidvalveA wire . Faulty lock-up control solenoid
Checkand recordthe freezedata rn caseit is neededlaterfor problem verification. lf the Honda PGM Tester is available:
P e r f o r mt h e l o c k , u p c o n t r o l s o l e n o i dv a l v eA t e s t u s i n gt h e HondaPGMTester.
Did the solenoid pass the test?
The solenoidis OK at this time. Verify that all connectors in the circuil are making good contact,
NO
PCMCONNECTORS Checkfor a Short to Power: r. I urn rne tgntUonswttchut-f. 2. Disconnecr the A (32P)and B ( 25 P ) c o n n e c t o r sf r o m t h e PCM. 3. Turnthe ignitionswitchON (ll). 4. Measurethe voltagebetween t h e 8 5 a n d A 9 o r A 2 2t e r m i nals. Wiresideof femaleterminals
ls there voltage?
Repairshort to power in the wire between the 85 terminal and the lock-upcontrol solenoidvalveA.
Measure Lock-upControl Solenoid Valve A Resistance: 1. Turnthe ignitionswitchOFF. 2. Measure the resistance betweenthe 85 and A9 or A22
ls the resistance 12 25 ()?
To page14 65
14-64
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Checkfor loose terminal fit in the PCM connectors, ll necessary, substitulea known-goodsolenoid valve assembly or PCM and recheck,
From page 14-64
PCMCONNECTORS Check Lock-up Control Sol6noid Valve A tor a Short Circuit: 1 . D i s c o n n e ct ht e 2 P c o n n e c t o r from the lock-upcontrolsole noidvalve4!/Bassembly. 2. Checkfor continuitybetween the 85 andA9 or A22termi nals. Wiresideof femaleterminals
Reprir short to ground in the wire between the 85 terrninal and the lock-uDcontiol solenoidvalveA.
LOCK.UPCONTROLSOLENOID VALVEA/B ASSEMBLYCONNECTOR
----E-
MeasuroLock-upControl Solenoid Valve A Resistanceat the solenoid valve Connector: Measurethe resistancebetween the No. 2 terminalof the connector and body ground.
lFr] .=-A LcA IYELI (nJ Y
t
Terminalsideof maleterminals
12- 25 O? ls the resistance
Check for open in the wire belwe€n the 85 teiminal and the lock-uocontrol solenoidvalve A
Replacethe lock-np control solenoid valve A/B assembly.
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14-65
ElectricalTroubleshooting('97Model) TroubleshootingFlowchart- Lock-upControlSolenoidValveB . OBOll ScanTool indicatesCode P1758. . Self-diagnosispr- indicatorlight blink3twice.
Check and record the {reeze data jn case it is needed later for prob,
PossibleCauso . Disconnoctedlock-up control sol€noid valve A/B assembly . Short or op€n in lock-upcontrol 3olenoidvrlve B wi.e . Faulty lock-up control solenoid valve B
lem verification.
Did the code return?
The system is OK at this time. Verify thet dll connectors in the circuit are makinggood contact.
PCMCONNECTORS
Checktor a Short to Powerl 1. Turnthe ignitionswitchOFF. 2. Disconnect the A (32P)and B ( 2 5 P )c o n n e c t o r sf r o m t h e PCM. 3. Turnthe ignitionswitchON {ll). 4. Measurethe voltagebetween the 84 and Ag ot A22 tetmi nals,
Wire sideof femaleterminals Repairshort to power in tho wire bstween the 84 terminal and the lock-upcontrol rolenoid valve B.
MeasureLock-upControl Solenoid Valve B Resistance: 1. Turnthe ignitionswitchOFF. 2. Measure the resistance b e t w e e nt h e 8 4 a n d A g o r A22terminals.
l s t h e r e s i s t a n c e1 2 2 5 O ?
To page14-67
14-66
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Checktor looseterminal tit in the PCM connectors, It necessary, subslitute a known-good solenoid valve assemblyo. PCM and rech€ck.
Frompage14 66
Check Lock-up Control Solenoid Valve B lor a Short Circuit: 1. Disconnectthe 2P connector from the lock-upcontrolsole noid valveA/8 assembly. 2. Checkfor continuitybetween the 84 and A9 or A22 lermi_ nals-
PCMCONNECTORS
Wiresideof femaleterminals
Repairshort to ground in the wire between the 84 lerminal and the lock-upconlrol solenoidvalve B.
LOCK-UPCONTROLSOLENOID VAI-VEA/B ASSEMBLYCONNECTOR Me6aureLock-upControl Sole_ noid Valve B Resistanceat the SolenoidValve Connector: Measurethe resistancebetween the No. 1 terminalof the connector and body ground.
12- 25 0? ls the resistance
LC B (GRN/BLK)
Check lor open in the wire bctween the 84 terminal and the lock-upcontrol solenoidvolva B.
Replacethe lock-up conttol solenoid valve A/B ass6mbly.
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14-67
ElectricalTroubleshooting{'97Model} TroubfeshootingFlowchart- AIT GearPositionSwitch (Short) . OBOll ScanTool indicat€sCode P1705. ' Selt-diagnosisp1- indicatortight blinb Iive times.
Checkand record the freeze data in caseit is neededlaterfor problem verification.
Po$ible Cause ' Short in A/T gear position switch . Faulty A/T gear position switch NOTE:Code P1705(5) is causedwhen t h e P C M r e c e i v e st w o g e a r p o s i t i o n anputsat the sametime.
Observethe A/T G€ar Po3ition Indicator: 1. Turnthe ignitionswitchON lll). 2. Observethe A./Tgear position i n d i c a t o r ,a n d s h i l t t o e a c h positionseparately.
Doesany indicatorstayon when the shift leveris not in that position?
The system is OK .t this time. Ch6ck ihe wii6 harnessfor dam490,
Do allgear positionindicators go out?
PCMCONNECTORS
MeasureATP R Voltago: 1. Shittto all positionsotherthan
tr.
2. lMeasure the voltagebetween the 816 and Ag or A22 terminals.
Check tor 3hort in the wire betwaenthe 816torminal and tho A/T gear pGilion switch or A/T gsar posiiion indicator. ff wire is OK, checkfor 10036torminal flt in lhe PICMconnectoB. It necessary, substitute a known-9ood PCM and recheck.
Wire sideof femaleterminals
MeasureATP NP Voltage: 1. Shiftto all positionsotherthan
NorE. 2. Measurethe vohagebetween lhe 825 and Ag or A22 terminals.
ls there battery vohage?
To page14-69
14-6 8
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Chock for ahort in the wire betw€entho 825 torminal end the A/T 96.r pGition indicstor, or a sho.t in tha wiro! b€tween the A/T gear po3ition indicator and the A/T g€ar position lwitch. lf wircs ar€ OK, ch6ck for loos€ terminal fit in the PCMconnectors.It nece3sary,substitute a knowngood PCMand recheck.
ATP NP {LT GRNI
Frompage14-68
MeasureATP D4 Voltage: 1. Shiftto all positionsotherthan
Eil
2. [/leasurethe voltage between the 824 and Ag or A22 terminals.
ls thereapprox.5 V?
M€asureATP D3 Voltage: L Shiftto all positionsotherthan
Check tor short in the wire betweenthe 824 terminal and the A/T geai position indicator. or a 3hort in the wir6s between the A/T gear position indicttor and the A/T gear position switch. lf wires are OK, checklor loose ter' minal fit in the PCMconneclo.s.lf necessary,substitute a known' good PrCMand recheck.
Wire side of female terminals
tr.
2. Measurethe voltagebetween the 88 and A9 or A22 termi nats.
ls there bafteryvoltage?
Check for short in the wi.e between the 88 torminal and the A/T gear position switch or A/T gear position indicator. lf wire i3 OK,checklor looseterminaltit in the PCM connectors. lf necessarY,3ubslitute a known'good PCMand recheck.
Measur€ATP 2 Vohage: 1. Shiftto all positionsotherthan l; 2. Measurethe voltagebetween the 817 and Ag or A22 termi' nals. Check for short in the wire bstwe€n the 817 terminal and the A/T gear posilion switch or A/T gear position indicator. lf wire is OK, checklor looseterminal fit in th6 PCM conn€ctoF. lf nec€ssaty, substitute a known-good PCM and recheck. Mersure ATP 1 Volt.ge: 1. Shiftto all positionsotherthan
El.
2. Measurethe voltagebetween t h e 8 1 8 t e r m i n a la n d A 9 o r A22terminals.
ls there batteryvoltage?
Check lor short in the wire betw.en the 818 torminal and the A/T gear position switch or A/T gear position indicator. lI wiro is OK. check for loose terminal fii in the PCM connectorc. lf necessary.substitute a known' good PCMand recheck.
Checkfor loose terminalfit in the PCM connectors, lf neces3aty, substitute e known-good PCM end rocheck.
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14-69
ElectricalTroubleshooting('97Model) TroubleshootingFlowchart- A/T GearpositionSwitch (Openl . OBD ll ScanTool indicat6 Code P1706. . Setf-diagnGb Dl indicatortight blinks six tim$.
Po$iblo C.u3e . DisconnectedA/T gear position switch connectol . Open in A/T goar position switch . Faulty A/T goar position switch
Checkand recordthe freezedata in caseit is neededlaterfor problem verilication.
Test the A,/Tgear position switch { s e ep a g e1 4 1 3 9 ) .
Measu.eATP R Voltage: '1. Turnthe ignition switchON (ll). 2. Shiftto E position. 3. Measurethe voltagebetween the 816 and Ag or A22 terminals.
Repeir op€n in the wire botween the 816t€rminaland the A/T g€.r po3itionswitch.
Wire sideot temaleterminals
MeasureATP NP Voltage: 1. Shiftto E or E position. 2. Measurethe voltagebetween the 825 and A9 or A22 termin al s , ATP NP ILT GRNI Repai. open in th6 wir6 bctwoan the 825 terminal and tho A/T gear polition indicltor or tho A/T gea. Doshionswhch.
MoasureATP 04 Voltage: 1. Shiftto E position. 2. Measurethe voltage between the 824 and A9 or A22 terminars,
Ropai. opcn in tho wiro betwoen the B24torminal .nd the A/T gcar Dosition switch.
To page14-71
14-70
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Frompage14-70 FCM CONNECTORS
MeasureATP D3 Vohag€: 1. Shiftto E position. 2. Nleasurethe voltagebetween the 88 and Ag or A22 termi nals, Wire sideof femaleterminals
Repairopen in the wirg bstween the 88 tolminal and tho A/l gear oo3ition 3witch.
MsasureATP2Volttg6: '1. Shiftto position. E 2. Measurethe voltage between the 817 and A9 or A22 termi' nals.
Repairopen in lhe wire between the 817 terminaland tho A/T gear position switch.
MoasureATP1Voltage: 1. Shiftto A position. 2. Measurethe voltagebetween the 818 and Ag or A22 terminats,
R€pairopon in the wiro between the 818 terminll and the A/T goar poshion switch.
Checktor looso terminal fit in the PCM connectors. lf necossarY, substitute a known-good PCM and rechock.
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ElectricalTroubleshooting('97 Model) TroubleshootingFlowchart- Shift ControlSolenoidValveA . OBD ll ScanTool indicatesCode P0753. . Self-diagnoskE indicator light blinks seventim€s.
PossibleCauso . Disconnectedshift control solenoid valve A/8 a$embly connector . Short or open in shift control solenoid valve A wire shift controlsolenoidvalveA
Checkand record the freezedata in caseit is neededlaterfor prob lem verification. lf the Honda PGM Tester is available:
I Performthe shiftcontrolsolenoid v a l v eA t e s t u s i n gt h e H o n d a PGMTester.
Did the solenoidpassthe test?
The sol€noid is OK at this time. Verify that all connectors in the circuit are making good contact.
PCMCONNECTORS Checktor a Short to Power: 1. Turnthe ignitionswitchOFF. 2. Disconnect the A (32P)and B ( 25 P ) c o n n e c t o r sf r o m t h e PCM. 3. Turnthe ignitionswitchON lll). 4. Measurethe voltagebetween the 83 and Ag or A22terminals.
Wire sideof femaletermin6ls Repairshort to power in the wire between the 83 terminal and the shift control solenoid valve A.
Measure Shift Control Solenoid Valve A Resistanco: 1. Turn the ignitionswitchOFF. 2, Measure the resistance betweenthe 83 and A9 or A22 termrnals,
ls the resistance 12 25 {)?
To page l4-73
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14-72
Checktor loose terminal tit in the PCM connectors, lf necessaay, subslituie e known-good solenoid valve assemblvor PCM and rech€ck.
Frompage14-72
C h e c kS h i f t C o n o l S o l e n o i d Valve A for a Short Circuit: 1. Disconnectthe 2P connector from the shiftcontrolsolenoid valve Ay'Bassembly. 2. Checkfor continuitybetween the 83 andA9 orA22terminals.
Wire sideof femaleterminals
Repai.short to ground in the wire belw€en th6 83 terminal and the shift cont.ol solenoidvalveA.
SHIFTCONTROLSOI.ENOID VALVEA/B ASSEMALYCONNEC1OR MeasureShift Control Solenoid Valv6 A Resistanceat the Solenoid Valve Connector: Measurethe resistancebetween the No. 1 terminalof the connec tor and bodyground.
lffil SHA IBLU/YELIl-(o) T I
Terminalsideof maleterminals
ls the resistance 12- 25 0?
Check lor ooen in the wire between the 83 terminal and the shift control sol€noidvalve A.
Replace the shift control solenoid valve A/B assemblv.
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14-73
ElectricalTroubleshooting('97Model) TroubleshootingFlowchart- Shift ControlSolenoidValveB . OBOll ScanToot indicrt8 Codo P0758. . Setf-diagnGisE indicatorlight blinks oight tim93.
Po33iblaCrusa . Disconnec{edshift cont.ol solenoid valve A/B dssomblyconnector . Short or open in shift conlrol solenoid valvg B wire ' Faultvshift comrol 3olenoidvalvo B
Checkand r€cord the lreere data in case it is neededlater for prob lem verilication. lf the HondaPGM T€steris available: Test solenoid valve B with the Honda PGM Tester in the FLrnc tion test mode.
Did the solenoidDassthe test?
The 3olonoid is OK at this time. Verifv that all connoctors in the circuit are making good contlct.
PCMCONNECTORS Chocktor a Sho.t to Power: 1. Turnthe ignitionswitchOFF. 2. Disconnect the A (32P)and B {25P)connectorsIrom the PCM. 3. Turnthe ignitionswitchON (ll). 4. Measurothe voltage botveen the 811 and Ag or A22 terminats.
Wiresideot femaleterminals R.p.ir 3hort to power in the wire botwo€n the 811 iormin.l and tho shift control sol.noid valve B.
M.6sure Shift Control Solonoid Valve B Reaistanco: 1. Turnthe ignitionswitchOFF. 2. Measure the r€sistance b e t w e e nt h e 8 1 1 a n d A 9 o r A22terminals.
ls the resistance 12- 25 O?
To page14-75
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14-74
Checl lor loosc terminal fil in the PCM connactors. It nocessarv, substitute a known-good aolenoid vllvo asssmbly or PCM and r6chsck,
Frompage14-74 PCMCONNECTORS C h e c kS h i f t C o n t r o l S o l e n o i d Valvo B tor a Short Circuil: 1. Disconnectthe 2P connector from the shift control solenoid valvey'y'8assembly. 2. Checkfor continuitybetween the 811 and Ag or A22 terminals, Wire side of female terminals
Ropairshort to ground in the wire b64w€€ntho 811 torminal and lhg shift control solenoidvalvo B. SHIFTCONTROLSOLENOID VALVE A/B ASSEi'BLY CONNECTOR
Meesure Shift Control Solenoid Valve B Rosistanceat lh€ Solenoid Vrlve Connector: Measurethe resistancebetween the No. 2 terminalol the connec tor and bodyground.
ti;Tll I sH B |GRN/W{T|
oY I
I
Terminalsideof maleterminals
ls the resistance 12- 25 O?
Check tor open in the wire bdtweonthe 811 torminal and the shift control sol€noidvalv6 B.
Reolacethe shift control solenoid valve A/B asJembly,
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14-75
ElectricalTroubleshooting('97 Model) TroubleshootingFlowchart- CountershaftSpeedSensor . OBO ll Scan Tool indicatesCode m720. ' solt-diagnosis iD!' indicator light blink3 nine tim6s.
PossibleCause . Looseor faulty connectionbetween ih€ PCMand vehicleharness . Disconnected countershaft spoed sensorconneclor . Short or open in countershaftspeed . FaultycounteBhaft speedlensor
Checkand recordthe freezedata in case it is neededlater for prob lem verification. lf the Honda PGM Tester is available:
I Connectthe Honda PGM Tester, a n d t e s t - d r i v et h e v e h i c l ew i t h the tester in Data Link or snap' Shot mode,Makesure the countershaftspeed sensor readsthe sameas the vehiclespeedsensor lVSS). The countershaftsooed sensor is OK sr this time. Veritv that all c o n n e c l o a si n t h e c i r c u i t a r e making good contacl.
J
C h e c kt h e c o u n t e r s h a f ts p e e d sensor installation,and check it for damage.
ls the countershaft speedsensor installedproperly,and not damaged?
neinstall or roDlacoand recheck. SPEEDSENSOR COUNTERSHAFT CONNECTOR
MeasuroCountoBhaftSpeedSensor Relbtance at the Sensor Connector: 1. Disconnectthe 2P connector from the countershaftspeed sensorconnector. 2. Measurethe resistance of the countershaft speedsensor.
ll-'T,ll -rT ral
YL__lI
Terminalsideof maleterminals ls the resistance400- 600 o?
To page14-77
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14-76
B I25PI PCMCONNECTOR
Ch€ck CounteGh!ft Spocd Sonsoi for a Short Cirruit: 1 . D i s c o n n e ctth e B 1 2 5 P c) o n ' nectorlrom the PCM. 2. Checkfor continuity botween the body ground and the B23 t e r m i n a la n d 8 2 2 t e r mi n aI individually. Repair short in tho wirgs b€twoen tho 823 ,nd 822 te.minals and thc countaBhaft sp€€d senso..
Wire sideof lemaleterminals
Mersuro Countorrhrtt Spoed Sonsor qrcuit tor an Open: '1.Connect the countershaft speedsensor2Pconnector, 2, Measure the resistance betweenthe 823 and 822 ter mrnals.
ls the resistance400- 600 0?
Rapair loor€ t.rminll or opon in tho wircs betwoon tho 823 .nd 822 terminrl! .nd th. countaF shaft specd san3or.
Checkfor loo3eterminsl fit in the PCM connecto13.It necess!ry, sub3titulg s known-good PCM and rochock.
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14-77
ElectricalTroubleshooting{'97Model) TroubleshootingFlowchart- MainshaftSpeedSensor . OBD ll Scan Tool indic.t6 Code m715. . Self-diagnosisE indic.tor light indicatagCode 15.
Po$ible Cau3o . Disconnocted mainshaft speod sensot connectot . Short or open in mainsh.ft sp6ed ' Faulty meinshaftspoedsensor
Checkand record the freeze data in case it is neededlater {or prob, lem verification.
N O T E : C o d e P 0 7 1 5 1 1 5o)n t h e P C M doesn'talwaysmeanthere'san electrical problemin the mainshaftor counlersharl speedsensorcircuit;code P0715(15) may problemin the also indicatea mechanical transmission. Checkthe freezedata with a Honda PGM Tester. lf the mainshaft speed sensor rpm was 0, proceedwith this troubleshooting. lf not, the probable problomwithinthe causeis a mechanical transmission,
Checkthe mainshaftand countershaft speed sensor installation, and checkthesensorsfor damage.
Are the mainshaftand countershaft speedsensorsinstalled properly,and not damaged?
Reingtallor reolaceand recheck.
MAINSHAFTSPEEO SENSORCONNECTOR _ E _
MeaaureMaiNhatt SpoedSen3or R6sist!nce at the Sensor Connecaor: 1. Disconnectthe 2P connector from the mainshaftspeedsensor connector. 2. lreasurethe resistance of the mainshaftspeedsensor.
ItiT,ll -F=r
9t LJ
Terminalsideof maleterminals
ls the resistance 400- 600O? B {25P' PCMCONNECTOR
Check MainahaftSpeed Sensor tor a Short Circuit: 1. Disconnect the B (25P)connector lrom the PCM. 2. Checkfor continuitybetlveen bodygroundand 815terminal and the 814 terminalindividu-
Wire side of female terminals
ReDairshort in the wir€6 b€t\ reen the 815 and 814 torminals and the mainsh!ft sp€ed sensor.
To pagel4-79
14-78
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Frompage14'78 PCMCONNECTOR B {25P}
MoasuroMrin3haft SpoedSanlor Resktanco: 1. Connectthe mainshaftspeed sensor2P connector, 2, Measure the resistance betweenthe 815 and 814 terminals, Wir€ sideof femaleterminals
ls the resistance400- 600 O?
Run the Electricrl Troubloshooting Flowchs tor codo m72O l9l. Chockfor loo3etorminal fh in the PCM conn6cto.s. It necessarY, substitute a known-good PCM and rochgck. MAINSHAFTSPEEDSENSOR CONNECTOR
CheckNM Wiro Continuity: 1. Disconnectthe 2P connector from the mainshaftspeedsensor connector. 2. Checkfor continuitybetween t h e 8 1 5t e r m i n a l a ntdh e N o . 2 terminal of the mainshaft speeosensorconneoor.
Ropairopen in the wir6 betw€on the 815 terminal and the mainshaft sDood$nsoa.
CheckNMSG Wire Continuity: Checkfor continuity between the 814 terminaland the No. 1 terminal of the mainshaftspeedsensor connector.
R€pai. opon in the wi.o between the Bltl terminal and tho main' 3haft sDe€dsensoa,
Ch.ck lor loos. t6rminallit in the PCM connecto13,lf neca3sary, substitute a known-good PCM and rochock.
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14-79
ElectricalTroubleshooting('97Modell TroubleshootingFlowchart- LinearSolenoid . OBD ll Scan Tool indicatesCode P1768. . S.lt-diagnosis E indicator light indicat* Code 16.
PossibleCaus€ . Disconnoctedlinear solenoid con. Short or oDen in linear solenoid . Fsultv linear solenoid
Checkand record the freezedata in case it is neededlater for prob lem verification.
LINEARSOLENOIDCONNECTOR t-TTI t]]lt
t-T lI ?rr l M€ssurc Linear Solanoid Re3istance ei th€ SolonoidConnoctor: 1. Disconnectthe 2P connector from the linear solenoidconnector, 2, Measurethe resistance ol the linearsolenoid.
at l
l
L_l Terminalsideot maleterminals
ls the resistance about5.0O? B I25PI PCMCONNECTOR LSM {WHTI
LSP{RED)
CheckLinearSolenoid{or a Short Cileuit: 1. Disconnect the B (25P)connec tor from the PCM. 2. Checkfor continuitybetween t h e b o d y g r o u n da n d t h e B 1 terminaland 82 terminalindi vidually. Wiresideof lemaleterminals Rooairshort in the wires between the Bl end 82 terminek .nd the linearsolenoid.
To page14-81
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Ch€ckGround Lin€: 1 . D i s c o n n e ct th e A ( 3 2 P )c o n nectorfrom the PCM. 2. Checklor continuitybetween t e r m i n a l sA g a n d A 1 0 a n d b e t w e e nt e r m i n a l sA 2 2 a n d A.23.
PGl IBLKI
PG2(ALKI
Wiresideof temaleterminals Repair loose terminal or opon in th€ wires between terminals A9, A10,A22 and A23 and g.ound,and repairpoor ground lG101,G4011.
Measure Linear Solenoid R*istance: 1. Connectthe linearsolenoid2P connector. 2. Measure the resistance betweenthe 81 and 82 termi nals,
ls the resistance about5.00?
Ropair loos€ terminal or op6n in the wiles between th€ 81 and 82 l6rminals and the linear solenoid.
Chocklor loose tarminalfit in the PCM connectors. lf necosaarv, subsiituto a known-good PCM and recheck.
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14-81
ElectricalTroubleshooting('97Model) TroubleshootingFlowchart- Lock-upControlSystem . OBD ll ScanTool indicrt6 Cod6 P0740. . Self-diagno3bE indicatorlight indicatos Codc 40.
PossibloCause Faulty Lock-upcontrol sy3t6m
Checkand recordthe freezedata in caseit is neededlaterlor problem verification
Checktor Another Code: C h e c kw h e t h e rt h e O B D l l s c a n t o o l o r t h e E i n d i c a t o rl i g h t indicatesanothercode.
Doesthe OBDll scantool or the E indicatorlight indicate anothercode?
Perlorm the Troubleshooting Flowchart lor th€ indicat€d Codo{s).Rochecktor code P0740 {ilol after troubl$hooting. NOTE:Do not continuewith this troubleshootinguntil the causesof any other DTCShave beencorrected.
Tesl Line Pressure: M e a s u r et h e l i n e p r e s s u r e( s e e p a g e1 4 - 1 6a1n d 1 4 - 1 6 2 ) .
ls the line pressurewithinthe servicelimit?
* Even if yotl cannot reproducecode P0740.test the line pressure,test the clutch pressures, replacethe lock-upcontrolsolenoidvalveassembly and i{ necessary,
R6pairtho hydraulicayst€m as necessary{seepage 14-162}.
Test lst, 2nd, 3rd, and 4th Clutch Pressure: Measurethe 1st,2nd,3rd,and 4th clutch pressure(seepage 14161 thru 14''163).
ls eachclutchpressurewithin the servicelimit?
To page14-83
1 4-82
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Repairthe hydraulicsystem ds necessary {see pago 14-152rnd 14-163).
From page14 82
R e p l a c et h e L o c k - u p C o n t r o l S o l e n o i dV a l v e A s s e m b l ya n d Recheck: 1 . R e p l a c et h e l o c k - u pc o n t r o l solenoidvalve A/B assembly (seepage14-'135). 2 . T u r n t h e i g n i t i o ns w i t c hO F F and reset the PCM by removing the BACKuP (7.5A) fuse in the under-hoodfuse/relay box for morethan 10seconds. 3. lJsingthe scantool, checkto be surethatthe enginecoolant is 176"F180'C)or temperature above, 4 . D r i v et h e v e h i c l ea t 5 5 m p h (88 km/h)constantlyfor more tnan one mrnute. 5. Recheck for code P0740(40).
Doesthe OBDll scantool indicate codePO74O or doesthe El indica tor light indicatecode40?
The svstem is OK ai this time.
R e p l a c et h e L i n e a r S o l € n o i d A$embly and Recheck: ' 1 . B e p l a c et h e l i n e a r s o l e n o i d assembly{seepage14-138). 2. Turn the ignition switch OFF and resetthe PCMmemory by removingthe BACKUP (7.5A) fuse in the underhood fuse/ r e l a yb o x f o r m o r e t h a n 1 0 seconds. 3. Usingthe scantool, checkto be surethatthe enginecoolant temperature is 176"F(80'C)or above. 4. Drivethe vehicleat 55 mph (88 km/h)constantlyfor more than oneminute, 5. Recheck for codeP0740{40).
Does the OBD ll scan tool i n d i c a t e c o d e P 0 7 4 0o r d o e s the E indicator light indi cate code 40?
Replacethe transmission and torque convertorassembly.
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The svsteo is OK at this tim€.
ElectricalTroubleshooting('97Model) TroubleshootingFlowchart- Shift ControlSystem . OBD ll ScanTool indicatesCode P0730. . S e l t - d i a g n o s i sE , l i n d i c a t o r light indicatesCode41.
PossibleCause F""lty "t lft ".tttr"l "y"t..
Check and record the freeze data in case it is needed later for problem verification.
Checktor Another Code: C h e c kw h e t h e rt h e O B D l l s c a n t o o l o r t h e P l l i n d i c a t o rl i g h t indicatesanothercode,
Doesthe OBDll scantool or the E indicatorlight indicateanothercode?
Test lst. 2nd, 3rd. and 4th Clutch Pressure: M e a s u r et h e 1 s t ,2 n d , 3 r d , a n d 4th clutchpressure(seepage 141 6 1t h r u 1 4 - 1 6 3 ) .
ls eachclutchpressurewithin the servicelimit?
To page 14-85
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P e r t o r mt h e T r o u b l e s h o o t i n g Flowchart for the indicated Codels). Do not conlinu€ with t h i s t r o u b l e s h o o t i n gu n t i l t h e causesof anv other DTCShave been corrected.Recheckfor code P0730 {41)after troubloshooting. + E v e n i t y o u c a n n o t r e p r o d u c ec o d e P0730,test drive the vehicle,test the c l u t c h p r e s s u r e sa, n d i f n e c e s s a r y , replacethe shiftcontrolsolenoidvalve
Repairthe hydraulicsvstem as necessary lsee page 1,1-162and r4-1631.
Frompage14-84
ReplaceShift Control Solenoid vslve Assemblyand Recheck: 1. Replacethe shift control solenoidvalve A/B assembly (seepage'14136). 2. Turn the ignitionswitch OFF and resetthe PCMmemoryby removingthe BACKUP (7.5A) fuse in the under-hoodfuse/ relaybox for more than 10 seconds. 3 . D r i v et h e v e h i c l ea t o v e r 1 2 mph (20km/h)in 1st,2nd,3rd, and 4th qear for more than 30 secondsin E position. for codeP0730(41). 4. Recheck
Doesthe OBDll scantool indicatecodeP0730or does the E indicatorlight indi catecode41?
The svstem is OK at this time.
ReplaceLinea. Solenoid Ass€mbly and Recheck: 1 . R e p l a c et h e l i n e a r s o l e n o i d assemblylseepage14-138). 2 . T u r n t h e i g n i t i o ns w i t c hO F F and resetthe PcM memory by removingthe BACKUP 17.5A) fuse in the underhood fuse/ relayboxtor morethan 10sec' onos. '12 3 . D r i v et h e v e h i c l ea t o v e r mph {20km/h)in 1st,2nd,3rd, and 4th geal for more than 30 secondsin -Daposition. 4. Recheck for codeP0730(41).
Doesthe OBDllscantool indicatecode P0730or does the Di indicatorlightindicatecode 41?
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The syslem is OK at this time.
14-85
ElectricalTroubleshooting('97Modell TroubleshootingFlowchart- E IndicatorLight On Constantly The E indicator light is on constantly {not blinking) whenever the ignitionswitch b ON (lll. B I25PI PCMCONNECTOR
MeasureD4 IND Voltage: '1. Turnthe ignitionswitchOFF. 2 . Disconnect the I (25P)connector lrom the PCM. 3. Turnthe ignitionswitchON lll). 4. Measurethe voltagebetween the 813 terminaland body grouno,
IGRN/8LKI
Wire sideof temaleterminals Ropairshort to powor in the wire betwean tho B13 terminal and tho gauge assembly.
Maa3ureATP D4 Voltage: 1. Turnthe ignitionswitchOFF. 2. Connectthe B (25P)connector to the PCM. 3. Turn the ignitionswitchON (ll). 4. Shiftto any positionother than
E.
5. Measurethe voltage between the 824 terminaland body ground.
Test the lVT gear position switch (seepage'14139).
Check lor a short to g.ound in the wire betwoen tho B2rlte.mi nal and A/T gear position switch. It wira i3 OK, substitute a knowngood PCMand r€check.
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TroubleshootingFlowchart- E IndicatorLight DoesNot ComeOn The E indicator light doos not como on whon the ignition switch is first turned ON {lll. (lt should come on lor about two aaclnd!.I
Checkthe SorviceCheckConnectori Make sure the specialtool 1SCS ServiceConnector)is not connected tothe servicecheckconnector,
ls the specialtool(SCSService Connectorlconnected to the servicecheckconnector?
Di3connectthe spccial tool trom the servica chock connoctor and rechsck.
chock th. El IndicatorLight: Shift to E position.
Ch6ckfor looie terminal fit in the PCM connoctors. ll nocesssry, sub.titule a known-good PCM and rechock. PCM CONNECTORA {32PI
LGl IBRN/BLKI Checkthe Ground Circuit: 1. Turnthe ignitionswitchOFF. 2. Disconnect the A {32P)connector from the PCM. 3. Check for continuity between the A9 terminal and body ground and tho A22 terminal and body ground.
LG2(BRN/BLKI
Wire sideot temaleterminals
R€pair opon in the wire3 between the Ag or A22torrninab and G101. Repairthe body ground (G1011.
To page14-88
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14-87
ElectricalTroubleshooting('97Modell TroubleshootingFlowchart- E IndicatorLight DoesNot GomeOn (cont'dl Frompage14-87
IYEL/BLK) Measure Power Supply circuit Voltage: 1. Turnthe ignitionswatch ON (ll). 2. Measurethe voltagebetween t e r m i n a lA s g a n dA 1 1 a n d b e t w e e nt e r m i n a l sA 2 2 a n d A24.
ls therebaReryvoltageT
IGP2IYEL/BLK)
Repair open or short in the wire botw€on the A11 and/or A24 terminals, the PGM-FImain relav, and ih6 fuse box.
Measur€Dil INOVoltag6: L Turnlhe ignitionswitchOFF. 2. Connectthe A 132P) connector to the PCM. 3. Connecta digital multimeter to the 813 and A9 or A22 ter mtnals, 4 . T u r n t h e i g n i t i o ns w i t c hO N (ll),and makesurethat voltage is available for two seconds. Check for an op€n in the wire between the 913 terminal and the gauge assembly. lf wire is OK. check tor a faulty E indicator lighl bulb or a taulty gauge a$embly printed circuil bo.rd.
CheckD4IND tor a Short Circuit: Checkfor continuitybetweenthe 813terminaland body ground.
Ropairshort in the wiro between the 813 lerminal and the gauge assembly.
Checktor looseterminal frt in the PCM connector3. Chock the A/T gear position switch. ll necessary, substitute a known-good PCM and recheck.
14-88
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Wire sideof femaleterminals
TroubleshootingFlowchart- InterlockSystem- Shift LockSystem Shift lever cannot be moved from E] position with the brake P€del preiseo.
ChockBrakeLight Operation: Pressthe brakepedal.
Are the brakelightsON?
Repsirfauhy brake switch circuit {seos€ction231. PCMCONNECTORS
M€asureSTOPSW voltage: l Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e A ( 3 2 P )a n d D (16P)connectorslrom the PCM. 3. Measlre the voltagebetween the D5 and Ag or A22 terma nals with the brake Pedal pressed, Wire sideof lem6letermanals
Repair opon in the wi.e be{w.en the D5 terminal and the br.ke switd!. CONTROLUNIT INTERLOCK CONNECTOR I8P) Measur€ILU vohage: 1 . C o n n e c tt h e A { 3 2 P )a n d D to the PCM. connectors 116P) 2. Disconnectthe 8P connector from the interlockcontrol unit 3. Turnthe ignitionswitchON (ll). 4. Measurethe voltage between the No.7 terminaloftheinter lockcontrol unit and body ground with the brake Pedal pressed,
ls there batteryvoltage?
ILU IWHT/REDI
Ch€ckfor an opon or thon in the wire Mwoon tho No. 7 terminrl of the inte ock control unit and the 812 termin.l of the PcM. ll the wirs is OK, check tor loo3e terminal fit in the PCM connec_ to13. ll nece3sary,3ubstitutea known-good PCM and rechock.
(cont'd) To page14 90 www.emanualpro.com
14-89
ElectricalTroubleshooting('97 Model) TroubleshootingFlowchart- InterlockSystem- Shift LockSystem(cont'd) Frompage14.89 INTERLOCK CONTROLUNIT CONNECTOR {8P) Measu.eATP P Voltage: Measurethe voltage betweenthe N o . 6 t e r m i n a lo f t h e i n t e r l o c k controlunit and body ground.
NOTE:Shiftlevermust be in E.
ATPP IBLK/BLU' Repai. open in the wir6 betwoen tho No.6 termin.l olthe intorlock control unit and the A/T geal po.ition rwitch.
Chock Shitt Lock Solenoid lor .n Opon Circuit: 1. Turn the ignitionswitchOFF. 2. Disconnect the shift locksole notoconnoctor. 3. Checkfor continuitybetween the No. 3 terminal of the interlock contrcl unit and the No. 2 terminal ot the shift lock solenoid connector.
Wire sideot femaleterminals
SHIFTLOCKIYEL/BLK} 1 2 5
6
7 8
o SHIFT LOCK LOCK!SOLENOID CONNECTOR
YEL/BLK
1
Wiresideof femaleterminals Rapair opon in the wiro bstwcen tho No. 3 torminal and tho shift lock solenoid.
Check Shift Lock Solenoid Operation: '1. Connectthe No. 1 terminalof the shiftlocksolenoidconnector to the battery positive ter minal. and connectthe No. 2 terminalto the batterynegative terminal. 2. Chockthe shift lock solenoid operation.
NOTE:Do not connectthe No. 2 terminalto t h e b a t t e r yp o s i t i v et e r m i n a l o r y o u w i l l damagethe diode insidethe shift lock solenoid.
SHIFTL@K SOI.ENOID CONNECTOB ldir.sily on .olrnoidl
Terminalsidoof maleterminals Doesthe shift locksolenoid op€rateproperly?
Check tor looso terminal frt in th6 interlock cont.ol unit connectoB. ll ngcara,lary,sutEtitut€ a knowngood interlockcontrol unit and rocheck.
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Replsc€tho .hift lock solonoid.
TroubleshootingFlowchart- Interlocksystem KeyInterlocksystem lgnition key cannot be moved Irom ACC (l) pGition to LOCK(0) positionwhile Pushingthe ignition kev with the shift lever in lll posifio;, and the shift lever button rcleased. IGNITIONSW]TCH6P CONNECTOR C h e c k K e y I n t e r l o c kS o l e n o i d Op€ration: the ignitionswitch 1. Disconnect connector(6P). 2. Connectthe No. 4 terminalof the ignitionswitch6P connector to the battery Positiveter minal, and connectthe No. 3 terminalto the batterynega tiveterminal. 3. Checkthe key interlocksole n o i d o p e r a t i o nA c l i c k i n g so!nd sho!ld be heard.
Doesthe keyinterlock solenoidoperateproperly?
Check Key Interlock Switch OPer' adon: 1. Connectthe No. 5 terminalof the ignitionswitch connector to the batteryPositivetermi nal,and connectthe No 3 ter minal to the bafterynegative termrnal, 2 . T u r n t h e i g n i t i o ns w i t c h t o ACC(l),then pushrt. 3. Checkthe key interlocksole' n o i d o p e r a t i o n .A c l i c k i n g sound shouldbe heardwhile pushingthe ignitionkey.
Doesthe key interlock solenoidoperateProPerlY?
To page14 92
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KEYLOCKSOL {WHT/BLU)
ACCPUSHSW (WHT/YELI
Wire sideoI femaleterminals
Faulty koy interlock solenoid. Replacethe ignition key cylinder/ steedng lock as36mbly
KEYLOCKSOL (WHT/BLUI
Faulty key inte.lock switch Replacothe ignition key cylindor/ stoering lock a3r.mblY.
(cont'd)
14-91
ElectricalTroubleshooting{'97 Model) TroubleshootingFlowchart- InterlockSystem- KeyInterlockSystemlcont'dl F r o mp a g e1 4 - 9 1 INTERLOCK CONTROLUNIT CONNECIOR{8PI Check Key Interlock Solenoid for a Short Circuit: 1. Disconnectthe interlockcontrol unitconnector. 2. Checkfor continuitybetween t h e N o . l t e r m i n a la n d b o d y groundand betweenthe No.5 terminalandbodygroundindividually.
KEYLOCKSOL {WHT/8I-UI
ACCPUSHSW IWHTI
Wire sideof femaleterminals
ls therecontinuity?
Repairshort in the wire between the No. 1 or No. 5 terminal and the ignition switch 6P connector.
CheckParkPin Switch ODeration: Checkfor continuitybetweenthe No. I terminaland body ground.
ls therecontinuity?
Measu16ATP P Voltage: 1. Turnthe ignitionswitchON lll). 2. Measurethe vohagebetween the No.6 terminaa l nd body ground.
Check tor shori in the wire betwo€n the No. 8 terminal ot the interlock control unit and the park pin switch. lf wire is OK, ch6ckthe park pin switch.
Shiftlevermust be in E.
ATP P (BLK/BLU)
R6pei. open in the wire between the No. 6 i€rminal and the A/T gea. position switch.
Checkfor looseterminalfit in the interlock control unil connectors. lf necessery,substitute a knowngood interlockcontrol unit and r6check.
14-92
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ElectricalTroubleshooting('98- 00 Models) Troubleshooting Flowchart - Lock-up Control Solenoid Valve A .OBD ll Scan Tool indicates Code Pl753. . Self-di.gnosis E or E indicator light blinks once.
Poslible Cause . . . '
Dbconnectedlock-up control solenoidvalve A/B assemblYconnector Short or open in lock-up control solenoid valve A wire Faulty lock-upcontrol solenoid valve A Open in vB SOLwire
l f t h e P G M T e s t e ri s a v a i l a b l e , retrievethe M FreezeData,then clearthe PCM.
Test-drivethe vehicle under the same conditionsthe FreezeData
Did the code return?
Checkfor a Short to Power: '1. Turnthe ignitionswitchOFF. the B (25P)and D 2. Disconnect ( 1 6 P )c o n n e c t o r st r o m t h e PCM, 3. Turnthe ignitionswitchON (ll). 4. Measlre the voltagebetween the D1 and 820 or 822 terminals,
lntermittent failul.. The system is OK at this time. Check the fit of the Din3in all connectorsaffected by thb code.
A t32Pl i I
r rrilt l,1 I I
ltDrste,0n,, 2 .t 3 r B ' r ! 5 1 r .
LGl IBRN/BLKI LG2 (BRN/BLKI Wire sideof femaleterminals n€pair short lo power in the wire betw€€n the Dl terminal and the lock-upcontrol solenoidvalve A
Mg.sure Lock-up Control Solenoid Valve A Rssistance: 1. Turnthe ignitionswitchOFF. 2 . M e a s ur e t h e r e s i s t a n c e b e t w e e nt h e D 1 a n d 8 2 0 o r 822 terminals.
A {32P)
LGI|BRN/BLK) LG2IBRN/BLK) 12- 25 o? ls the resistance
To page 14 95
To page14-94
(cont'd)
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14-93
ElectricalTroubleshooting('98- 00 Models) TroubleshootingFlowchart- Lock-upControlSolenoidValveA (cont'dl Frompage14-93 FCM CONNECTORS
a t32P)
B {25P}
D l16Pl
C t31Pl
Checktor continuity between the B20 terminal and body ground, a n d b e t w e e nt h e 8 2 2 t e r m i n a l and body ground.
Wire sideot femaleterminals Ropair open in the wire3 b€tweon tha 820 and 822 terminalsand groundlG101l.
Ch6ck Lock-up Control Solonoid Valv6 A tor a Short Ci.cuit: '1. Disconnect the 2P connector from the lock up control solenoidvalveA/B assembly. 2. Checkfor continuitybetween the Dt and B2Oor 822 te(mi nals.
a l32Pl
c t3lPl
LGlIARN/ALKI LG2IBRN/BLKI
Ropai.lhort to g.ound in the wire b€twe€n the Dl terminal and the lock-upcontrol solonoidvslvg A.
LOCK-UPCONTROLSOLENOID VALVEA/B ASSEMBLYCONNECTOR Mersurg Lock-up Co|ttrol Solonoid Valvo A Rolktanco at tho Solonoid Connoctor: Measure the resistancobetween the No. 2 terminalof the lock,up control soleno;d valve A/B a s s e m b l yc o n n e c t o ra o d b o d y ground.
tFttl ._T= A
(o) Y
LCA (YELI
I
Terminalsideof maleterminals ls the resistance 12- 25 0?
Chsck for open in th€ wirc bctwe€n tho Dl terminal lnd th6 lock-up cont.ol solonoid v.lve A.
14-94
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R e p l a c et h e l o c k - u p c o n t r o l solonoid vrlve A/B a$ambly,
PCMCONNECTORS Moa3uraVB SOLVoltago: 1. Turnthe ignitionswitchON (ll) 2. lreasure the voltage between the D5 and 820 or 822 terminats.
a t32Pl
B (25P1
c (31P1
D {16P1
Wire side of lemalo terminals Chockfor blown No. 15 (7.5 Al luse in tho undor-dr.h lusa/lel.Y box. lf tho fulo i! oK, roprir op€n in the wiro betw6on th. D5 tor' minal and the und.r_dtah tuao/rohY box.
Chockfor looto torminrl fit in the PCM connectoJr. ll nocot3a.Y, rubstitut. . known-good PCM and rschock.
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14-95
ElectricalTroubleshooting('98- 00 Models) TroubleshootingFlowchart- Lock-upControlSotenoidValveB .OBD ll Scan Tool indicates Code P'l758. . Sell-diagnosis Dl or E indicator light blinkstwic€.
Possibl€Cause . . . .
Disconnectedlock-up control solenoidvalve A/8 assemblyconnector Short or open in lock-upcontrol solenoidvalve B wire Fauhy lock-upcontrol solenoidvalve B Open in VB SOL wir€
l f t h e P G M T e s t e ri s a v a i l a b l e , relrievethe A,/TFreezeData,then clearthe PCM-
Test-drivethe vehicle under the same conditionsthe FreezeData
Did the codereturn?
Intermittant tailure.The lystem is OK at this time. Check the tii ot tho pin3 in all connectorsathed by this code.
PCMCONNECTORS
Checkfor a Short to Pow€r: 1. Turnthe ignitionswitchOFF. 2. Disconnect the B 125P)and D ( 1 6 P )c o nn e c t o r sl r o m t h e PCM. 3. Turnthe ignitionswitchON 1ll). 4. Measurethe voltage betlveen the D3 and 820 or 822 terminals.
LC B {GRN/8LKI
LG1{BRN/BLK}I-G2{BRN/BLK) Wire sideof femaleterminals
Repairshon to power in the wire between tho D3 terminal and the look-upcontrol solenoidvalve B.
MeasureLock-upControlSolanoid ValveB Resistanc€: 1. Turnthe ignitionswitchOFF. 2. Measure the resistance between the D3 and 820 or 822terminals.
ls the resistance 12- 25 O?
To page 14-97
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A {32P1
To page14 98
Frompage14-96 PCMCONNECTORS c (31P1
B (25Pt CheckIor continuity betlveenthe B2Oterminal and body ground, a n d b e t w e e nt h e 8 2 2 t e r m i n a l and body ground.
D (16P1
{BRN/BLKI
rc1rBRN/BLKk' c$G2 t
Wire sideol femaleterminals Bepair open in the wirea between the 820 and 822 te.minalsand ground(G1011.
Check Lock-up Control Solenoid Valve I fo. a Short Circuit: 1. Disconnectthe 2P connector f r o m t h e l o c k _ pu c o n t r o l solenoidvalveA,/Bassembly 2. Checkfor continuitybetween the D3 and 820 or 822 termi nats.
ls therecontinuity?
A {32P1
Rep.ir short to ground in the wiie between the D3 terminal and the lock-uDcontrol solenoidvalve B.
SO1TNOID L(rcK.UPCONTROL CONNECTOR VALVEA/B ASSEMBLY Measure Lock-up Control Solenoid valve B Resistanceat the solenoid Connedo Measurethe resistancebetween the No. 1 terminalof the lock_up control solenoid valve A/B a s s e m b l yc o n n e c t o ra n d b o d Y ground.
12- 25 O? ls the resistance
LC B IGRN/BLK)
R e p l a c et h e l o c k _ u p c o n i r o l solenoidvalve A/8 a$embly.
Check for open in the wiro betwoen the D3 terminal and the lock-upcontrol solenoidvalve B.
(cont'd)
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14-97
ElectricalTroubleshooting('98- 00 Modelsl TroubleshootingFlowchart- Lock-upControlSolenoidValveB (cont,d) Frompage14 96
PCM CONNECTORS MeasuroVB SOLVoltago: 1. Turnthe ignitionswitchON llt). 2. Measurethe voltage betlveen the D5 and 820 or 822 termi nals,
VB SOL (BLK/YEL} A l32P)
LG1 (BBN/8LKI
LG2 (BRN/BLKI
Wire sideof Iomaleterminals
ls there battery voltage?
Checkfor loose terminal lit in the PCM connectors. ll n€ces3a.y, substitute a known-good pCM and .€check.
14-9 8
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Check tor blown No. t5 (7.5 Al fuse in the underdash fu36/.elay box. lf th6 fuse is OK, ..pair open in the wire betwooo tho D5 t.rminel and thg underdash two/relay Itox.
TroubleshootingFfowchart' O8O ll ScanTool indicatasCode P1705. . self-diagnGi3 E or El indica' tor light blinks five time3
AIT GearPositionSwitch {Short) PossibleCau3e . short in A/T gear position switch wire . FaultyA/T gear pGition switch
NOTE:Code 1705(5) is set when the PCMreceivestwo gear positioninputsat the sametime,
Obs€rvethe A/T Goar Position lndicalor: 1. Turnthe ignitionswitchON (ll). 2. Observethe A/T gearPosition indicator,and shift eachPosi' tion seParatelY.
Doesany indicatorstayon when the shiftleveris not in that position?
The system is OK at lhis time. Checkthe wir€ harne3sfot dam' age.
PCMCONNECTORS
A (32P1 Moasu.eATP R Voltage: 1 . S h i f t t o a l l p o s i t i o n so t h e r than E. 2. Measurethe voltage between the D6 and 820 or 822 terminals,
LGl IBRN/BLK) LG2 (BRN/BLK) Wire sideof femaleterminals
Check for short in the wire betwoon thc DSterminal and tho A/T gear position switch or A/T gear porition indicatol, and check for open in the wires batween the 820 and 822 t6lmi' lf nals and body ground 1G1011. wires are OK, checklor loos€ i€r_ minel fit in the PCM connectors. lf necBsarv, substittlle a known' good PCMand recheck.
To page'14-100
(cont'd)
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14-99
ElectricalTroubleshooting('98- 00 Modelsl TroubleshootingFlowchart- A/T Gearpositionswitch (short) (cont'dl From page 14-99 FCM CONNECTORS
A t32Pl Measur. ATP NP Voltago: 1 . S h i f t t o a l l p o s i t i o n so t h e r than E or E. 2. Measurethe voltage belween the 013 and 820 or 822 terminats.
B t25Pl
c (31P)
LGl {BRN/BLK)
Wire sideof lemaleterminals
Check for short in the wir6 b.twoen tha Dl3 terminal and the A/T go.r polition 3witch, and in th6 El and E poiition signal wir.! betwoen the A/T garr po3ition indicetor and the A/T garr position switch. lf wi.6s are OK, checkfor loole torminal fit in tho PCM connccto.s, lf neccasary, lubstituto a known-good PCMand rocheck.
Mcrsure ATP D4 Vohrg6: 1 . S h i f t t o a l l p o s i t i o n so t h e r than E {'98)or El ('99 - oo). 2. Measurethe voltage between the Dg and 820 or 822 terminals.
a t32Pl
LGl IERN/BLK}
Check tor Bhort in the wi.. bctw6cn thg Dg torminal and the A/T ge.r position .witch or A/T geor poaition indicator. lf wiaaa are OK, ch.ck lor loose torminal fit in the PICMconn.cto6. lf n€ce3sary, subgthute r lnown-good rcM and roch6d(.
To page14-101
14-100
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ATP NP ILT GRNI
From page 14 100
PCMCONNECTORS
B (2sP)
c (31P}
D t16P)
' t d. , lll;
;l';nl, :if
Measure ATP D3 Vollage l'98 model): 1 . S h i f t t o a l l p o s i t i o n so t h e r t h a nE . 2, Measurethe voltagebetween the D8 and 820 or 822 terminals-
ls therebatteryvoltage?
LGl (BRN/BLK}
ATPD3 {PNK)
Wire sideof femaleterminals
Check for shott in the wire belween lh6 08 terminal and the A/T gear posilion switch or A/T gear position indicator ('98) lf wires are OK, checklor loose terminal tit in rhe PCM connectors. ff necessary,substitute a known_ good PCMand recheck.
A (32P1 Mearure ATP 2 voltage: 1 . S h i f t t o a l l p o s i t i o n so t h e r than E. 2. Measurethe voltagebetween the D14and 820 or 822 termi nals.
LG2IBRN/BLK)
B l25Pl
c (31P1
D {16P1
LGl IBRN/BLKI
Check for short in the wire between tho D1{ terminal and the A/T gear posilion switch or A/T gear position indicalor. lf wiles are OK, checkfor loose t€r' minal fit in the PCM connectors. It necessarv,substitute a knowngood PCMand recheck.
To page14-102
(cont'd)
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14-101
ElectricalTroubleshooting('gg- 00 Modelsl TroubleshootingFlowchart- A/T Gearpositionswitch {short) (cont,d) Frompage14 101
MeasureATP 1 Voltag€: 1 . S h i f t t o a l l p o s i t i o n so t h e r than E. 2. Measurethe voltagebetween the D15and 820 ot 822 tetminals.
PCM CONNECTORS
B t25Pt
c t3lPl
LGl {BRN/BLK)
Wire sideof femaleterminals
Chock lor short in the wire between the D15 terminal and the A/T gear position switch or A/T gear position indicator. lf wires a.e OK, ch6ckfor loos€ t6rminal fil in tho PCM connectorc. ll neco$ary, substiiute a knowngood PCMand rechsck.
Chockfor loose terminalfit in the PCM connectors. lf nocessary, sub3titut€ s known-good PCM and recheck. The system 3hould be OK at this point. lf any indicators stay on when the shift lever is not in ihe select€dposition, pertorm this troubleshootingtlowchart again.
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D {16P1
TroubleshootingFlowchart- A/T GearPositionSwitch (Open) Po$iblg Cause
. OBD ll Scan Tool indicates Codo Pl706. . Self-diagnosisFl or E indicato. lighl blinks six times.
. DbconnectedA/T gear position switch connoctor . Open in A/T gear po3ition switch wiro . Faulty A/T g€ar position switch
Are any ofthe gearpositionindi catorsnot workingwhen you shiftthem?
The systemis OK.tthis time. Checkfor oth6r probl€ms such as harne3sdamage.
Test the A/T gear position switch (seepage14-139).
P,CMCONNECTORS MeasureATP R Vohago: 1. Turnthe ignitionswitchON (ll). 2. Shittto E position. 3. Measureihe voltage between the D6 and 820 ot 822 tetfii nals,
LGT(BNN/BLKI LG2IBRN/BLK) Wire sideof femaleterminals
Repairopen in tho wiro betwoen the D6 terminal and the A/T gear oosition switch.
c l31P)
A {32P) MeasureATP NP Volt.g€: 1. Shiftto Elor E position. 2. Measurethe voltagebetween the D13and 820 or 822termi nals,
LGl {SRN/BLK)
ATP NP (LTGRN}
Repairopen in the wiro between t h € D l 3 t e r m i n a la n d t h € A / T gesr posilion awitch.
To page14-104
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{cont'd)
14-103
ElectricalTroubleshooting('98- 00 Model) TroubleshootingFlowchart- A/T GearPositionSwitch (Open)(cont'd) Frompage14-103 PCMCONNECTORS Me.sure ATP D4 Vohrge: 1. Shift to E 1'98)or E ('9900) position. 2. Measurethe voltage between the Dg and 820 or 822 terminats.
B {25Pt
c (31P|
LGl IERN/BLKI
Wire side of female terminals
Repairopon in th6 wire between tho m tarminal and the A/T geal position swhch.
Me..ure ATP 03 Vohage l'98 modell: 1. Shiftto E position. 2. Measurethe voltage between the DB and 820 or 822 tetminals,
LGl {BRN/BLKI
Repairopen in the wire botwoon th6 08 terminal .nd the A/T geat position switch (381.
MeasuroATP 2 Voltage: 1. Shilt to E position. 2. Measurethe voltage between the D14and 820 or 822termi nats.
LGl {BRN/ELXI
Repairopon in the wire between the D14 t€.minal end the A,/T gear po3ition switch,
To page 14 105
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Frompage14-104 FCM CONNECTORS B t25Pl
MeasureATP 1 Voliag€: 1. Shiftto E position. 2, Measurethe voltagebetween the D15and 820 or B22terminals.
c t3lPt
D tl6Pl
LGl IBRN/BLKI
Wire sideof femaleterminals
Repairopen in the wire between t h e D 1 5t e r m i n a l a n d t h e A / T gear poaition switch.
Check LG Wire tor an Open Circuit: '1. Turnthe ignitionswitchOFF. 2. Checklor continuitybetween t h e 8 2 0 t e r m i n a la n d b o d y ground,and betweenthe 822 terminaland body ground.
ls therecontinuity?
A (32P1
B (2sP)
c (31P|
LGl (BRN/BLKI
Repair open in th. wires between the B20 and 822 tarminals and body ground. and repair poor ground{G101).
Checktor loose terminaltit in the PCM connectors. lf n6cassary, substitute d known-good PCM and recheck.
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14-105
ElectricalTroubleshooting('98- 00 Models) TroubleshootingFlowchart- Shift ControlSolenoidValveA . OBD ll Scan Tool indicates Code P0753. . Self-diagnosisEl or E indicator light blihk5 ievon times.
Po$ible Caus€
' . Short or open in shift control solenoid valve A wire . Faulty3hift control 3olenoidvalvo A . Ooen in VB SOL wire
It the PGM Tester is available, retrievethe A"/TFreezeData,then clearth€ PCM.
Test drive the vehicle under the sameconditionsthe FreezeData
Did the code return?
Ch6ckfor a Short 1o Power: 1. Turnthe ignitionswitchOFF. 2. Disconnect the B (25P)and D ( 1 6 P i c o n n e c t o r sf r o m t h e PCM, 3. Turnthe ignitionswitchON (ll). 4. Measurethe voltagebetween the D7 and 820 or 822 termi nals.
Intermittent tailure. The system b OX at this timo. Check the fit o{ the pins in all connectora .ttected by this code.
8 {2sPl
A t32P)
Ct3lPt
LG1IBRN/BLKI LG2IBRN/BLK} Wi16sideof femaleterminals
Repairshort to power in the wire betwoen tho D7 terminal and the shift control solenoid valve A.
Moasure Shift Control Solenoid Valv6 A Resistanco: 1. Turnthe ignitionswitchOFF. 2 . [ r e a s ur e t h e r e s i s t a n c e between the D7 and 820 or 822terminals.
A (:l2Pl
a t25Pl
LGl
ls the resistance l2 - 25 0?
To page14-107
14-106
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To page 14-108
-
c {31P}
(BRN/BLKI LG2 (BRN/BLKI
ll Dll6Pt
F r o mp a g e1 4 - 1 0 6 A l32Pl Checkfor continuity between the 8 2 0 t e r m i n a la n d b o d y g r o u n d . a n d b e t w e e nt h e 8 2 2 t e r m i n a l and body ground.
PCMCONNECTORS (31 B (25P1 cC (31P)
LGl IERN/BLKI
D {16P)
LG2 {BRN/BLK)
Wiresideof femaleterminals
Ropairopen in the wir.s betweon the 820 and 822 terminal3 and ground(G1011.
C h e c kS h i l t C o n t r o l S o l e n o i d Valve A for . Short Circuit: 1. Disconnectthe 2P connector from the shiftcontrolsolenoid valve !y'B assembly. 2. Checktor continuitybetween the D7 and B2Oot 822 tetminals.
ls therecontinuity?
LGl IBRN/BLK} LG2 (BRN/BLK}
Repairshort to ground in the wire be{we€nthe D7 terminal and the 3hift control solonoidvalvo A.
SHIFTCONTROISOLENOID VALVEA/B ASSEMBLYCONNECTOR Measure Shift Control Solenoid Valve A Resistanceat ihe SolenoidConnector: Measurethe resistancebetween t h e N o . I t e r m i n a lo f t h e s h i f t c o n t r o l s o l e n o i d v al v e A / B a s s e m b l yc o n n e c t o ra n d b o d y ground,
IiiE-] "*otrau/"aalF
I Termanal sideof maleterminals
l s t h e r e s i s t a n c e1 2 2 5 Q ?
Replacethe shrft control solenoid valve A/B assembly.
Check for op.n in the wire betwoon tho D7 terminal and the shift control solenoidvalve A.
(cont'd)
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14-107
ElectricalTroubleshooting('98- 00 Models) TroubleshootingFlowchart- Shift ControlSolenoidValveA (cont'd) Frompage14-106
MoasureVB SOLVoftago: 1 . T u r n t h e i g n i t i o ns w i t c hO N flr). 2. Measurethe voltagebetween the D5 and 820 or 822 terminals,
VB SOL IBLK/YEL)
Wire sideof femaleterminals
ls therebatteryvohage?
Checkfor loose terminalfit in the PCM connectors. lf necessary, subltitute a known-good PCM and recheck.
14-108
www.emanualpro.com
Checklor blown No. 15 (7.5 Al fuse in the under-dashfuse/relay box. lf the tuse is OK, repair open in the wi.e between the D5 terminal and the under-dashfuse/ relay box.
TroubleshootingFlowchart- Shift ControlSolenoidValveB . OBD ll ScanTool indicatosCode P0758. . Self-di.gnosis E or E indicalor lighf blinb 6ight times.
Po3sibleC.us€ .Dt . Short or oDenin shift control solenoidvalve B wira ' F.ulW shitt cont.ol solonoidvalvc B . Opon in VB SOLwir6
lf the PGM Tester is available. retrievethe A/f FreezeData,then clearthe PCM.
Test-drivethe vehicle under the same conditionsthe FreezeData
Did the code return?
Checklol o Short to Power: 1. Turnthe ignitionswitchOFF. 2. Disconnect the B 125P)and D ( 1 6 P )c o n n e c t o r sf r o m t h e PCM, 3 . T u r n t h e i g n i t i o ns w i t c hO N 0ll. 4. Measu.ethe voltagebetween the D2 and 820 or 822 terminals.
Intermittent failu16. Tha 3yltgm is OK at thi3 time. Check the fit of the Dins in all connectors affocted by this codo.
PCMCONNECTOBS
a l32Pl
B {2sPl
c t3tP}
LG2 {BRN/BLK}
LGl {BRN/BLKI
Wire side of lemale terminals
Ropairshort to powor in lhe wire betwoon the D2 termin.l .nd tho shift cont.ol solenoid vslv6 B.
Measuro Shift Control Solonoid Valve I Rosbtance: 1. Turnthe ignitionswitchOFF. 2 . M e a s ur e t h e r e s i s t a n c e between tho D2 and 820 or 822terminals.
c (31P1
LGI {8RN/BLKI
ls the resistanc€ 12- 25 O?
LG2IBRN/BLKI
T o p a g e1 4 - 1 1 1
(cont'd) To page14-110
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ElectricalTroubleshooting('98- 00 Models) TroubleshootingFlowchart- Shift ControlSolenoidValveB {cont'd) Frompage14-109 PCMCONNECTORS A (32P1
a {25P)
cC 13lPl t31
D tl6Pl
Checkfor continuity between the 8 2 0 t e r m i n a la n d b o d y g r o u n d , a n d b e t w e e nt h e 8 2 2 t e r m i n a l and body ground.
Wire sideof l6maleterminals Repairopen in the wire! b€twoen th6 B20 and 822 terminals and groundlG101l.
C h e c kS h i l t C o n t r o l S o l e n o i d Valve B for a Sho.t Circuit: 1, Disconnectthe 2P connector from the shiftcontrolsolenoid valve !VB assembly. 2. Checktor continuitybetween the D2 and B2Oo( 822 tetminals,
a t32Pt
c {31P1
LG1IBRN/BLKI
LG2IBRN/BLKI
R e p a i rs h o r t t o g r o u n d i n t h e wir€ b€twe6n th€ D2 terminal and the shift control solenoid valve B. SHIFTCONTROLSOLENOID VALVEA/B ASSEMBLYCONNECTOR
Measu.e Shift Control Solenoid Valve B Rasistanceat tha Solonoid Connector: Measurethe resistancebetween the No.2 terminalof the shiftcon trol solenoidvalve NB assemblv connectorand body ground.
lF-E] I
SH B IGRN/WHTI
(ol
Y I
I
Terminalsideof maleterminals 12 25 O? ls the resistance
Check for oDen in the wire b€twoen ths D2 torminal and the shift control 3olenoidvalve 8.
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1 4 -1 1 0
ReDlac.the shift control solenoid valve A/B r$embly.
I
Frompage14-109
PCMCONNECTORS M6r3ure vB SOLvoltage: 1. Turn ihe ignition switch ON flr). 2. Measurethe voltage between the D5 and B20or B22terminals.
A l32Pl
B (25Pt
C (31P1
o (16P)
Wire sideof femaleterminals
Ch6cktor blown No. '15{7.5 Al fuse in tho undo.-dashtuso/telay box. It the fu3s is OK, tepair open in the wire bctweon the D5 terminal and the under-dash fose/ rolaYbox.
Chackto. loo3ete.minal fit in lho PCM connectols. lf nccoa3ary, substituto a known-good PCM snd rechock.
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14-111
ElectricalTroubleshooting('98- 00 Models)
. OgD ll Sc.n Tool indicat* Code m720. ' selt-diagnosis E or E indicator light blinks nin6 time3.
Po$ibl€ Csuse . . . .
Loo3€or tauhy conn€ctionbatween the PCMand vehicle harness Diaconnectedcountetshaft3Deodsensorconnectoa Short or opon in countershaltspegdsensorwiro Faulty countershattspoedsensol
It the PGM Tester is available, retrievethe A"/TFreezeData,then clearthe PCM.
Test-drivethe vehicle under the same conditionsthe FreezeData
Intormittent failuro. The systom is OK .t thb time. Checkthe Iit of the pins in rll connsctors .fLctod bv thi! code.
C h e c kt h e c o u n t e r s h a f ts p e e d sensor installation.and check it for damage.
ls the countershaftspeedsensor installedproperly.and not damaged?
Measure Countershaft Sp6€d SonsoaR€sistsnc€at the Senlor Connector: 1. Disconnectthe 2P connector from the countershaftspeed 2. Measurecountershaftspeed sensorresrstanceat the sensor connector.
ls the resistance400 - 600 0?
T o p a g e1 4 - 1 1 3
14-1 1 2
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Reinstallor replaceand rechcck.
COUNTERSHAFT SPEED S€NSORCONNECIOR
ttt'l -T-TrY oI l LI
Terminalsideof maleterminals
F r o mp a g e1 4 ' 1 1 2
Check Countershaft Speed Sensor for a Short Circuit: ' 1 . D i s c o n n e ct th e D ( 1 6 P )c o n nectorfrom the PCM. 2. Checklor continuitybetween body groundand the D10term i n a la n d D l 6 t e r m i n a il n d i vidually.
NCIBLUI
PCMCONNECTORS
A t32Pl
B (25P1
D {16P1
c l31P)
ial,tu]g NCSGIGRNI
Wire sideol femaleterminals
Repairshort in the wire3 botweon the Dl0 and D16 terminals and the countershaft 3De€dsensor.
M e a s u r eC o u n t e r s h a t tS p e e d S6n3orCircuit to. an Open: 1 , C on n e c t t h e c o u n t e r s h a f t speeosensorconnector, 2 . M e a s ur e t h e r e s i s t a n c e betweenthe D10and D16termrnals,
a l32Pl
B (25P1
c (31PI
NCSGIGRN}
ls the resistance400- 600 0?
Repair loose terminal or open in the wiies between the D10 and O16 terminals and th. countetshaft sD€edsensor.
Checktor loos. terminal fit in the PCM conn€ctoas.It necessary, substitute a known-good PCM and recheck.
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14-113
ElectricalTroubleshooting('98- 00 Modelsl TroubleshootingFlowchart- MainshaftSpeedSensor . OBD ll ScanTool indicat$ Code m715. . S€lf-diagnosi3E or @ indicator light indicatosCode 15.
l f t h e P G M T e s t e ri s a v a i l a b l e , retrievethe A/f FreezeData,then clearthe PCM.
PorsibleCruse . Disconnsct€dmsinsh.ft 3pood3gnlor conncctol . Short or open in mainshaft 3poedsensorwire . Faultv mainshrtt speedsonsot NOTE:Codo P0715(15)on the PCM doesn'talwaysmoan there'san electrical problemin the mainshaftor countershaft (15) speedsensorcircuit;code P07'15 problemin the transmission. may also indicatea mechanical Any problemcausing irregularcountershaftto mainshaftspoeddifferencecan causethis codo;this can sometimesbe seen in A'/TFree2eData.FreezeDatacan also indicatean electrical problemin the sensorcircuits;f one of the sensorsreads0 mph duringa test dnve.
Test-drivethe vehicle under the sameconditionsthe FreereData
Did the code return?
Intermittont tailuro. Tha sy3tem b OK at this tims. Checkthefit of tho pins in .ll connoctoB alt6cted bv this code.
Checkthe mainshaftand countershaft speedsensorsinstallation, and checkthem for damage.
Are the mainshaftand countershaft speedsensorsinstalled properly,and not damaged?
MoasureMainshattSpe€dSenror R€sirtancoat ths S€nsol Connoctor: 1. Disconnectthe 2P connector from the mainshaftspeedsen sor. 2. Measuremainshattspeedsensor resrstanceat the sensor connefior.
ls the resistance400 600 0?
To page14-115
14-1 1 4
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Reinstallor ropllce and rochock.
MAINSHAFTSPEED SENSORCONNECTOR
Terminalsideof maleterminals
Frompage14-114 PCMCONNECTORS Check Mainshaft Speed Sensor for a Short Circuit: 1 . D i s c o n n e ct th e D ( 1 6 P )c o n nectortrom the PCM. 2- Ch€cktor continuity between body groundand the D11terminal and Dl2 terminal indi vidually.
D t16Pt
c t3lPl
A {32P}
-'lTZ
NMSG
lit4'l Fl l'1tilFTil ,'l unr
v v v v v l.t1lLtLt?!/]|,1tut larrlrllllpr=r tavtq tptntatEElt [1!]t! pl NM (RCD| (O)
(o)Y Y =
wire sideol femaleterminals
ReDairshort in tho wiros botwe€n th€ Dl1 and D12 torminal3.nd tho main3haft 3Doedaonlor.
MoasureMainshaftSp6€dSonsor Rosi3tancei 1. Connectthe mainshaftspeed sensorconn6ctor. 2. Measure the resistance betweenthe Dl1 and D12termrnals,
ls the resistance400- 600 0?
B l25Pt
Run the Eloctric€l Troubldhooting Flowdrrrt for co& F0720(codo 91. Chocklor loo3otorminrl fit in the PCM connectors. It necos3ary, substitute r known-good PCM and r€ch€ck.
c {31P1 -1-\ 2_1 |1 -1 -,s/ / 1
ChockNM Wire Continuity: 1. Disconnectthe 2P connector trom the m6inshaftspeedsen-
st/
v,1zzfififinffiiFr F/l,6t FFF| LrLrEll
2. Checkfor continuitybetween the D11terminalandthe No.2 terminal of the mainshaft speeosensorconnector,
NM {REDI
MAINSHAFTSPEEO SENSORCONNECTOR
Wire sideof temaleterminals Rcpair opon in tho wire betw.en th6 Dll tarminal and the mainshaft lpood sonsor.
To page'14-1'16
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(cont'd)
14-115
ElectricalTroubleshooting('98 - 00 Models) TroubleshootingFlowchart- MainshaftSpeedSensor(cont'd) Frompage14 115
PCMCONNECTORS
Ch6ckNMSG Wire Continuitv: Chockfor continuity between the Dl2 terminaland the No. 1 terminal of the mainshaftspeedsensor conn€ctot. MAINSHAFTSPEED SENSORCONNECTOR Wire sideof femaleterminals
ls therecontinuity?
Checkfor looso terminal fit in the PCM connoctorc. lf necessary, substitute a known-good PCM and aech6ck.
14-1 1 6
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Ropai. op€n in the wi.e hn eon the D12 terminal and the mainshaft sDeedlensor,
. OBD ll ScanTool indic{t.. Cods P1768. . selt-diagnosis El or E indicator light indicrt.. Codo 16.
Po$ible Cau3e ' . . . .
Disconnectsdlinoar solenoid conneclol Short or open in linear solenoidwire Faulty linear3olenoid Open in VB SOL wire Open in PGI and PG2wires or poot g.ound {G101).
l f t h e P G M T e s t e ri s a v a i l a b l e . retrievethe A/T FreezeData,then clearthe PCM.
Test drive the vehicleunder the same conditionsthe FreezeData
Did the code return?
Inlermittont tailure, The 3yrtom is OK at thb time. Checkthe tit ot lhe oins in all connectoE affoctod by this code. LINEARSOLENOIDCOiINECTOR
Meaaure Linear Solenoid R€sistanc€ at the SolenoidConnector: 1. Disconnectthe 2P connector from the linearsolenoid2. Measurelinearsolenoidresistanceat the solenoidconnec tor.
t-rtt (9l t t Terminalsideol maleterminals
ls the resistance about5 O?
Chock Lino.r Sol.noid to. a Short Circuh: 1 . D i s c o n n e ctth e B ( 2 5 P )c o n nectorlrom the PCM. 2. Checktor continuity between body ground and the 88 terminal and the 817 terminal individually.
A l32Pt
B {2sP)
LSP(REDI
wire sideoI temaleterminals
ls therecontinuity?
Repair 3ho to ground in the wires belween the 88 rnd B17 terminalsand tho linaar3olenoid.
T o p a g e1 4 - 1 1 8
(cont'd)
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14-117
('98- 00 Models) ElectricalTroubleshooting Troubleshooting Flowchaft - Linear Solenoid (cont'dl F r o mp a g e1 4 - 1 1 7
MeasureLinea. SolenoidResistance: 1 . C o n n e c t h e l i n e a rs o l e n o i d connector, 2. Measure the resistance betweenthe 88 and 817 ter mrnals,
a t32Pl
c t3lPl
LSP(REO) Wire sideof femaleterminals
ls the resistance about5 O?
MeasureVB SOLVoltago: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ct th e D 1 1 6 Pc) o n nectortrom the PCM. 3. Turnthe ignitionswitchON (ll). 4. Measurethe voltagebetween the D5 and 920 ot B22 tetminals.
ls therebafteryvoltsge?
Repair loose torminal oi open in the wires between rhe 88 and 817 terminalsand the linear solenoid.
a l32Pl
Checkfor blown No. 15 17.5Al fuse in the under-da3htus€/relay box. lI the fuse is OK, rap.ir open in the wire betwe€n the D5 terminal and th€ under-dash tuso/ relav box. A (32P1
Check LG Wire for.n Open Circuit: 1. Turnthe ignitionswitchOFF. 2. Checkfor continuitybetween t h e 8 2 0 t e r m i n a la n d b o d y ground,and betweenthe 822 terminaland body ground.
ls therecontinuity?
Chacktor loose terminel fit in the PCM connecto13.It nocosaary, substitute a known-good PCM .nd recheck,
1 4 -1 1 8
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B l2sP)
LGl IBRN/BLK}
Repair op6n in the wiros betwe€n the 820 and 822 terminals and body ground, and repair poor g.oundiG101).
c 13lPl
LG2{BRN/BLKI
D l16P)
TroubleshootingFlowchart- Lock-upControlSystem . OBD ll Scan Tool indicates Code P07,10. . selt-diagnGis El or E indicator light indicatesCode40.
PossibleCaus6 Faultylock-up control system
l f t h e P G M T e s t e ri s a v a i l a b l e , retrievethe A/T FreezeData,then clearthe PCM.
Test-drivethe vehicle under the same conditionsthe FreezeData
Did the codereturn?
lntermittent failur6. The system is OK at this time, Check the fil ol the pins in all connectors affectedbv lhis code.
Checkfor Another Codc: Checkwhetherthe OBDll scantool or rhe E or E]indicatorlightindi catesanothercode,
Doesthe OBD ll scan tool or the @ or E indicator light indicateanothercode?
P e r f o r mt h o T r o u b l e s h o o t i n g Flowchart for lh6 indicated Codolll. Rechocktor code P0740 (,lO)after troubleshooting. N O T E :D o n o t c o n t i n u et h i s t r o u b l e s h o o t i n gu n t i l t h e c a u s e so f a n y other DTCShave beencorrected.
Test Lin€ Pres3uro: Measurethe line pressure(see page14'161and 14-162i.
ls the line pressurewithin the servicelimit?
T o p a g e1 4 - 1 2 0
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Repairth6 hyd.aulic system as necessary {see page 14-161and 14-152).
(cont'd)
14-119
ElectricalTroubleshooting('98 - 00 Models) TroubleshootingFlowchart- Lock-upControlSystem(cont'd) F r o mp a g e1 4 - 1 1 9
R e p l a c et h e L o c k - u p C o n t r o l Solenoid Valve A/B Assombly and Recheck: 1 . R e p l a c et h e l o c k - u pc o n t r o l solenoidvalve A,/Bassembly (seepage14-!35). 2. Turn the ignition switch OFF and resetthe PCMmemoryby removingthe BACKUP (7.5A) f u s e i n t h e u n d e F d a s hf u s e / relaybox for more than 10 seconds. 3. Usingthe scantool, checkto be surethatthe enginecoolant temperature is 176"F{80'C)or above. 4 . D r i v et h e v e h i c l ea t 5 5 m p h (88 km/h)constantlytor more than one minute. 5. Recheck {or code P0740(40i.
Doesthe OBDll scantool indicate code P0740or does the [9i] or E indicatorlightindicatecode40?
14-120
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The system is OK at this time.
TroubleshootingFlowchart- Shift ControlSystem . OBD ll Scan Tool indicates Code P0730. . Self-diagnosisJir or E indicator light indicatesCode41.
PossibleCause Faultvshift control sYstem
lf the PGM Tester is available, retrieve the AJ.I Freeze Data, then clear the PCM.
Test-drivethe vehicle under the same conditionsthe FreezeData
Didthe codereturn?
lntermittent failure. The system is OK at this time. Ch€ck the fit of the pins in all connectors atfectedby this code.
Checkfor Another Code: C h e c kw h e t h e rt h e O B D l l s c a n tool or the l-Drlor E] indicator light indicatesanothercode.
Doesthe OBD ll scan tool or the Da or E indicator lighlindicateanothercode?
P e r l o r mt h e T r o u b l e s h o o t i n g Flowchart for the indicaled Codets).Recheckfor code P0730 {4116ft6r troubleshooting. N O T E :D o n o t c o n t i n u et h a s t r o u b l e s h o o t i n gu n t i l t h e c a u s e so f a n y otherDTCShavebeencorrected.
MeasureEachClutch Pressure: M e a s u r et h e 1 s t ,2 n d , 3 r d , a n d 4th clutchPressure(seePage14 1 6 1t h r u1 4 1 6 3 ) .
l s e a ch c l u t c h P r e s s u r e withinthe servicelimit?
Repairthe hydraulicsYstem as necessary (se€ page 14-162and 14-163).
(cont'd) T o p a g e1 4 - 1 2 2
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14-121
ElectricalTroubleshooting{'gB- 00 Models} TroubleshootingFlowchart- Shift ControlSystem(cont,d) Frompage14 121
ReplaceShilt Cont.ol Solenoid Valve A$ambly and Recheck: '1. Replace the shift control solenoidvalve A/B assembly (seepage 14-136)and the lin, e a r s o l e n o i da s s e m b l y( s e e p a g e1 4 1 3 8 ) . 2. Turn the ignition switch OFF and resetthe PCMmemory by removingthe BACKUP (7.5A) tuse in the !nder-hood luse/ r e l a yb o x f o r m o r e t h a n 1 0 seconos. 3. Drive the vehicle at over '12 mph (20km,/ti) in lst,2nd,3rd, and 4th gear tor more than 30 secondsin E position. 4. Recheck for codeP0730(41).
Doesthe OBD ll scantool indicatecodeP0730or does the E orE indicatorlight indicatecode41?
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Tho system is OK .l this tim€.
TroubleshootingFlowchart- Df or @ IndicatorLight DoesNot ComeOn The E or El indicator light doe3 not cofie on when the ignitaon switch is first turned ON {ll). {lt should como on for about two s.cond3 and ihen go out.l Check ths Service Check Conneclor: Make sure the specialtool (SCS S e r v i c eC o n n e c t o r i)s n o t c o n nectedto the servicecheckcon nector. ls the specialtool (SCSService Connector)connectedto the ser_ vice checkconnector?
Disconneclthe special lool lrom tha service check connoctor and recheck.
check the E or E Indicator Ught: Shiftto E or E position. Doesthe E or P indicator lightcome on?
Checkfor loo3et6lminal tit in the PCM connectors. lf necessary. substitute a known-good PCM and recheck.
A l32Pl Checkthe Gtound Circuil: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e B ( 2 5 P )c o n nectorfrom the PCM. 3. Checkfor continuitYbetween l ndbody t h e 8 2 0t e r m i n a a ground,and betweenthe 822 terminaland body ground.
PCMCONNECTORS (31 c (31P)
B t2sPl
f -t l r p r i i r r 6 3 r o l , : 11/ / l//| $fe?0?r/a)1 e 'oI 13 I , rrr ltelx ?r2? r,/ i - T _
D (16P)
l*f4tr8-
LG2 (BRN/BL()
LG1 {8RN/BI-KI I I
@ @ I +
+
Wiresideof lemaleterminals
ls therecontinuity?
Repairopen in the wires between the 820 and 822 terminals and ground {G1011,and r€Pair Poor ground(G101).
c (31P) Measure Power Supply Circuit Voltage: 1. Turnthe ignitionswitchON 1ll). 2. Measurethe voltagebetween terminalsB1 and 822 and betweenterminalsBg and 820.
ls there battery voltage?
YES
Repairopen or short in tho wi.e between the 81 and/or Bg torminals and the PGM-FImain r€lay, .nd between tho PGM-FImain relay and the under-hoodtuse/ relay box.
(cont'd)
To page14-124
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14-123
ElectricalTroubleshooting('98- 00 Modelsl Troubleshooting Flowchart- E or @ IndicatorLightDoesNot come on (cont'd) F r o mp a g e1 4 - 1 2 3 PCMCONNECTORS B {25P} MeasureD4IND or D lNDVoh.ge: 'L Turn the ignitionswitchOFF. 2. Connectthe B (25Plconnector to the PCM. 3. Connecta djgital multimeter to the A14 and 820 or B22ter minals, 4 . T u r n t h e i g n i t i o ns w i t c hO N (ll),and makesurethatvoltage is availablefor two seconds.
(3 cC (31P)
D (16P1
n f,-ff n t f,Fjrti.trnn mflnr LG2 (BRN/BLKI
D4 INOor D IND IGRN/BLKI
Wire sideof femaleterminals
Check lor open in the wire b€tweenthe Al/t terminal .nd the geugo a$eftbly. lf wi.a is OK. check tor a fautty E or E indicator light bulb or a faulty gauge ass€mbly p.inted circuit board.
D {16P) CheckD4 IND or D IND for a Short Circuiti Checkfor continuitybetweenthe A14terminaland body ground.
D4 IND or D IND
Ropairshort in tha wiro b€twesn the A14 termin.l and th€ gaugo .ssemblv.
Checktor looso telminal tit in the PCM connoctors. Chock the A/T gear position swiich. It neces3ary, substitute a known-good PCMand rech€ck.
14-124
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TroubleshootingFlowchart- E or E IndicatorLight On Gonstantly The E or E indicator light is on constantly(not blinkingl whenev€r lhe ignition switch is ON 0. PCMCONNECTORS A {32P) Me.3rtreD4IND o. D INDVottage: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ct th e A ( 3 2 P )c o n nectorfrom the PCM. 3. Turnthe ignitionswitchON (ll) 4. Measurethe voltagebetween t h e A 1 4 t e r m i n a la n d b o d y ground.
B (25P)
c (3'tP)
D lr6Pl
1 1 t r . / / a t tonl /1! /1/ /llt /
F't!4[r
t',lxr uu?lLrfr4 D4 IND or D IND {GRN/BLKI
Wiresideof femaleterminals
Repairshort to power in the wire b€iween th€ A14 terminal and the gaugea$.mbly.
A l32Pl
t rl3l/ 5/,
MeasuroATP D4 voltage: 1. Turnthe ignitionswitchOFF 2. Connectthe A (32P)connector to the PCM. 3. Turn the ignitionswitchON (ll) 4 . S h i { t t o a n y p o s i t i o no t h e r than E or E. 5. Measurethe voltagebetween t h e D 9 t e r m i n a la n d b o d y ground.
ls thereapprox.5V?
c t3lPl _ = - - - r - : =? e- V
t\ r?V
t
t/l,4lzulErt!t!!j!t!u3t ll]]lll1lglt]| r.i b AE A.W6l ld$!'lLM.l1t I
ATPD' (YEL)I I
O)
I
T6st the A/T g.ar Po3ition indicator at the gauge e$embly con_ '98 nectorc (se€ P.go 1,1-139lor '99 - 00 for 14-140 model .nd modelsl, f the A/f gear Poshion indicator is OK, replacethe FCM.
Test the A/T gear position switch (seepage14-139i.
Checkfor r 3hofi to ground in the wire betweon tho IXI teYminal and A/T gear position switch. lf wire is OK subBtihrte a known-good PCM and recheck.
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14-125,
ElectricalTroubleshooting('98- 00 Modelsl TroubleshootingFlowchart- InterlockSystem- Shift LockSystem Shift levor cannot be mov6d llom the E po3ition when th6 blako pedal is pre3sed.
NOTE:li the MIL is on, ropairthe PGM-FIcontrotsystem {seesection11),and recheck.
Ch€ckBJakeLight Oporation: Pressthe brakepedal.
Are the brakelightsON?
B6pair tlutty brrko 3whch circuit l..e rection 231.
PCM CONNECTORS
a (25P1 Me.sure ILU Voltage: 1. Turn the ignitionswitchON (ll1, andshifttoE position. 2 . P r e s st h e b r a k e p e d a l ,a n d releasethe acceleratorpedal. 3. Measurethe voltage between t h e A 2 8 t e r m i n a la n d b o d y grouno.
c l3lPl
D {16P1
1 tttt/
5t/ 1 a t /tlt 1 t\/t , . I 3 rholr1t? / VVV tl t ttj,r\1e\10l211n
m@-@Effilil"
Wire side of femalelerminals
Chock tor an open or short in the wi.o botwoen tha A28 t6rminrl and thc intorlod( control unit, rnd check tor loose torminrl fit in the intorlock conftol unh connoctor. lf nocassaryraubstitute a knowngood intollock control unit rnd roch6d(
c t3lPt
Mor3uro STOPSW vohsgo: 1. Turnthe ignitionswitchOFF. 2. Disconnect the A (32P1and B ( 2 5 P )c o n n e c t o r s{ r o m t h e PCM. 3. Measurethe voltage between the A32 and 820 or 822 terminals,
ls there batteryvoltage?
fo page 14-121
14-126
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D (lCPl
| 2ttt/ ;t /n) ).tt)/ 1 21:/ t vvvvv nnvl.lnl2\n I r r ero 12
wE
gp]P] polr EI!l!!i r.
LGl {8RN/ALKI
Repairop6n in tho wir€ betwsen the A32 t6.minal and th6 brake 3witch.
Frompage14-126 FCII CONNECTOFS MeasureTPSVoltage: 1. Reconnectthe A (32P)and B (25P)connectors to the PCM 2. Turnthe ignitionswitchON (ll) 3. Measurethe voltagebetween the C27 and B20ot 822 te(mi' nats.
c (31P)
B {25P1
A t32Pl
LG1 (BRN/BLKI
wire sideof femaleterminals
ls thereapprox.0.5V?
Check Throttlo Position Sensol Ground Line: '1. Turnthe ignitionswitchOFF 2. Disconnectthe throftleposition sensorconnector. 3. Checktor continuitybetween t h o N o . 1 t e r m i n a lo f t h e throttle positionsensorconnector and the 820 and 822 terminslof the PCM.
To page'14-128
LG2IBRN/BIXI
LGl IBRN/BIXI
THROTTTIPOSMON SENSORCONNECTOR
SG2IGRN/BLK}
rL2l3t
Wiresideof femaleterminals
ls therecontinuity?
Checktor continuity betlveenthe C18and 820 or 822terminals
B {25P1
D (16P1
n l,I-il n FFFTI,T';T;I EFML"| LGl IBRN/BLKI
ls therecontinuity?
c l3lPl
SG2 {GRN/BLK}
Rgpsir opan in lhe wire botween the Cl8 torminal .nd the throttle gosiiion Sensor.
Checklor looss tetminalfit in the PCM conn€ctoia. It nece3sarY, subslituta a known-good PCM and .echock.
(cont'd)
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14-127
ElectricalTroubleshooting('98 - 00 Modelsl TroubleshootingFlowchaft- InterlockSystem- Shift LockSystem{cont'dl Frompage14-127 INTERLOCK CONTROL UNTTCONNECTOR ISPI SHIFTLOCK{YEL/BLKI IYEL/BLX
Check Shift Lock Solenoid tor an Open Ci.cuit: 1 . D i s c o n n e c tt h e s h i l t l o c k solenoidconnector, 2. Checkfor continuitybetween the No. 2 terminalof the shift l o c k s o l e n o i dc o n n e c t o a r nd the No. 3 terminalof the inter lockcontrolunit connector,
1
1
6
2
3
7
8
o SHIFTLOCKSOLENOID t CONNECTOR
YEL/BLK
1 2 ls therecontinuity?
Repairopen in the wir6 between th€ No. 2 termin.l oI ihe interlock control unit and ahift lock solenoid.
Measu.e Shift Lock Solenoid Voltage: 1 . T u r n t h e i g n i t i o ns w i t c hO N flr). 2. Measurethe voltagebetween the No. 1 terminal and body ground.
ls therebatteryvoltage?
Check Shift Lock Solenoid Operrtion: 1. Connectthe No. 1 terminalof t h e s h i t t l o c k s o l e n o i dc o n nector to the battery positive terminal,and connectthe No, 2 terminal to the battery neg, ativeterminal. 2. Check that the shift lock solenoidoperates.
Doesthe shiftlocksolenoid operateproperly?
Checktor looso torminal tit in th6 interlock control unit connector. lf necessary,substitute a knowngood int€rlockcontrol unil and recheck.
14-128
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Wire side of female termtnals
SHIFT LOCK SOI.ENOID CONNECTOR "-irr- l
Checklor blown No.25 {7.5 Al fuse in the underdash fuse/relay box. It the tuse i3 OK, repair opon or short in lhe wire betw€en the No. 1 terminal of tho shift lock solenoid connector rnd the under-dashfuso/r€laybox,
NOTE:Do not connectthe No. 2 terminalto t h e b a t t e r yp o s i t i v et e r m i n a l ,o r y o u w i l l d a m a g et h e d i o d e i n s i d et h e s h i f t r o c K solenoid.
z
YEL]
(v) !
I
Wiresideof femaleterminsls
SHIFTLOCKSOLENOIO CONNECTOR (dir.ctly on $lenoidl
Terminalsideof maleterminals Roplacethe shift lock solenoid.
TroubleshootingFlowchart- Interlocksystem - Key Interlocksystem lgnition ksy cannot be moved from ACC (l) pGition to LOCK(01 position while Pushing it with the shift lever in E PGition.
Check Key lntorlock Solenoid Operation: the ignitionswitch 1. Disconnect connector(6P). 2. Connectthe No. 4 terminalof the ignitionswitch6P connector to the battery Posativeter_ minal, and connectthe No. 3 terminalto the batterynega tiveterminal. 3. Checkthe key interlocksolen oi d o p e r a t i o n A . clicking soundshouldbe heard.
IGNITIONSWITCH6P CONNECTOR
KEYLOCKSOL IWHT/BLU)
ACCPUSHSW (WHT/YEL}
Wire sideot femaleterminals
Doesthe keyinterlock solenoidoperateProPerlY?
Ch€ck Key |motlock Switch OPer' etion: 1. Connectthe No. 5 terminalof th€ ignitionswitch connector to the batteryPositiveterminal,and connecttheNo.3 teF minal to the bafterynegative termrnal, 2 . T L r r nt h e i g n i t i o n s w i t c h t o ACC(l),then PUshit. 3. Checkthe key interlocksolen o i d o p e r a t i o n .A c l i c k i n g sound should be heardwhile pushingthe ignitionkev.
Doesthe keyinterlock solenoidoperateProperly?
F.ulty key interlock solenoid. Replacetho ignition key cylinder/ steering lock asembly.
KEYLOCKSOL IWHT/BLUI
+B KEY LOCK (WHT/GRN)
Faulty key interlock 3witch. Roplacothe ignidon key cylinder/ steoring lock tssamblY.
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14-129
ElectricalTroubleshooting('98 - 00 Models) TroubleshootingFlowchart- InterlockSystem- KeyInterlockSystem(cont,dl Frompage14'129 INTERLOCK CONTROLUNITCONNECTOR {8PI KEYLOCKSOL (WHT/BI-U}
Check Key Intorlock Solonoid tol a Short Circuit: 1. Disconnectthe interlockcontrol unit connector, 2. Checkfor continuitybetween t h e N o . l t e r m i n a la n d b o d y groundand betweenthe No.5 terminaland bodygroundindi vidually.
ACCPUSHSW {WHT)
Wire sideof femaleterminals
ls therecontinuity?
Repairshon in thc wire betweon the No. 1 or No. 5 terminal and th€ ignhion switch 6P connector.
Check Park Pin Switch Operation: Checkfor continuity between the No.I terminaland body ground.
ls therecontinujty?
MoasureATP P Voftegel 1. Turnthe ignitionswitchON (lli. 2. Measurethe voltagebetween the No. 6 terminal and body ground.
Check for short in the wir6 between the No. 8 terminal of the int€rlock control unit and tho park pin switch. ll wire is OK, ch6ckthe park pin switch.
Shiftlevermust be in E.
ATP P IBLK/BLUI
Repairopen in the wiro between the No. 6 termin.l and the A/T gear position 3witch.
Checkfor looseterminal fit in th€ interlock control unit connoctors. lf necosssry,substitute t knowngood interlock control unit and recheck.
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ElectricalTroubleshooting('99 - 00 Modelsl TroubleshootingFlowchart- o/D oFF IndicatorLight DoesNot GomeOn The O/D OFFindicator light doos not come on when the ignition switch i3 tiBt tulned ON {lll. {lt should come on lor about two secondsand then go outl
C h e c kt h e O / D O F FI n d i c a t o l Light: 1. Turnthe ignitionswitchON (ll). 2. Shiftto E position,and Press the Over-Drive(O/D)switch.
Does the O/D OFF indicator lightcome on?
Chocklor looaet.rmin.l tit in tho PCM connoctor3. lf nocesstrY, substitute a known'good PCM and r.chock. PCMCONNECTORS A (32Pt
Ch€ck O/O IND lor an OPen Circuit: 1. Turnthe ignitionswitchOFF 2. Disconnectthe B (25P)con' nectorIrom the PCM. the 14Pconnector 3. Disconnect from the gaugeassemblY. 4. Check {or continuity between the 819 terminaland the No. 6 terminal of the gauge assembly14Pconnector.
B t25Pl
GAUGEASSEMBLY CONNECTOR I14P)
(31 cc (3rPt
O,/DIND ILT BLU}
Wire sideoI lemaleterminals
ls therecontinuitY?
Replir open in the wiro botween the 819 terminal and gauge .ssemblY | 4P connector.
Check for a fauhv O/o OFF indi' cator light bulb or . laulty gluge a3semblyprinted circuit bo.rd.
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ElectricalTroubleshooting('gg - 00 Modelsl Troubleshooting Flowchart- O/D OFFIndicatorLightOn Constantly The O/D OFFindicator light is on constanllv whenever the ignition switch is ON {ll),
C h e c kt h e O / D O F F I n d i c a t o r Lighti '1. Turn the ignitionswitchOFF. 2 . D i s c o n n e ctth e B ( 2 5 P )c o n nectorfrom the PCM. 3. Turnthe ignitionswitchoN flt).
Doesthe O/D OFFindicator lightcomeon?
Fepair short to ground in lhe wire between the B'19terminal a n d t h e g a u g e a a s o m b l y1 4 p GOnnectot,
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Flowchart- O/D OFFIndicatorLightDoesNot ComeOn Troubleshooting EvenThoughO/D Switch ls Pressed The O/D OFFindicator light does not come on ev€n though the Over-Driv6 lO/Dl 3witch is pre$ed in E position. lThe o/o OFF indicatol light come on wh6n the ignition switch is fir3t turned on tor two seconds,then 9o out.l
Checkthe Over-Drivs {O/D) Switch al lhe Switch Connector: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe park pin/O/D swrtchconnector. 3. Checkfor continuitybetween t h e N o .1 a n dN o . 2 t e r m i n a l s of the switchconnectorwhale p r e s si n g t h e s w i t c h , a n d when releasedat.
PARKPIN/O/D SWITCHCONNECTOR
Terminalsideof maleterminals ls therecontinuitywhile pressingthe switch, and no continuitywhen releasedit?
CheckO/D Switch fol an Opsn Circuit: 1 . D i s c o n n e ctth e D ( 1 6 P )c o n nectorfrom the PCM. 2. Checkfor continuitybetween the D8 terminaland the No. 1 terminalo{ the switchconnec' tor,
Checklor loose torminallit in the O/O switch connestor. lf termin a 1 3a r e O K , r e p l a c et h e O / D switch and pa]k pin switch as a se.tlseep.go l+1511.
PCMCONNECTORS A {32P1
B l25Pl
c (31P)
O/D SW (PNKI PARKPIN/
o/D swtTcH CONNECTOR Wire sideof femaletermanals
Ropairopen in the wire batwean the D8 te.minal and the park pin/O/D Bwhchconnocto..
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14-133
ElectricalTroubleshooting('gg - 00 Modelsl TroubleshootingFlowchart- o/D oFF lndicatorLight DoesNot come on EvenThoughO/D Switch ls pressed(contd) Frompage14-133
Check O/D Switch Ior a Sho.t Circuit: Checkfor continuitybetweenthe D8terminaland body ground.
PCMCONNECTORS
O/D SW{PNKI
Wiresideof femaleterminals
ls therecontinuity?
Repair short to ground in the wire betweon the D8 terminal and the park pin/O/D.witch connectoa,
PAFKPIN/O/D SWITCHCONNECTOR
Ch€ck O/D Switch G.ound Circuit: Checklor continuitybetweenthe No. 2 terminalof the switchconnectorand body ground.
Wiresideot femaleterminals
Repairopon in the wire b€tween th€ No. 2 terminal of the park pinlO/D 3witch connector snd ground 1G401.c402), or rep.ir poor ground (G401,4021.
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Lock-upControlSolenoidValveA/B Assembly Test
Replacement
1 . Disconnectthe 2P connectorfrom the lock-upcon' trol solenoidvalveA'lBassembly.
NOTE:Lock-upcontrolsolenoidvalvesA and B must be as an assembly. removed/replaced
2.
Measurethe resistancebetweenthe No. 2 terminal ( s o l e n o i dv a l v e A ) o f t h e c o n n e c t o ra n d b o d y ground. and bet\iveenthe No. 1 terminal (solenoid valveB) and body ground.
1.
Removethe mountingbolts and the lock-upcontrol assembly. solenoidvalveA,,/B
6 x 1.0mm 12N.m11.2kgf.m,8.7lbf.ft)
12 - 25 o STANDARD:
CONTROL LOCK.UP VALVE SOLENOIO A/B ASSEMBLY
LOCK-UP CONTROL VALVE SOLENOID CONNECTOR I2P)
oa
Terminalsideof maleterminals
Replace.
2. LOCK.UPCONTROL
Cleanthe mountingsurface and fluid passages.
and Cleanthe mountingsurfaceand fluid passages, valve IVB with solenoid lock-up control installa new a new filter/gasket. Checkthe connectorfor rust,dirt, or oi!, and reconnectit securely.
R e p l a c et h e l o c k - u pc o n t r o l s o l e n o i d v a l v e A / B is out of specification assemblyif the resistance lf the resistanceis within the standard,connectthe No. 1 terminal of the connectorto the batterypositive terminal.A clickingsound shouldbe heard Connect the No. 2 terminal to the battery positiveterminal. A clickingsound shouldbe heard.Replacethe lock-up control solenoidvalve Ay'Bassemblyif no clicking sound is heardwhen eitherterminalis connectedto terminal. the banervDositive Checkthe lock-upcontrol solenoidvalve fluid passagesfor dust or debris,and replaceas an assem bly, if necessary.
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14-135
Shift ControlSolenoidValveA/B Assembly Test '1.
Replacement
Disconnectthe 2P connectorfrom the shift control solenoidvalveAy'Bassembly.
NOTE: Shift control solenoid valves A and B must be removed/replaced as an assembly. 1.
Removethe shiftcontrolsolenoidcover.
2.
Removethe mountingbolts,the clamp and the shift controlsolenoidvalveAy'Bassembly, then disconnect the connector.
6x1.0mm 12 N.m {1.2k9 .m,8.7lbtft}
w
CLAMPARACKET
\--
qK Terminalsade of maleterminals
-!t'">,,
SHIFTCONTROL SoLENO|OCOVEn SHIFTCONTROL SOLENOIDVALVEA/B ASSEMBLY
FILTER/GASKET
Measurethe resistancebetweenthe No. 1 terminal (solenoidvalveA) of the shift controlsolenoidvalve connectorand body ground,and betweenthe No. 2 terminal(solenoidvalveB) and body ground.
Replace.
Cleanthe mounlingsurface and fluid passages.
STANDARD:12 - 25 O Replacethe shift controlsolenoidvalveA,/Bassembly if the resistanceis out of specification. lf the resistanceis within the standard.connectthe N o , I t e r m i n a lo f t h e s h i f t c o n t r o ls o l e n o i dv a l v e connectorto the batterypositiveterminal.A clicking sound should be heard.Connectthe No. 2 terminal to the battery positive te.minal. A clicking sound should be heard.Replacethe shift control solenoid v a l v e A / B a s s e m b l yi f n o c l i c k i n gs o u n d i s h e a r d w h e n e i t h e rt e r m i n a li s c o n n e c t e dt o t h e b a t t e r v positiveterminal.
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14-136
Cleanthe mountingsurfaceand fluid passages. and installa new shift controlsolenoidvalveAy'Bassembly with the clampand a new filter/gasket. Installthe shiftcontrolsolenoidcover. Checkthe connectorfor rust,dirt. or oil, and reconnectit securely.
LinearSolenoidAssembly Test 1.
lf a clickingsound is not heard,removethe linear solenoidassembly.
Disconnect the linearsolenoidconnector.
Checkthe linear solenoidfluid passagefor dust or orn. LINEARSOLENOIO
1.
Connectthe No. 1 terminalof the connectorto the batterypositiveterminaland the No. 2 te.minal to the battery negativeterminal. Make sure that the valvemoves. Disconnect the negativebatteryterminal.and make sure the valve releases.You can see valve movem e n t t h r o u g h t h e f l u i d p a s s a g ei n t h e m o u n t i n g surfaceof the linearsolenoidassembly. LINEAR SOLENOID
Measurethe resistancebetweenthe No, 1 and the No. 2 terminals. STANDARD:About 5.0 o lf the resistanceis out of specification,replacethe linearsolenoidassembly. Connectthe No. 1 terminalof the connectorto the batterypositiveterminal and the No. 2 terminalto t h e b a t t e r y n e g a t i v et e r m i n a l ,A c l i c k i n gs o u n d shouldbe heard.
K
VALVE
lf the valvebinds,or movessluggishly. or if the linear solenoiddoesnot operate,replacethe linearsolenoid assemotv.
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14-137
LinearSolenoidAssembly
Mainshaft/Countershaft SpeedSensors
Replacement
Replacement
'1. Remove the mountingbolts and the linearsolenoid assemblY.
1.
surface Cleanthemounting and fluid passages.
6x1.0mm 12 N.m (1.2kg{.m. 8.7tbtftl
Removethe 6 mm bolt and the countershaftsDeed sensorfrom the end cover.
5x1.0mm 12 N.m 11.2kgf.m, 8.7 rbf.frl
COUNTERSHAFT SPEEDSENSOR
\
@ @ O.RING Replace.
GASKET
6x1.0mm
12N'm 11.2kgl.m, 8.7tbf.ftl
Cleanthe mountingsurfaceand fluid passageof the linearsolenoidassemblyand transmissionhousing.
R e m o v et h e 6 m m b o l t a n d t h e m a i n s h a f st p e e d sensorfrom the transmissionhousing.
Installa new linear solenoidassemblvwith a new gasket.Do not pinch the gasketduring installation, and makesure it is installedproperlyin the mounting grooveof the linearsolenoid.
Replacethe O-ringwith a new one beforeinstalling the countershaftspeedsensoror the mainshaftspeed sensor,
Checkthe linearsolenoidconnectorfor rust.dirt, or oil, then connectit securelv.
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A/T GearPositionSwitch Test 1. Removethe A,/Tgear position switch connsctorfrom the connectorbracket,then disconnectthe IVT gear position switchconnector(10P). 2. Checkfor continuitybetweenthe terminalsin eachswitchpositionaccordingto the table below. A/T GEARPOSITION SWITCHCONNECTOR (10P1
Wire side oI female terminals
A/T Gear PGition Swhch Coniinuity Ch6ck '97 - 98 Models
\_-__l"'ry1
'l
7
Position
tr tr t!l!l
E E E E
ooo-o_ o_ oo-
6
o
10
-o -----o ---o ----o -----o ---o ----o
'99 - O0Models
\______lg,-r4 Position
tr tr E E E E
1
oc\ooo o_
4
6
7
.'
l0
---o ---o ----o - o o ----c
NOTE:TerminalNo.3: Neutraloositionswitch www.emanualpro.com
14-139
A/T GearPositionSwitch Replacement Make 3ure lifts, iacks, and safety stands @ ar€ placod properly lsoo soction 1). 1.
Raisethe front of the vehicle,and support it with safety stands (see section 1).
2.
Set the parking brake,and block both rear wheels securely.
3.
Shiftto E position.
6.
R e m o v et h e h a r n e s sc l a m p f r o m t h e e n d c o v e r , then remove the Aff gear position switch cover and Ay'Tgear position switch. A/T GEAFPOSITION swrTcHcovER
6x1.0mm 12 N.m 11.2kgt m. 8.7 lbf.ftl
Remove the A/T gear position switch connector from the connectorbracket,then disconnectit. Removethe AfI gear position switch harnessclamp.
6x1.0mm 12 N.m {1.2 kg{.m,8.7 lbtftl
1.
5x1.0mm 12Nm11.2kgf.m, 8.7 tbf.ftt
Set the IVT gear position switch to E position. The AfI gear position switch clicks in E position.
BRACIGT
POSmON
swlTcH
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8. Set the control shaft to E] position.then installthe A,/Tgear position switch on it. SHAFT CONTROL
12, Start the engine. Move the shift lever through all gears.and verifythe following: . . .
The shift lever cannot be moved to E] position from E positionunlessthe shift leveris pulled. The engine will not start in any position other than E or E. The back-uplightscome on when the shift lever is in El position.
9 . Installthe Ay'Tgear positionswitch cover and harnessclampon the end cover. 1 0 . Connect the A,/Tgear position switch connector. then installit on the connectorbracket. 1 1 . Turn the ignitionswitchON (ll).Move the shift lever through all gears,and checkthe AfI gesr position switch synchronizationwith the A/T gear position indicator.
A/TGEARPOSMON INDICATOR '99 - 00 MODELS
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A/T GEARPOSITION INDICATOR '97 - 98 MOOELS
14-141
A/T GearPositionIndicator fnput Test-'97 - 98 Models 1 . Removethe gauge assemblyfrom the dashboard(seesection20).and disconnectthe 14Pconnectorfrom the gauge
assemblv(seesection23), Inspectthe connectorand socketterminalsto be surethey are all makinggood contact. . .
lf the terminalsare bent,loose,or corroded,repairthemas necessary, and recheckthe system. lf the terminalslook OK, makethe following inputtestsat the 14Pconnector. - lf I test indicatesa problem,find and correctthe cause,then recheckthe system. - lf all the input testsproveOK, but the indicatoris faulty.replacethe printedcircuitboard, GAUGEASSEMBLY14PCONNECTOR
Wire sideof femaleterminals
Wirs Color
Cavity
Test Condition
Test: Desir€dResult
lgnitionswitchON (ll)
Checkfor voltageto ground: Thereshouldbe batteryvoltage,
. Blown No. 25 (7.5A) fuse in the under-dashfuse/relaybox . An open in the wire
Combinationlight
Checkfor voltagebetweenNo. 2 a n d N o .3 t e r m i n a l s ; Thereshouldbe batteryvoltage.
Blown No. 47 (7.5A) fuse in the under-dashfuse/relaybox FaultycombinationIightswitch Faultydash iight brightness controller An open in the wire
YEL
RED/BLK switchON and dash lightsbrightnesscontrol dial on full bright RED
BLU
Shift leverin E
BRN
Shift leverin E
7
YEL
Shift leverin @
8
BLK
4
9
Underall conditions
lgnitionswitchON {ll) and shift leverin any GRN/BLK position except E
10
GRN
PossibleCause {lf rosult is not obtainod)
1'l
RED
Shift leverin E Shift leverin @
12
WHT
Shift leverin E Shift leverin E
' Faulty Ay'Tgear position switch Checkfor continuityto ground: . An open in the wire Thereshouldbe continuity. NOTE:Thereshouldbe no continuity in any other shift lever position. Checkfor continuityto ground: Thereshouldbe continuity Checkfor voltageto ground: Thereshouldbe batteryvoltage for two secondsafterthe ignition switchis turned ON {ll),and less than 1 V two secondslater,
. Poorground{G401) . An open in the wire ' FaultyPCM . An open in the wire
Checkfor continuityto ground: Thereshouldbe continuity. NOTE:Thereshouldbe no continuity in any othershift leverposiUOn.
. Faulty A,ff gear position switch . An open in the wire
Checkfor voltageto ground: Thereshouldbe about5 V.
. FaultyPCM . An open in the wire
BLVBLU NOTE:Do not push the brakepedal.
14
LT GRN
lgnitionswitchON {ll) and shift leverin any positionexceptE and
E
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InputTest-'99 - 00 Models L Removethe gaugeassemblyfrom the dashboard{seesection20), and disconnectthe 14Pconnectorfrom the gauge assembly(seesection23). Inspectthe connectorand socketterminalsto be surethey are all makinggood contact. a lf the terminalsare bent.loose,or corroded.repairthem as necessary. and recheckthe system. . lf the terminalslook OK, makethe followinginput testsat the 14Pconnector. - lf a test indicatesa problem,find and correctthe cause,then recheckthe system. - lf all the input testsproveOK, but the indicatoris faulty,replacethe printedcircuitboard. GAUGEASSEMBLY14PCONNECTOR
Wire sideof femaleterminals
Cavity
Wire Color
1
YEL
2
5
7 '10
Test Condition
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
. Blown No.25 (7.5A) fuse in the under-dashfuse/relaybox . An open in the wire
Combinationlight RED/BLK switchON and dash lightsbrightnesscontrol dial on full bright RED
Checkfor voltagebetweenNo. 2 a n dN o . 3 t e r m i n a l s : Thereshouldbe batteryvoltage.
Blown No. 47 {7.5A) fuse in the under-dashfuse/relaybox Faultycombinationlight switch Faultydash light brightness controller An open in the wire
BRN
Shift leverin E
YEL
Shift leverin E
BLU
Shift leverin E
BLK
Checkfor continuityto ground: Thereshouldbe continuity.
FaultyO/Dswitch FaultyA/T gear positionswitch FaultyPCM An open in the wire . Poorground(G401) . An open in the wire . FaultyPCM . An open in the wire
Checkfor continuityto ground: Thereshouldbe continuity
lgnitionswitchON (ll) and shift leverin any positionexceptE
Checkfor voltageto groundl Thereshouldbe batteryvoltage for two secondsafterthe ignition switchis turnedON (ll).and less than 1 V two secondslater. Checkfor continuityto ground: Thereshouldbe continuity. NOTE:Thereshouldbe no continuity in any other shift leverposiIton.
. FaultyA/T gear positionswitch . An open in the wire
Check for voltage to groundl There should be about 5 V,
. FaultyPCM . An open in the wire
a:FI\|/Et| ta
11
RED
Shift leverin S
12
WHT
Shift leverin E Shift leverin E
BLI(BLU NOTE:Do not push the brakepedal.
LT GRN
. FaultyA/T gear positionswitch Checkfor continuityto ground: . An open in the wire Thereshouldbe continuity. NOTE:Thereshouldbe no continuity in any othershiftleverposition.
Underall conditions
9
14
PossibleCaus6 {lf resutt is not obtainod)
lgnitionswitchON (ll)
lgnitionswitchON (ll), shift leverin E. and LT BLU Over-Driveis OFFby pressingO/Dswitch. 8
Test: DesiredResuh
lgnitionswitchON (ll) and shift leverin any positionexceptE and
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14-143
InterlockSystem InterlockControlUnit Input Test and proceduresin the SRS SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions, section(24)beforeperformingrepairsor service. '1. Removethe instrumentpanellower cover(seesection20). the 8P connectorfrom the interlockcontrolunit. 2. Disconnect 3. Inspectthe connectorand connectorterminalsto be surethey are all makinggood contact. . .
and recheckthe system lf the terminalsare bent,loose,or corroded,repairthem as necessary, lf the terminalslook OK, makethe followinginputtestsat the connector. - lf a test indicatesa problem,find and correctthe cause,then recheckthe system - lf all the input tests prove OK, substitutea known-goodcontrolunit, and recheckthe system.lf the checkis OK, the controlunit must be faulty;replaceit.
NOTE: lf the shift locksolenoidclickswhen the ignition switchis tu rned ON (ll)while pressingthe brakepedalwiththe shift lever in E position,the shift lock system is OK. lf the shift lever cannot be shiftedfrom E position.test the A/T gear positionswitch.
14-144
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?
1 4
6
7
8
Wiresideof femaleterminals
Cavity
1
Wire Color
Test Condhion
Checkfor voltageto ground: There should be battery voltage.
Blown No. 48 {30A} fuse in the under-hoodfuse/relaybox Blown No.33 (7.5A) fuse in the under-dashfuse/relaybox Faultysteeringlockassembly {keyinterlocksolenoid) An open in the wire
lgnitionswitchON (ll)
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
Blown No.25 (7.5A) fuse in the under-dashfuse/relaybox An open in the wire
lgnitionswitchON (ll)
Checkfor voltageto ground: There should be baftery voltage.
Blown No. 25 (7.5A) fuse in the under-dashfuse/relaybox Faultyshift locksolenoid An open in the wire
Underall conditions
Checkfor continuityto ground: Thereshouldbe continuity.
lgnitionswitchturned to ACC(l), ignitionkey pushedall the way in
Checkfor voltageto ground: There should be battery voltage.
Blown No.48 (30A) fuse in the under-hoodfuse/relaybox Blown No. 33 (7.5A) fuse in the under-dashfuse/relaybox Faultysteeringlockassembly (keyinterlockswitch) An open in the wire
Shift leverin E
Checkfor continuityto ground: Thereshouldbe continuity,
Faulty Ay'Tgear position switch Poorground(G101) An open in the wire
Checkfor continuityto ground: Thereshouldbe continuity.
Faultyparkpin switch Shon to ground
WHT/BLU
YEUBLK
5
BLK
WHT
BLI(BLU
8
PossibleCause (lf result is not obtainedl
lgnitionswitchturned to ACC(l), ignitionkey pushedall the way in
YEL
4
Tost: DesiredRosult
Shift leverin @ and pulled toward steering wneel WHT/BLK Shift leverin E
. Poorground(G401) . An open in the wire
Checkfor continuityto ground: Thereshouldbe no continuity.
Reconnect the interlockcontrolunit 8P connector. lgnition switch ON (ll) and brake pedal presseo
7
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WHT/RED lgnitionswitchON (lll, brakepedal and acceleratorpedal pressedat the sametime
Checkfor voltage to ground: Thereshouldbe 1 V or less. Check for voltage to ground: There should be baftery voltage,
Faulty brakeswitch Faultythrottleposition(TP) sensor Faulty PCM An open in the wire Faultyinterlockcontrolunit
14-145
lnterlock System KeyInterlockSolenoidTest SRScomoonentsare locatedin this area. Reviewthe SRS and proceduresin the componentlocations,precautions. SRSsection(24)before pertorming repairsor service. 1.
2.
3.
Checkfor continuitvbetweenthe terminalsin each key positionaccordingto the table.
Removethe instrumentpanel lower cover (seesection 20).
IGNITIONSWITCH6P CONNECTOR
Disconnectthe ignition switch 6P connectorat the connectorholder.
\____________r{r4 Position lgnition Key pushedin switch Key released ACC0)
o
---'o
o- ---o
Check that the key cannot be removed with power connectedto the No. 5 terminaland ground connected to the No. 3 terminal. lf the key cannot be removed.the key interiock solenoidis OK. lf the key can be removed,replacethe steering lock assembly(the key interlocksolenoidis not availableseparately).
6P CONNECTOR
14-146
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Shift LockSolenoidTest SRScomponentsare locatedin this area.Reviewthe SRS component locations,precautions,and proceduresin the SRSsection(24)before performingrepairsor service,
6.
Checkthat the shift lock releaseswhen the release lever is pushed,and checkthat it locks when the releaseleveris released,
7.
lf the solenoiddoes not work, replaceit.
'1. Removethe instrumentpanel lower cover (seesection 20). 2.
Removethe steeringcolumncovers(seesection17).
3.
Disconnect the shift locksolenoid2P connector. Connectthe No. 1 terminalof the shift locksolenoid connectorto the batterypositivetgrminal,and connect the No. 2 terminalto the batterynogativetermrnal. Checkthat the shift levercan be moved from the E o o s i t i o n .R e l e a s et h e b a t t e r vt e r m i n a l sf r o m t h e shift lock solenoidconnector.Move the shift lever backto the E position,and makesure it locks. NOTE:Do not connectpower to the No. 2 (-) terminal {reversepolarity)or you will damagethe diode insidethe solenoid.
2P CONNECTOR SHIFTLOCK
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14-147
InterlockSystem Shift LockSolenoidReplacement SRScomponentsare locatedin this area.Reviewthe SRS and proceduresin the componentlocations,precautions, SRSsection(24)beforeperformingrepairsor service. 'L
Removethe instrumentpanel lower cover (seesection 20).
2.
Removethe upper and lower steeringcolumn covers (seesection17).
3.
B e m o v et h e f l a n g e n u t s a n d b o l t s s e c u r i n gt h e steeringcolumn,then lowerthe steeringcolumn.
4.
Disconnectthe shift lock solenoidand the park pin switchconnectors. Removethe bolts securingthe shift leverassembly, then removethe shift leverassemblv. Removethe screwssecuringthe shift locksolenoid, then removethe shift locksolenoid.
2.5 N.m {0.25kgl.m,1.8lbf.ft}
14-148
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7 . Installthe new shift lock solenoid by aligning the joint of the shift lock solenoidplungerwith the tip of the shift lockextension Securethe shift locksolenoidwith the screws, 9 . Installthe shift lever assemblyin the reverseorder of the removal. 1 0 Checkthe operationof the shift lever and the shift lock.
ParkPinSwitch Test SRScomponentsare locatedin this area. Reviewthe SRS compongnt locations,precautions,and proceduresin the SRSsection(24)before performingrepairsor service, 1.
Removetho instrumentpanel lower cover (seesection 20).
Shiftthe shift leverout of the E position,and check for continuity betweenthe terminalsas in step 4. Thsreshouldbe no continuity. lf the parkpin switchis faulty,replaceit.
Removethe upper and lower steeringcolumn covers (seesection 17). Disconnect the parkpin switchconnector. Shift the shift lever into E position,then checkfor continuitybetwsgntheseconngctorterminals: . '97 - 98 models;No. 1 and No, 3 terminalsof the parkpin switchconnector. . ' 9 9 - 0 0 m o d e l sN : o .3 a n d N o . 4 t e r m i n a l s o tf h e park pin switch/Over-Drive{O/D) switch connector. Thereshouldbe continuity, 37 - 98 MODELS:
PAR( PIN
'99 00 MODELS:
PARKPIN SWITCH/ oVER-DRTVE {O/D) SWTTCH CONNECTOR
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14-149
InterlockSystem ParkPinSwitch Replacement-'97 - 98 Models SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions, and proceduresin the SRS section(24)beforeperformingrepairsor service. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Removethe instrumentDanellower cover(seesection20). Removethe upperand lowersteeringcolumncovers(seesectionli,. Removethe flangenutsand boltssecuringthe steeringcolumn.then lowerthe steeringcolumn. Disconnect the shift locksolenoidand the park pin switchconnectors. Removethe harnessclamp bracket. Removethe boltssecuring the shift leverassembly,then removetheshiftleverassembly. Removethe screwssecuringthe shift locksolenoid.then removethe shift locksolenoid, Removethe parkpin switchconnectorfrom the shift levercontrolbracket. Removethe control checkerfrom the shift lever control bracket. Removethe parkDinswitchfrom the controlchecker.
PARKPIN SWITCH PARKPIN SWITCHCONNECTOR
scnEw 2.5 N m 10.25kgt.m, 1.8 lbtftl
9.3 N.m 10.95kgf.m, 6.9 lbl.ft) BRACKET
CONTROLCHECKER
11. Installthe new DarkDinswitchon the controlchecker. 12. lnstallthe controlcheckeron the shift levercontrolbracket. 13. Routetheparkpin switchharnessthroughthecutoutofthe shift levercontrolbracket,then installthe parkpin switch connectoron the bracket. 14. Installthe shift locksolenoidby aligningthe joint of the shift locksolenoidplunger with the tip of the shift lock extension. 15. Securethe shift locksolenoidwith the screws. 15. Installthe shift leverassemblyin the reverseorderof the removal. '17. Checkthe operationof the shift leverand the shift lock.
14-150
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-'99 - 00 Models ParkPin Switch - Over-Drive(O/DlSwitch Replacement and proceduresin the SRS SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions, performing repairs or service. section{24)before NOTE:lf replacement of the parkpin switchor the O/Dswitchis required.replacethem as a set. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Removethe instrumentpanellowercover(seesection20). Removethe upperand lowersteeringcolumncovers(seesection17). Removethe flangenuts securingthe steeringcolumn.then lowerthe steeringcolumn. Disconnect the shift locksolenoidand the parkpin switch- O/Dswitchconnectors Removethe harnessclamp bracket. Removethe boltssecuringthe shift leverassembly,then removethe shift leverassembly. Removethe screwssecuringthe shift locksolenoid,then removethe shift locksolenoid. Cutthe O/Dswitchwires (REDandBLK),thenremovethe connectorfrom the shift levercontrolbracket Removethe controlcheckerfrom theshift levercontrolbracket Removethe oarkoin switchfrom the controlchecker. Removethe shift leverknobfrom the shift lever,then removethe O/Dswitchfrom the shift leverknob. SCREW 2.5 N.m 10.25kgtm, 1.8lbf,ft)
SHIFTLEVERCONTROL BRACKET PARKPIN SWITCH-
o/DswlTcH CONNECTOR
2.5 N.m (0.25kgt m, 1.8 tbf.fr)
SHIFTLEVER
HABNESSCLAMPBRACKET
9.3 N.m 10.95kgl.m. 6.9 tbf ft)
o/o swlTcH SHIFTLEVERKNOB 6-12N,m {0.6- 1.2kgt.m.4- 8.7 lbf ftl
12. Routethe new O/D switchwires through the shift lever knob,shift lever,and shift lever control bracket,then install the knob on the shift lever,and installthe switchin the knob. 13. Installthe new parkpin switchon the controlchecker,then installthe controlcheckeron the shift levercontrolbracket. 14. Routetheparkpin switchharnessthroughthecutoutoftheshiftlevercontrolbracket. 15. Installthe O/D switchwire terminalsin the connectorcavitiessecurely.The wire terminalscan be installedin cavity N o .1 o r N o . 2 . 16, Installthe connectorand the harnessclampon the bracket. 17. tnstallthe shift locksolenoidby aligningthe joint ot the shift locksolenoidplunger with the tip of the shift lockextension,then securethe shift locksolenoidwith the screws, 18. lnstallthe shift leverassemblvinthe reverseorderof removal. 19. Adjustthe clearancebetweenthe O/Dswitchwires and the edgeof the shift levercontrolbracket(seepage 14-270). 20. Checkthe shift leveroperationand shift lockoperation.
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14-151
Over-Drive(O/Dl Switch ('99- 00 Modelsl Test SRS componentsare located in this area. Review the SRScomponentlocations,precautions,and procedures in the SRSsection(24)beforepertormingrepairsor servtce. 1.
Removethe instrumentpanel lower cover (seesection 20). Removethe upper and lower steeringcolumn covers (seesection17). Disconnectthe park pin switch - O/D switch connector.
4.
Checkfor continuity betweenthe No, 1 and No. 2 t e r m i n a l sw h i l e p r e s s i n ga n d h o l d i n gt h e O / D switch,and when it's released. Thereshouldbe continuitywhile pressingand holding the switch,and no continuitywhen it's released.
PARKPINSWITCH
lf the O/D switch is faulty, replaceit and the park pin switchas a set (seepage14-1511.
14-152
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Chart Symptom-to-Component HydraulicSystem Dl ('97 - 98) or Lq ('99 - 00) indicator Beforetroubleshootinga problemon Hydraulicsystem, checkthe self-diagnosis perform the electricaltroubleshootingaccordingto code, a trouble light indication.lf the El or E indicatorlight indicates a troublecode and failureis not not indicate does light or indicator lf the Chart. Ol E the ElectricalSystem-to-Component followingthe chart. performthe hydraulictroubleshooting found on the electricaltroubleshooting, Checktheseitemson the CAUSEList PROBABLE
SYMPTOM Engineruns,but vehicledoes not move in any gear.
1 r 2 F A t ? 8 2 ?
movesinEl. @, butnotin lE. E, E, or E, position 6, 8, 9, 10,29, 52 Vehicle movesin [D!.E, E. E, E, butnotinE] position. Vehicle Vehiclemovesin .&1,E. E, E, E, but not in E position Vehiclemovesin E position. idle vibration Excessive flareson startingoff in E, Di position Pooracceleration; or E position
Stallrpm hishin El, El, E, E, E Position Stallrpmhiqhin E, E, E, E position
Checktheseitemson the NOTESList K,L.R,S
c,M,o a l
4 , 6 ,1 4 ,1 5 'l4, '16,2A,32, 33, 34 10, 12, 13, 1,2, 18,3'1,35,44, 46,41
c,L.o
4 ,0 1,2,3,6,37
K,L,R
6 ,8 , 1 0
C,D
B,K,L
c,D
Stall rpm high in E position Stallrpm high in hl position
14
N
Stall rpm low
17,31,44,46,47
R
No shift
18, 19,39, 47,48
G,L
Failsto shift in Pr, E positionor E position;from 1stto 3rd gear Failsto shift in EJ, E positionor E position;from 1stto 4th gear
21, 48 2 1 , 2 24, 7
Erraticupshifting fz
upshlft. ,3 ripshlft, 3r. up+ilft
ffi
il
3-4 upshift Harshupshift('l-2)
57 20,47 21, 4A 22, 47 12,18, 19,2A,49,50,56,57 13,1A,19,23,26,28,49,50,56,57
C,D.E,H,L
14,1A,19,24,27,28,49,50,56. 57
C , D ,E ,I , L
18,19,23,42,53,56,51 1 2 ,1 8 , 1 9 , 2 4 , 4 1 , 4 25 ,4 .5 6 ,5 7 ,5 8
o
13,'1A,19,25, 41, 42,55,56,57
C, D, E, I
Flareson 2-3 upshift
13,1A,19,23,26,50
F
Flareson 3-4 upshift Excessive shockon 2-3 upshift
1 4 ,1 A ,1 9 , 2 4 , 2 7 , 5 0 13. '18,19, 23, 26, 42,49, 50, 51
E,L,N
Excessive shockon 3-4 upshift
14,1A,19,24,27, 42,49,50,51 10,29
E,L,N
4,14,20,51
o
2,36
K,L.O
Harshupshift(2-3) Harshupshift{3-4) Harshdownshitt(2-1) Harshdownshift(3-2) Harshdownshift(4-3)
Lateshiftfrom N positionto ld or Erl position.or to E position Lateshift from E positionto E position Noisefrom transmissionin all shift leverpositions more than 3l mph (50 km/h). Vehicledoes not accelerate
I
E.L.N M
11 (cont'd)
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14-153
Symptom-to-Component Chart HydraulicSystem (cont'd) Checktheseitemson the PROBABLE CAUSEList
SYMPTOM Shift leverdoes not operatesmoothly. Failsto shift;stuckin 4th gear. Transmission will not shiftintoparkin E position. Stallrpm high;all clutchpressuresare in specification. Lock-upclutchdoes not disengage. Lock-upclutchdoes not operatesmoothly. Lock-upclutchdoes not engage. Vibrationin all positions. No enginebrakingin I position. Shift positionindicatordoes not indicateanv position,
Checktheseitemson the NOTESLisr P
o, Jd
14, 41, 48 6, 38,61 40 18, 43,44,45, 46,49,50,57 14, 40, 43, 44, 45, 46, 49, 50. 57 't8, 40, 43, 44, 45, 46, 49,50, 56, 57
P D,K,O
59 6. 38, 60
PROBABLE CAUSE ATF pump worn or binding
I
33
34
Regulatorvalve stuck or regulator valve spflng worn
7 I 10 11
't2 t5
14 tc
16 17 18 '19 20 21
26 27
2a 29
30 31 32
14-154
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Servovalvestuck Mainshaftworn/damaged Shiftcablebroken/outof adjustment Finalgearsworn/damaged One-way(sprag)clutchworn/damaged 1stgearsworn/damaged{2 gears) lst clutch defective 2nd gearsworn/damaged(2 gears) 2nd clutch defective 3rd clutchdefective 4th clutch defective Reversegearsworn/damaged(3 gears) ExcessiveATF Torque converter one-way clutch defective Linearsolenoidassemblvdefective(,98- OO models) CPCvalvestuck l-2 shift valvestuck 2-3 shiftvalvestuck 3-4 shift valve stuck 2nd accumulatordefective 3rd accumulatordefective 4th accumulatordefective 2nd orificecontrolvalvestuck 3-4orificecontrolvalvestuck Foreignmaterialin main orifice Foreignmaterialin lst orifice Foreignmaterialin reverseorifice Engineoutput low Needlebearingworn/damaged
Thrust washer worn/damaged Clutchclearanceincorrect Drive plate delective or transmission mtsassembled
5tt
Torqueconverterhousingor transmission housingbearingworn/damaged ATF strainer clogged
38
Shift cableis worn where it attachesto the transmissionor at the body mounts
39
Modulatorvalvestuck Torque converter checkvalve stuck Foreignmaterialin separatorplate CPBvalve stuck Lock-uptiming valvestuck Lock-upshift valvestuck Lock-upcontrolvalvestuck Lock-upclutch Distondefective Shift control solenoid valve A defecttve Shift control solenoid valve B dsfectrve Lock-upcontrol solenoid valve A defective Lock-upcontrol solenoid valve B deleqtve Servocontrolvalvestuck lst accumulatordefective Foreignmaterialin 2nd exhaustorifice Foreignmaterialin 3rd exhaustorifice Foreignmaterialin 4th exhaustorifice Mainshaftspeedsensordefective Countershaft speedsensordefective 3rd sub accumulatordefective lst-holdclutchdefective A/T gear position switch defectiveor out of adjustment
40 41 43 44
46 47 48 49 51 52 53 54 56 58 59 60 61
Parkgear mechanismdefective
The followingsymptomcan be caused by improperrepairor assemblY
Checktheseitems
Vehiclecreepsin N position.
. lmproperclutchclearance . lmpropergearclearance
or E Vehicledoes not move in E, [D.lj, position. Transmissionlocksup in E position.
One-way(sprag)clutchinstalledupsidedown
drag in transmission. Excessive
Parkleverinstalledupsidedown Shiftfork bolt not installed ATF pump bindingand seizure Usepropertools when replacingthe ATF pump gears,and be carefulnot to damagethe ATF pump when torquedown the main valvebody. Checkthat the shiftfork bolt is installedon the shiftfork shaft
vibration,rpm related. Excessive
Torqueconverternot fully seatedin ATF pump
Noiseonly with wheelsmoving. Mainshaftoil sealpo9s out.
Reverseselectorhub installedupsidedown
Variousshiftingproblems.
. Springsimproperlyinstalled . Valvesimproperlyinstalled
Harshupshift.
Checkvalveballsnot installed
Mainshaftoil sealimproperlyinstalled lnstallthemainshaftoil sealtlushwith the torqueconverterhousing lf the mainshaftoil sealis installedinto the torqueconverterhousinguntil it bottoms.it will blockthe fluid returnpassageand resultin damage
(cont'd)
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4-15 5
ponentChart Symptom-to-Com HydraulicSystem(cont'd) NOTES Seeflushingprocedure,page l4-264and 265, B
Set idle rpm in gearto specifiedidle speed.lf still no good,adjustmotor mountsas outlinedin engine sectionof this manual.
c
lf the largeclutchpistonO-ringis broken,inspectthe pistongroovefor rough machining.
D
lf the clutchpackis seizedor is excessively worn. inspectthe other clutchesfot wear,and checkthe orifice controlvalves,CPCvalve,and linearsolenoidfor free movement. lf the linearsolenoidis stuck,inspectthe clutchesfor wear. lf the 1-2shift valveis stuckclosed.the transmissionwill not upshift.lf stuckopen,the transmissionhas no lst gear.
H
lf the 2nd orificecontrolvalveis stuck,inspectthe 2nd and 3rd clutchDacksfor wear. lf the 3-4 orificecontrolvalveis stuck,inspectthe 3rd and 4th clutchpacksfor wear.
J K L M
N
lf the clutchpressurecontrolvalveis stuckclosed.the transmissionwill not shift out of lst gear. lmproperalignmentof main valve body and torqueconverterhousingmay causeATF pump seizure.The symptomsare mostlyan rpm-relatedtickingnoiseor a high-pitchedsqueak. 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 torqueconverter. lf the lst clutchfeed pipe guide in the end cover is scoredby the mainshaft.inspectthe ball bearingfor excessivemovementin the transmissionhousing.lf oK, replacethe end coveras it is dented.The o-rino underthe guide is probablyworn. ' Replace the mainshaftif the bushingfor the 4th feedpipeis looseor damaged,lf the 4th feed pipeis darrF agedor out of round.replacethe end cover. ' Replace the mainshaftif the bushingfor the l st feedpipe is looseor damaged.lf the 1stfeedpipeis damagedor out of round,replaceit.
o
A worn or damagedspragclutchis mostlya resultof shiftingthe transmissionin E!. E, or E position while the wheelsrotatein reverse.suchas rockingthe vehiclein snow.
P
Inspectthe framefor collisiondamage. lnspectfor damageand wear: l. Reverseselectorgearteethchamfers. 2. Engagement teethchamfersof countershaft 4th and reversegear. 3. Shift fork for scuff marksin center. 4. Differentialpinionshaftfor wear underpiniongears. 5. Bottomof 3rd clutchfor swirl marks. Replaceitems1,2, 3. and 4 if worn or damaged.lf transmission makesa clicking,grinding,or whirringnoise, alsoreplacemainshaft4th gear,reverseidlergear,and countershaft 4th gearin additionto 1,2, 3, or 4. lf differentialpinion shaft is worn, overhauldifferentialassembly,replaceATF strainer,and thoroughlycjean transmission, flushtorqueconverter. cooler,and lines, lf bottom of 3rd clutch is swirled and transmissionmakesgear noise.replacethe countershaftand final driven oear, Be very carefulnot to damagethe torqueconverterhousingwhen replacingthe main ball bearing.you may also damagethe ATF pump when you torquedown the main valvebody.This will resultin ATF pump seizureif not detected.Usethe Drooertools.
S
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Installthe main sealflush with the torqueconverterhousing.lf you push it into the torqueconverter housinguntil it bottomsout, it will blockthe fluid returnpassageand resultin damage.
RoadTest NOTE:Warm up the engineto normaloperatingtemperature(the radiatortan comeson). 1.
Beforetesting,checkthe transmissionfluid level,see page14-160.
2.
Apply the parkingbrakeand blockthe wheels.start the engine,then shift to E {'97 98) or E {'gg 00) position not stall. pedaland releaseit suddenly.The engineshould while pressingthe brakepedal.Pressthe accelerator
3.
Repeatsametest in E position('97- 98 models).
4.
Test-drivethe vehicle on a flat road in the E or E position. Checkthat the shift points occur at approximate speeds shownon a flat road.Also checkfor abnormalnoiseand clutchslippage. Throttlepositionsensorvoltagerepresentsthe throttleopening.Monitorit with the HondaPGMTesteror as follows: a. Unboltthe PCMfor roadtesting;reJerto page14-58. b. Setthe digitalmultimeterto checkthrottlepositionsensorvoltagebetweentheseterminalson the PCM: . '97 Model:BetweenterminalsD'! (+)and A9 (-) or A22 {-} . '98 - OOModels; Betweenterminals C27 (+) and 820 (-) or 822 {-)
BACKPROBE ADAPTER
SET BACKPROBE
orsAz- 001moA (two roquircdl
STACKINGPATCH CORD DIGiTALMULTIMETER {Comm€rcirllY.vailablc} KS-AHM-32-003, or equival.nt
'97 Model: PCMCONNECTORS
'. o a 2r
/
//B
1
l'o ti
t-'a:IM-&E
, jl. t
-Llfiffi-fl)\"".'E
11111t1.t nait la t1 t213tr / t6t, tl / / / /
/
1 3 / 10n v
Wire sideof femaleterminals
'98 - 0OModels: PCMCONNECTORS
A l32Pt
B {25Pt
c l31P}
(cont'd) LGl (BRN/BLK)
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Wire sideot femaletermanals
14-157
RoadTest (cont'd) lgrror E Position: Upshift Throftle Opsning Throttlepositionsensor voltage:0.75V Throttlepositionsensor voltage;2.25V Fully-opened throttle, Throttlepositionsensor voltage:4.5V
Unit of sps€d
lsi + 2nd
2nd * 3rd
3rd + ilth
mph
9-12
20-23
28-33
Lock-up ON
km/h
15-19
mph
22-26
43-49
km/h
35-41
69-79
mph
37-43
k-/h
60-69
Unit ot speed
Lock-upOFF
i{th + 3rd
mpn
19-23
1 A- 2 ' l
6 - 10 {3rd- 1st)
km/h
5t-5D
29-34
1 0- 1 5( 3 r d* 1 s t )
mph
88-99
86-96
57-64
26-32
km/h
142- 't59
1 3 8- 1 5 4
9 2- 1 0 3
42-51
111- 124
45-53
34-40
oz - ott
9 9- 1 0 8
68-74 1 0 9- 1 1 8
1 0 1- 1 1 1
9 0- 1 0 1
1 6 3- 1 7 9
1 4 5- 1 6 3
Downshift Throttle Opening Fully-closed throttle, Throttlepositionsensor voltage;0.5V Fully-opened throttle, Throttlepositionsensor voltage:4,5V
3rd * 2nd
znd + lst
NOTE: . Lock-upON:Thelock-upcontrolsolenoidvalveA turns ON. . Lock-upOFF:The lock-upcontrolsolenoidvalveA turns OFF. 4.
Accelerateto about 35 mph (57 km/h)so the transmissionis in 4th. then shift from E The vehicleshouldimmediatelybeginslowingdown from enginebraking.
5.
Checkfor abnormalnoiseand clutchslippagein the followingpositions.
or E positionto E position.
E {1stGear)Position Accelerate from a stop at full throttle,Makesurethere is no abnormalnoiseor clutchslippage. Upshiftsshouldnot occurwith the shift leverin this position. E (2ndcear) Position Accelerate from a stop at fuI throttre.Makesurethere is no abnormarnoiseor crutchsrippage. Upshiftsand downshiftsshouldnot occurwith the shift leverin this position. Position E (Reverse) Accelerate from a stop at full throttle.and checkfor abnormalnoiseand clutchslippage. 6.
Testin E (Park)Position Parkthe vehicleon slope(approx.16"),applythe parkingbrake,and shift into position.Release E the brake;the vehicle shouldnot move.
14-158
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Stall Speed Test CAUTION: . To prevent transmission damage,do not te3t stall speedfor mors than 10 s€€ondsat a time' . Do not shift the lever while raising th€ engine spsed. . Be sure to remove tho pressurogauge bofore testing stall speed, 1. Beforetesting,checkthe transmissionfluid level,s€epage 14-160. 2. Engagethe parkingbrakeand blockall four wheels 3. Connectthe tachometer,and startthe engane. 4. Make sure the Ay'Cswitch is OFF position. 5. Afterthe enginehaswarmedupto normaloperatingtemperature(the radiatorfan comeson),shiftinto@ for 6 to 8 seconds,and noteenginespeed' 6. Fullypressthe brakepedaland accelerator j. A|ow 2 minutesfor cooling,then repeatthe test in E, E ('97- 98).E {'99- 00},and E positions.Stallspeedshould be the samein E, E, E, tr. and E positions Stall Speedrpm: Specitication:2,550rpm S€rviceLimit: ?,400- 2.700rpm PROBAELECAUSE
TROUBLE
Stallrpm highin El, E, E, E andE positions
Stallrpm high in E position Stallrpm high in E position
Slippageof 1stclutch,1st-holdclutch,or 1stgearone-wayclutch
stall rpm high in E! or E position Stallrpm high in E position
Slippageof 1stclutchor 1stgearone-wayclutch
Stallrpmlow in [dd,E. E, E, anaE positions
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ATF pump outputis low CloggedATFstrainer Pressureregulatorvalvestuckclosed Slippingclutch Slippageof 2nd clutch Slippageof 4th clutch . Engineoutput low . Torqueconverterone-wayclutchslipping
14-159
FluidLevel Checking NOTE: Keep all foreign particlesout of the transmisston, 1.
7.
Insertthe dipstickback into the transmissionin the directionshown.
Warm up the engineto normal operatingtemperature (the radiatorfan comeson) Parkthe vehicle on level ground. Turn off the engine.
FRONT
Removethe dipstick(yellow loop) from the transmission,and wipe it with a cleancloth. Insertthe dipstickinto the transmission. DIPSTICK
-'-Y' Insrallthe dipstickwithin 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 .l t shouldbe betweenthe upperand lower marKs.
lt
UPPERMARK MARK
El--
lf the level is below the lower mark. pour the recommendedfluid into the filler holeto bring it to the upper mark,Alwaysuse GenuineHondaPremiumFormula AutomaticTransmissionFluid (ATF).Using a nonHondaATFcan affectshift oualitv.
14-160
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PressureTesting Changing NOTE: Keep all foreign particlesout of the transmission. 1.
Bringthe transmissionup to operatingtemperature (the radiatorfan comes on) by driving the vehicle. P a r kt h e v e h i c l eo n l e v e lg r o u n d .t u r n t h e e n g a n e off. then removethe drain Plug. NOTE: lf a cooler flusher is to be used, see page 14-264and 14-265.
a Wlrile testing, be careful of the rotaling wheols. a Mako sure lifts, iacks, and safety stands ar€ placed
properly (seescction 11. 1.
B e f o r et e s t i n g ,b e s u r e t h e t r a n s m i s s i o nf l u i d i s filledto the proPerlevel.
2.
4WD: Raisethe vehicle(seesection11. 2WD: Raisethe front of the vehicle,and make sure it is securelysupported.Setthe parkingbrake,and block both rearwheelssecurely.
TRANSMISSION END COVER
Allow all four wheels {4WD)or front wheels (2wD} to rotate freely. Warm up the engine (the radiatorfan comes on), then stop it and connectthe tachometer. 5.
Connectthe oil pressuregaugesto each inspection holesecurely,and do not allow dust or otherforeign particlesto enterthe inspectionholes. TOROUE:18 N'm ll.8 kgf'm, 13 lbf'ft)
DRAIN 1 8x 1 . 5m m
SEALINGWASHEB Replace.
49 N.m{5.0kgt.m,36 lbf.tl)
Reinstallthe drain plug with a new sealingwasher, then refill the transmissionwith the recommended fluid to the uDpermark on the dipstick.Always use G e n u i n eH o n d a P r e m i u m F o r m u l aA u t o m a t i c TransmissionFluid (ATF) Using a non-HondaATF can affectshiftquality. Automatic TransmissionFluid Capacity: 4WD; 2.9 { (3.1 US qt. 2.6 lmp qt) 8t change 5.8 ? {7.2 US $, 6.0 lmp qt} at ovethaul 2WD: 2.7 | l2.SUS qt,2.1lmp qtl ai change 5.9 ? {6.2 US $, 5.2 lmp qtl at ovolhaul
A/T OIL PRESSURE GAUGESETW/PANEL 07{06 - 0020400
/4\
\-J--
HOS€, A/T PRESSURE 2210mm 07MAJ - PYiOllA {4 Requircd}
,4
(
\r+..\.-.\-'-\
A/T LOW PBESSURE GAUGEw/PANEL 07406 - 0070300
'/"' ,a
W'
HOSE A/T PRESSURE ADAPTER 07MAJ - PYt0120 (il Rcquiledl
6.
Measurethe followingPressure: ..........,14-162 . L i n eP r e s s u r e . 1 s t .1 s t - h o l C d l u t c hP r e s s u r .e. . . . . . . . . . . . '1. 4 - 1 6 2 . 2 n d , 3 r da n d 4 t h C l u t c hP r e s s u r .e. . . . . . . .1. 4 - 1 6 3
7.
Installnew sealingwashersand the sealingbolts in the inspectionholes, and tighten to the specified toroue. TOROUE:18 N'm 11.8kgf'm, 13 lbf'ft)
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(cont'd)
14-161
PressureTesting (cont'd) Line Proslure, lst Clutch, lst.hold Clutch prsssuro Measuromont 1.
Startthe engine,and shiftto E or @ position.
2.
Run the engine at 2,000rpm, then measureline pressure.Higherpressuremay be indicatedif measurements are madein shift leverpositionsotherthan E or @ position. shift to E ('97- 98) or E ('99- oo) positionand holdthe engineat 2.ooorpm, then measure1stclutchpressure.
4.
Shiftto E positionand hold the engineat 2,000rpm, then measurelst-hotdctutchDressure.
LOCK.UPCONTROL SOLENOIDVALVE A/B ASSEMBLY
PRESSURE Line
1stClutch
SHIFTLEVER POSmON
Eor@
14-162
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tr
FLUIDPRESSURE
PROBABLECAUSE Standald
No (or low) line pressure
E (97 - 98) No or low 1st
E ('se- oo) lst-hold Clutch
SYMPTOM
Torque converter. ATF pump,pressure regulator, torque converter checkvalve lst Clurch
pressure No or low lsthold pressure
1st-holdClutch
830 - 880 kPa (8.5* 9.0 kgflcm,, 120- '130psi)
ServiceLimit 780 kPa 'l10 psi) {8.0kgf/cm,,
'99 - 00 Models:
znd, 3rd, and ,lth Clutch PressursMeasuremenl '97 - 98 Modols: 1. 2.
1.
Startthe engine,and shiftto El position.
2.
R u n t h e e n g i n e a t 2 , 0 0 0r p m . t h e n m e a s u r e2 n d clutchpressure.
3.
Shift to E position,and turn the Over-Drive(O/D) OFF by pressing the O/D switch (O/O OFF indicator light comeson).
Stan the engine,and shiftto E position. R u n t h e e n g i n ea t 2 , 0 0 0r p m , t h e n m e a s u r e2 n d clutchpressure.
3.
Shift to E position,and hold the engine at 2'000 rpm, then measure3rd clutchpressure.
4.
Shift to E position,and hold the engine at 2,000 rpm, then measure4th clutchpressure.
4.
Hold the engine at 2,000 rpm, then measure 3rd clutchPressure.
5.
Shift to @ position,and hold the engine at 2,000 rpm, then measure4th clutchpressure.
5.
Turn the Over-DriveON by pressingthe O/D switch ( O / DO F F i n d i c a t o rl i g h t g o e s o u t ) , a n d h o l d t h e engineat 2,000rpm, then measure4th clutch pressure.
6.
Shift to E position,and hold the engine at 2,000 rpm, then measure4th clutchprgssure
4TH CLUTCHPRESSURE HOLE INSPECTION
2ND CLUTCHPRESSURE HOLE INSPECTION
"..# '"r.,-ur"" HOLE INSPECTION
--t"1'-. 3RDCLUTCHPRESSURE HOLE INSPECTION
PRESSURE 2nd Clutch
3rd Clutch
4th clutch
SHIFTLEVER POSmON
PROBABLECAUSE
tr
No or low 2nd pres$ure
2nd Clutch
E (97 - s8) Elwith OverDriveis OFF (99 - 00) E (97,98) E (99 - oo)
No or low 3rd pressure
3rd clutch
No or low 4th pressure
4th Clutch
E
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FLUIDPRESSURE SYMPTOM
Standard 800 - 850 kPa \A.2- 8.1 kgtlcm2, '120- '124psil
Servico Limit 760 kPa (7.7kgf/cm' ,110psi)
ServoValveor 4th Clutch
14-163
Transfer Inspection Mako suro lifts, jacks, and safety stands @E are placod properly lsoe section t). 1.
Raisethe front of the vehicle,and make sure it is supported securely.
2.
Set the parkingbrake,and block both rear wheels securely.
6. Set a dial indicatoron the transferassemblyflange. then measurethe transfergear backlash. STANDARD:0.06- 0.16 mm (0.002- 0.006inl
COMPANIONFLANGE
Shift to E position. 4.
Make a referencemark acrossthe propeller shaft and the transferassemblyflanges. S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r assembly.
7. lf the measurementis out of standard,removethe transferassemblyand adjusttransfergear backlash '14-232 {see page thru 14-2491. 8. Checkfor fluid leaks betweenthe mating faces of transfer cover A and cover B. 9. lf there is a fluid leak,removethe cover,and reDlace the O-ring. '10. 8 x 1.25mm 32 N.m 13.3kgl,m, 24 lbf.ftl Replace.
Checkfor fluid leaks betweenthe mating face of the transferassemblyand transmission.
11. lf there is a fluid l€ak, removethe transf€rassembly, and replacethe O-ring, 1 2 . C h e c kt h e t r a n s f e ro i l s e a l f o r d a m a g ea n d f l u i d le8ks. 13, lf oil sealreplacementis required.removethe transfer assembly,replacethe oil seal, and adjust the total starting torque (see page 1+232 thtu ]'4-249||. NOTE:Do not replacethe oil seal with the transfer assemblyon the transmission.
\
14-164
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TransferAssembly Removal Make sure the lifts, iacks, and safety @ stands are placed properly (seesection 11. 1.
Raisethe front of the vehicle,and make sure it is supportedsecurely.
2.
Set the parkingbrake,and block both rear wheels securelv.
3
Drainthe automatictransmissionfluid (ATF). Reinstallthe drain plug with a new sealingwasher'
5.
Disconnect he primary heatedoxygen sensor {PrimaryHO2S)connector. RemoveexhaustpipeA.
SELF-LOCKING NUT Beplace. SEI-F.LOCKING NUT Replace.
NUT Replace
DRAINPLUG '18x'1.5rnm 49 N.m 15.0kgf.m, 36 lbl.ftl
7.
4.
Removethe guard bar and the splashshield.
GUARD8AR
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Removethe shift cablecover. Removethe snap pin and controlpin, then separate the shift cablefrom the control lever.Do not bend the shift cableexcessively.
(cont'd)
14-165
TransferAssembly Removal(cont'dl 9, Make referencemarks across the prooeller shaft and the transferassemblyflanges. 1 0 . S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r assemblyflanges. REFERENCE MANKS
PROPELLER SHAFT
'l
l. Removethe rear stiffener.then removethe transfer
assembly. NOTE: While servicingthe transfer assembly,do not allow dust or otherforeignparticlesto enterthe transmission. REARSTIFFENER
14-166
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lnstallation 1.
Installa new O-ringon ths transferassembly.
5.
Installthe propellershaft to the transferassembly by aligningthe referencemarks
Clsan the areaswhere the transferassemblycontacts the transmissionwith solvent or carburetor cleaner,and dry with compressedair. Then apply ATF to the contact areas.
REFERENCE MARKS
Installthe transterassemblyon the transmission. PROPELLER SHAFT
NOTE: while installingthe transfer assembly,do not allow dust or other foreignparticlesto enterthe transmission. lnstallthe rearstiffener.
8 r 1.25mm 24 N.m {2.4 kgf m, r7 bl.ftl 10 x'l.25 mm araN.m 14.5kgtm, 33 tbf trl
8 xl,25]nm 32 N.m(3.3kgl.m, 2a tbf.ftl Replace.
I n s t a l lt h e s h i f t c a b l e w i t h t h e c o n t r o l p i n , t h e n secureit with the snap pin. Do not bend the shift cableexcessively. 7.
lnstalltheshift cablecover.
SHIFTCABLE O.RING TNANSFER ASSEMALY
8 xl.25 mm 22 N.m 12.2kd-m, 16 tbt.ftl
(cont'd)
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14-167
TransferAssembly Installation(cont'dl Installthe exhaustpipe A.
'I 'I.
Connectthe primaryheatedoxygensensor(Primary H02S) connector,
12. Startthe engine,and run it to normaloperatingtem-
GASKET
EXHAUSTPIPEA
Replace.
SELF.LOCKING NUT 10 x 1.25mm 54 N.m {5.5kgf.m, 40 rbf.ft) Replace. SELF-LOCKING NUT 8 x 1.25mm 22 N.m (2.2kgl.m, 16 rbr.ftt Replace.
-LOCKING NUT 8 x 1.25mm 16Nm11.6kgf.m, 12 lbf.fO Replace.
10. Installthe s p l a s hs h i e l da n dt h e g u a r db a r .
6x1.0mm 9.8N.m {1.0kgt.m, 7.2 tbt.ftt
14-168
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Refillthetransmissionwith ATF (seepage14-161).
p e r a t u r e( t h e r a d i a t o r f a n c o m e s o n ) , T u r n t h e engineoff and checkATF level.
Transmission Removal @
6.
Make sure lifts. iacks, and safety stands aro placed properly, and hoist brackets are attached to the colrest position on the engine lsee section 11. Apply th€ parking brake and block the r€ar wheels, so vehicls will noi roll off the stands and fall on you while working under it.
Disconnect the vehiclespeedsensor(VSS),the countershaft speed sensor, and the A/T gear position switch connectors.
A/T GEARPOSITION SWITCHCONNECTOR
VEHICLESPEED SENSOR|VSS'
NOTE: Use fender covers to avoid damaging painted surfaces. ' 1 . Disconnectthe negativeterminal,then disconnect the positiveterminalfrom the battery. 2.
Removethe intakeair duct and the air cleanerhousing assembly, R e m o v et h e s t a r t e rc a b l e s .R e m o v et h e h a r n e s s clampfrom the clampbracket. CLAMP CONNECTOR BfiACKET SPEEDSENSOR CONNECTOR
7.
Remove the transmission housing mounting bolts.
STARTER CABLES
R e m o v et h e t r a n s m i s s i o ng r o u n d c a b l et e r m i n a l and the radiatorhose clamp lrom the transmission hanger. 5.
Disconnectthe lock-upcontrol solenoidvalve connector,then remove the harnessclamp from the clamp bracket. HARNESS CLAMP
RADIATORHOSE CLAMP
MOUNTINGBOLTS
CONTROL SOLENOIDVALVE CONNECTOR
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(cont'd)
14-169
Transmission Removal(cont'd) 8.
Disconnectthe mainshaftsp€ed sensor, the shift controlsolenoidvalve,and the linearsolenoidconnecrors,
10. Removethe guard bar and the splashshield.
SENSORCONNECTOR
R e m o v et h e d r a i n p l u g . a n d d r a i n t h e a u t o m a t i c t r a n s m i s s i o nf l u i d { A T F ) .R e i n s t a ltlh e d r a i n p l u g with a new sealingwasher.
1 1 . Removethe cotter pins and castlenuts, then separatethe ball joints from the lower arms (seesection 18).
12. Removethe right damper fork bolt, then separate right damperfork and damper.
DAMPERPINCHBOLT
DRAIN 1 8x 1 . 5m m
4eN.mrs.oksr.m. 36rbrft)
;:i:$:
*o"*." SELF.LOCKING NUT Replace.
14-170
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OAMPERFORK
CASII.E NUT DAMPERFORK BOLT
Replace.
1 3 . Pry the right driveshaftout of the differential.and orv the left driveshaft out of the intermediate shaft {seesection16). 1 4 . Pull out the inboardjoint, and removethe right and left driveshaft(seesection18). Tie plastic bags over the driveshaftends. Coat all finishedsurfaceswith cleanengineoil. Drecision
1 8 . Removethe shift cablecover. 1 9 . Removethe shift cable. ilWD: Removethe snap pin and controlpin, then separate the shift cable from the control lever. Do not bend the shift cableexcessively.
ORIVESHAFT
Replace.
16. Disconnect he primary heatedoxygen sensor (PrimaryHO2S)connector.
't7. RemoveexhaustpipeA. GASKET Replace.
2WD: Removethe control lever, then separatethe shift cablefrom the control shaft. Do not bend the shift cableexcessivelv. SHIFT CAELE
EXHAUST
Replace.
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14-171
Transmission Removal(cont'dl Make referencemarks across the transfer assemblv and propellershaftflanges.(4WD) 2 1 . S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r assembly.(4WD)
2 4 . Removethe right front mounvbracket. Remove the ATF cooler hoses at the ATF cooler lines.Turn the ends of the cooler hosesuo to orevent ATF from flowing out, then plug the linesand hoses.Checkfor any sign of leakageat the hose ioints.
REFERENCE MARKS
I x 1.25mm Replace.
RIGHTFRONT MOUNT/BRACKET
2 2 . Removethe intermediateshaft, Tie plasticbagsover the both ends of the intermediate shaft. Coat all precisionfinished surfaceswith cleanengineoil.
R e m o v et h e r e a r s t i f f e n e ra n d t o r q u e c o n v e r t e r cover.
27. Removethe eight drive plate bolts, one at a time. while rotatingthe crankshaftpulley. DRIVE PLATE
COVER
14-172
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28. Place a jack under the transmission,raise it just enough to take it off of the mounts, then remove the transmissionmount bracket.
30. R€movethe rear side transmissionhousingmounting bolt and the rearenginemountingbolts.
REARENGINEMOUNTINGBOLTS
3 1 . Pull the transmissionaway from the engine until it 29. Removethe front sidetransmissionhousinomounting bolt.
clearsthe dowel pins,then lower it on the transmissionjack. Remove thg torque converter assemblyfrom the transmission. Removethe starterfrom the transmissionhousing.
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14-173
lllustratedIndex(4WDl EndCover/Transmission
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O O O @
ENDCOVER olL SEAL Replace. BALLBEARING A/T GEARPoSITIoN swITcH coVER
€) A/TGEAnPosrloNswrrcH @ ROLLER O coLLAR G) o-RING Replace. {9) FEEDPIPEFLANGE @ O-RINGReplace. O SNAPRING @ 3RDCLUTCHFEEDPIPE (D CoUNTERSHAFT LOCKNUT23 x 1.25mm Replace. (} coNtcAL SPR|NGWASHER Reptace. @ PARKGEAR @ ONE.WAYCLUTCH (, COUNTENSHAFT lST GEAR (D NEEOLEBEARING (O COUNTERSHAFT lST GEARCOLLAR @ o-RING Reptace. @ lST CLUTCHFEEDPIPE @ O-RINGReptace. @} FEEOPIPEFLANGE @ SNAPRING @ DOWELPIN @ ENDcoVER GASKET Feplace. @ PARKPAWLSToP @ PARKPAWL @ PARKPAWLSPRING @ PARKPAWLSHAFT O} A/T GEARPOSITIONSWITCHHARNESSCLAMP @ PARKLEVER @ LOCKWASHER Replace. @ PARKSTOP Selectivepart @ PARKLEVERSPRING @ DRAINPLUG O SEALINGWASHER Reptace. @) MAINSHAFTLOCKNUT2l x 1.25mm Replace. @ CONICALSPRINGWASHER Replace. @ lST CLUTCHASSEMBLY
i!, O-RING Replace. @ THRUSTWASHER @ THRUSTNEEDLEBEARING @ NEEDLEBEARING @ MAINSHAFI 1STGEAR @ MAINSHAFT1sT GEARcoLLAR @ o-RING Replace. SPEEDSENSOR 6!, COUNTERSHAFT @ ROLLER @) COLLAR @ o-RtNG Replace. 6A FEEoPIPEFLANGE @ o-RtNG Reptace. @ SNAPR|NG @ IST.HOLDcLUTcH FEEDPIPE LOCKNUT 19 x 1,25mm Reptace. @ SUB-SHAFT O coNtCALSPR|NGWASHERReptace. E! SUB.SHAFTlST GEAR €} LINEARSOLENOIDASSEMBLY soLENotD aSSEMBLyGASKET Reptace. @ LTNEAR @ HARNESSBBACKET WASHERSFeptace. @ SEALING @ ATF COOLERLINE @ LIN€ BoLT @ ATF DIPSTICK @ ATF COOLERLINE @ LINEBoLT @ SEALINGWASHERSReptace. @ VEHICLESPEEDsENsoR (vss) @ o-RtNG Beptace.
TOROUE SPECIFICATIONS
Bolt/Nut No.
Torque Valuo
Size
6B 8A 12J 18D 19S 21M 23C
'12N'm ('1.2kgf.m,8.7lbf.ft) 14 N.m (1.4kgf.m,10lb{.ft} 22 N.m 12.2kgf.m, 16 lbf.ft) 28 N'm (2.9kgf.m,21lbf.ft) 49 N.m (5.0kgf.m,36lbf'ft) 93 N'm {9,5ksim.69 lbf.ft) 78 N.m {8.0kgnm,58lbf.ft) 103* 0- 103N{n {10.5* 0+ 10.5kgfn, 75.9-0-75.9 lbf{t)
6 x 1 . 0m m 6x1.0mm 8 x 1 . 2 5m m 1 2x 1 . 2 5m m 1 8x 1 . 5m m 1 9x 1 . 2 5m m 2 1 x 1 . 2 5m m 2 3 x 1 . 2 5m m
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Remarks
Linebolt Drainplug Sub-shaftlocknut Mainshaftlocknut:Left-handthreads Countershaft locknut:Left-hand threads
14-175
lllustratedIndex(4WD) Transmission Housing
{;
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r] REVERSE IDLERGEARSHAFT/HOLDER 'A N€EDLEBEARING ..] TRANSMISSIONHOUSING al TRANSMISSIONHOUSINGOIL SEAL Replace. g SETBING.80mm Selecrive part GEARCOLLAB O REVERSE GEAB E couNTERSHAFTREVERSE .9,]NEEDLEBEARING i9 LOCKWASHER Replace. .1!i REVERSE SHIFTFORK O REVERSE SELECToR HUB SELECTOR iJ. REVERSE 4TH GEAR ii' COUNTERSHAFT .14 NEEDLEBEARING iD D|STANCEcoLLAR,28 mm Selectivepart (i3 COUNTERSHAFT 2NO GEAB i7-]THRUSTNEEDLEBEARING (10COUNTERSHAFT 3RDGEAR (9 NEEDLEBEARING E9 COUNTERSHAFI3RDGEABCOLLAR .li THRUSTNEEDLEBEARING .?) SPLINEOWASHER ,,O 3RDCLUTCHASSEMBLY €1 O-RINGBeplace. i23 COUNTERSHAFT 4i SHIFTCONTROLSOLENOIDCOVER ?Z]HARNESSCLAMPBRACKET ?9]SHIFTCONTROLSOLENOIDVALVEA/B ASSEMBLY 8 HARNESSCLAMPBRACKET GI SHIFTCONTROLSOLENOIDVALVEFILTER/GASKET ReplaceSNAPRING THRUSTWASHEB THRUSTNEEDLEBEARING 04MAINSHAFT4TH GEAR NEEDLEBEARINGS @ THRUSTNEEDLEBEARING MAINSHAFT4TH GEABCOLLAR @ 2NO/4THCLUTCHASSEMBLY @ O-RINGReplace. :.ro)THRUSTWASHER,36.5 part x 55 mm Selective ai THRUSTNEEOLEBEARING
(4 MAINSHAFT2ND GEAR i49 NEEDLEBEARING BEARING @ THRUSTNEEDLE (49 MAINSHAFT @r SEAL|NGR|NG,35mm O SEALINGRING,29mm @ NEEDLEBEARING .49SET RING €) lST.HOLDCLUTCHASSEMBLY O o-RING Replace. 6E THRUSTWASHER €9 THRUSTNEEDLEBEARING 6' NEEDLEEEARING €ir SUB-SHAFT4TH GEAR 6 THRUSTNEEDLEBEARING @ SUB.SHAFT4TH GEARCOLLAR @ sUB-sHAFf 6I NEEDI-EB€ARINGSTOP @ NEEDLEBEARING (6t ATF GUIDECAP Replace. (64TRANSMISSIONHANGEB CAP @ BREATHER i@ MAINSHAFTSPEEDSENSOR 6i O-RINGReplace. IDLERGEAR 6D REVERSE @r DOWELPlN, 14 x 25 mm .6d SNAPRINGS QlI SUB.SHAFTTRANSMISSIONHOUSINGBEARING E) MAINSHAFTTRANSMISSIONHOUSINGBEABING .2, COUNTERSHAFITRANSMISSIONHOUSING BEARING DOWELPlN, 14 x 25 mm BRACKET @ CONNECTOR [E ATF MAGNET DOWELPlN, 14 x 20 mm TRANSMISSIONHOUSINGGASKET Replace. ASSEMBLY t, DIFFERENTIAL n9DOWELPlN,10x 12 mm t0 O-RINGReplace. @)TRANSFERASSEMBLY @)TOROUECONVERTERHOUSINGOIL SEAL Replace. ,lDTOROUECONVERTERHOUSING
TOROUESPECIFICATIONS Bolt/Nut No.
6A 6B 10A
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Torque Value 1 2 N . m( 1 . 2k g f . m , 8 . 7l b f . f t ) 1 4 N . m( 1 . 4k g f . m 1 , 0l b i f t ) 44 N.m (4.5kgf.m,33lbf.ft)
Size
Rgmarks
6 x 1 . 0m m 6 x 1 . 0m m 1 0x 1 . 2 5m m
14-177
lllustratedIndex(4WDl TorqueConverterHousing/ValveBody
37-94
6A
a^\
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14-178
U
ATFFEEDPIPE,8x 145mm o a;\
@ MAIN SEPARATORPLATE @ DOWELPIN @ ATF PUMPDRIVEGEAR @ SUCTIONPIPECOLLAR TOROUECONVERTER HOUSING @ COUNTERSHAFT
a
@ ATF GUIDEPLATE @ LOCKWASHER Replace. @ CONTROLLEVERASSEMBLY @ TOROUECONVERTERHOUSING @ CHANGESHAFT @ OIL SEAL Reolace. @ MAINSHAFTOIL SEAL Reolace. @ MAINSHAFTTOROUECONVERT€RHOUSING
ATF STRAINER ,6 SERVOBODY G)SERVOSEPARATORPLATE VALVEEODY !o, SECONDARY DOWELPIN PLATE SECONDARY SEPARATOR @ SERVODETENTBASE('97- 98 model3 onlyl ,6 ATF FEEDPIP€,8 x 145 mm @ ATFFEEDPIPE,8x 40 mm ATF FEEDPIPE.8 x 62 mm ATFFEEDPIPE.8x 112mm @ ATF FEEDPIPE,8 x 192.5mm (} ATF FEEOPIPE.I x 105.8mm STOPSHAFTBRACKET @ ATF LUBRICATIONPLATE ATF FEEOPIPE @ DOWELPIN @ LOCK-UPVALVEEODY @ LOCK-UPSEPARATORPLATE @ REGULATORVALVEBODY @ DOWELPIN @ COOLERRELIEFVALVESPRING @ COOLERRELIEFVALVE CHECKVALVESPRING 6 TOROUECONVERTER CHECKVALVE @ TOROUECONVERTER @)CONTROLSHAFT @ OETENTARM SPRING @ OETENTARM @ DETENTARM SHAFT @ FILTERReplace. @ CHECKBALLS @ lST ACCUMULATORCHOKE @ O"RING Replace. @ STATORSHAFT @ STOPSHAFT @ ATF FEEDPIPE,I x 112 mm @ MAIN VALVE BOOY @ ATF PUMPDRIVENGEARSHAFT @ ATF PUMPDRIVENGEAR
o (a a
BEARING
BEARING
@ LOCK.UPCONTROLSOLENOIDVALVEA/B FILTER/GASKETReplace.
@ LOCK.UPCONTROLSOLENOIDVALVEA/B ASSEMBLY
TOROUESPECIFICATIONS Bolt/Nut No.
Torque Valug
Size
64 6B
12 N'm (1.2kgf.m,8.7lbf.ft) 14 N.m (1.4kgf.m,10 lbf.ft)
6x1.0mm 6x1.0mm
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Romarks
14-179
lllustratedIndex(2WDl EndCover/Transmission
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O ENDCOVER iLl OILSEAL Beplace. O BALLBEARING i.) A/T GEARPOSITIONSWITCHCOVER i5] A/T GEARPOSITIONSWITCH aq)RoLLER ? COLLAB i0 o-BtNG Replace. €) FEEDPIPEFLANGE f,o)o-RING Replace. 1' SNAPRING 1A 3RDCLUTCHFEEDPIPE 23 x 1.25mm Replace. LOCKNUT O COUNTERSHAFT WASHERReplace. [} coNtcal SPRING iO PARKGEAR (!I ONE.WAYCLUTCH lST GEAR E COUNTERSHAFT @ NEEDLEBEARING 1STGEARCOLLAR @ COUNTERSHAFT Or o-RtNGS Reptace. ?] lST CLUTCHFEEDPIPE @ o-RING Replace. e3 FEEDPIPEFLANGE 4I SNAPRING €i DOWELPIN i?0 END COVERGASKET Replace. ?7)PARKPAWLSTOP E9 PARKPAWL C9 PARKPAWLSPRING €D PARKPAWLSHAFT OI A/T GEARPOSITIONSWITCHHARNESSCIAMP @ PARKLEVER €3 LoCK WASHER Replace. 04 PARKsToP Selectivepart (!' PARKLEVERSPRING @ DRAINPLUG Ot SEALINGWASHER Replace. LocKNuT 21 x 1.25mm Replace. 60 MA|NSHAFT (9 CONICALSPRINGWASHER Replace. @ lST CLUTCHASSEMBLY
,!4!O-RING Replace. @I THRUSTWASHER BEARING @ THRUSTNEEDLE i.!' NEEDLEBEARING i MAINSHAFTlST GEAR @i MAINSHAFT1STGEARCOLLAR !r, O-RINGReplace. SPEEDSENSOR iO COUNTERSHAFT E ROLLER @, coLLAR Ct o-RING Replace. 5.] FEEDPIPEFLANGE 09 o-RING Replace. 6A SNAPRING 5' IST.HOLDCLUTCHFEEDPIPE @-]SUB-SHAFTLOCKNUT19 x 1.25mm Replace. WASHERReplace. SPRING !t CONICAL 6i' SUB-SHAFTlST GEAR G) LINEARSOLENOIDASSEMBLY (6!)LINEARSOLENOIDASSEMBLYGASKET Replace G] HARNESSBRACKET 6a SEALINGWASHERSReplace. C' ATF COOLERLINE @ L|NEBoLT GI ATF DIPSTICK GI ATF COOLERLINE O LINEBOLT @ SEALINGwasHERs Replace. aooVEHICI.ESPEEDSENSORIVSS) f,E O-RING Replace.
TOROUE SPECIFICATIONS
Bolt/Nut No. 6A 6B 8A 12J '18D 195 21M
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Torque Value
Size
12 N.m (1.2kgf.m,8.7lbf.ft) 14 N.m (1.4kgf.m,10lbf.ft) 22 N.m 12.2kgim, 16lbf.ft) 28 N.m (2.9kgim,21 lbf.ft) 49 N'm (5.0kgim,36 lbf.ft) 93 N.m (9.5kgf.m,69lbf.ft) 78 N.m (8.0kgf.m,58lbf.ft) 103+ 0+ 103N{n (10.5+ 0+ 10.5kSfm, 75.9' 0 - 75.9lbfft)
6x1.0mm 6x1.0mm 8 x 1 . 2 5m m 1 2x 1. 2 5m m 1 8x 1 . 5m m 1 9x 1 . 2 5m m 2 1 x 1 . 2 5m m 2 3 x 1 . 2 5m m
Remarks
Line bolt D r a i np l u g Sub-shaftlocknut Mainshaftlocknut:Left-handthreads locknut:Left-hand Countershaft threads
14-181
lllustratedIndex(2WDl TransmissionHousing
6A
Lt--" &""--
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o REVERSEIDLERGEARSHAFT,/HOLDER atl ,6
NEEOLEBEARING TRANSMISSIONHOUSING @ TRANSMISSIONHOUSINGOIL SEAL R€place. part !., SETRING,80mm Selective REVERSE GEARCOLLAR COUNTERSHAFT REVERSE GEAR NEEDLEBEARING 6l LOCKWASHER Replace. @ REVERSESHIFTFORK REVERSE SELECTOR HUB @ REVERSESELECTOR 4TH GEAR @ COUNTERSHAFT @ NEEDLEBEARING @ DISTANCECOLLAR,28mm Selectivepan 2ND GEAR @ COUNTERSIIAFT THRUSTNEEDLEBEARING 3RDGEAR @ COUNTERSHAFT @ NEEDLEAEARING 3RDGEARCOLLAR @)COUNTERSHAFT @ THRUSTNEEOLEBEARING @ SPLINEOWASHER @ 3RDCLUTCHASSEMBLY @ O-RINGSReplace. @ COUNTERSHAFT @ SHIFTCONTROLSOLENOIDCOVER @ HARNESSCLAMPBRACKET @ SHIFTCONTROLSOLENOIDVALVEA/B ASSEMBLY @ HARNESSCLAMPBRACKET @)SHIFTCONTROLSOLENOIDVALVEFILTER/GASKET Replace. @ SNAPRING @ THRUSTWASHER @ THRUSTNEEDLEBEARING @)MAINSHAF ,ITH GEAR @ NEEDLEBEARINGS @ THRUSTNEEDLEBEARING @ MAINSHAFT4TH GEARCOLLAR @ 2ND/4THCLUTCHASSEMBLY @ O-RINGS ReDlace. @ THRUSTWASHER,36.5x 55 mm Selectivepart @ THRUSTNEEDLEBEARING
a o o
o
@ MAINSHAFT2ND GEAR @ NEEDLEBEARING @ THRUSTNEEOLEBEARING @ MAINSHAFT @ SEALINGRINGS,35mm @ SEALINGRING.29 mm @ NEEDLEBEARING @ SETRING @ lST-HOLDCLUTCHASSEMSLY @ O-RINGSReplace. @ THRUSTWASHER @ THRUSTNEEDLEBEARING @ NEEDLEBEARING @ SUB.SHAFT4TH GEAR @ THRUSTNEEDLEBEARING @ SU&SHAFT,ITHGEARCOLLAR @ SUB.SHAFT @ NEEDLEBEARINGSTOP @ NEEDLEBEARING @ ATF GUIDECAP Replace. @ TRANSMISSIONHANGER CAP @ BREATHER @)MAINSHAFTSPEEDSENSOR @ O-RING Reolace. @ REVERSEIDI.fR GEAR @ DOWELPlN, lil x 25 mm @ SNAPRINGS @ SU&SHAFTTRANSMISSIONHOUSINGAEARING @ MAINSHAFTTRANSMISSIONHOUSINGBEARING TNANSMISSIONHOUSING @ COUNTERSHAFT @ @ @ @ @ @ @
BEABING DOWELPlN, 14 x 25 mrn CONNECTORBRACKET DOWELPlN, 14 x 20 mm TRANSMISSIONHOUSINGGASKET Replace. DIFFERENTIAL ASSEMBLY TOROUEOONVERTER HOUSINGOIL SEAL Replace. HOUSING TOROUECONVERTER
TOROUESPECIFICATIONS Boli/Nut No.
6B 10A
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Torque Value
Size
12 N.m (1.2kgf.m,8.7lbf.ft) '14N.m (1.4kgim, 10 lbf'ft) 44 N.m (4.5 kgim, 33 lbf.ft)
6 x 1 . 0m m 6x1.0mm mm 1 0x ' 1 . 2 5
Remarks
14-1A3
lllustratedIndex(2WD) TorqueConverterHousing/ValveBody
to\ I @
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ai_lATF FEEDPIPE,I a2', ATF STRAINER
PLATE i4ll MAIN SEPARATOR (4dDOWELPIN @ ATF PUMP DRIVEGEAR @ SUCTIONPIPECOLLAR .!!l COUNTEBSHAFT HOUSING TOROUECONVERTER
x 145 mm
SERVOBODY (41 SERVOSEPARATOB PLATE /4. SECONDABY VALVE BOOY :4.
DOWELPIN PLATE SEPARATOR \7) SECONDARY SERVODETENTBASE('98 model onlvl ATFFEEDPIPE,8 x 145mm 1.0)ATFFEEDPIPE.8x 40 mm tl ATFFEEDPIPE,8x 62 mm ATFFEEDPIPE,I x 112mm (3] ATFFEEDPIPE,8 x 192.5mm ATFFEEDPIPE,8 x 105.8mm t9 STOPSHAFTBRACKET PLATE .1qATF LUERICATION ATF FEEDPIPE DOWELPIN ID LOCK-UPVALVEBODY @,LOCK-UPSEPARATORPLATE VALVEBOOY 8! REGULATOR Itt\ DOWELPIN ,29 COOLERRELIEFVALVESPRING €4 COOLERBELIEFVALVE CHECKVALVESPRING TOROUECONVERTER 69 TOROUECONVERTERCHECKVALVE CONTNOLSHAFT aaDETENTARM SPRING .21DETENTARM 60 DETENTARM SHAFT 0t FILTERReplace. CHECKBALLS CHOKE 1STACCUMULATOR 04O-RINGReplace. STATORSHAFT 6!)STOPSHAFT ATFFEEDPIPE.8 x 112mm t0 MAIN VALVE BODY 0t ATF PUMPDRIVENGEARSHAFT .@ ATFPUMPDRIVENGEAR
o o,
BEARING
art)ATF GUIDEPLATE @ ATF MAGNET
HOUSING @ TOBOUECONVERTER @ OILSEAL Beplace. OILSEAL Replace. @ MAINSHAFT li]t MAINSHAFTTOROUECONVERTER HOUSING BEARING LOCK.UPCONTROLSOLENOIDVALVEA/B FILTER/GASKETReplace. LOCK-UPCONTROLSOLENOIDVALVEA/B ASSEMELY
oa
en
TOROUESPECIFICATIONS Bolt/Nut No.
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Torque Value
Size
12 N.m (1.2kgim,8.7 lbf'tt)
6x1.0mm
Remarks
14-185
End Cover Removal NOTE: o The illustrationshowsthe 4WDautomatictransmission; the 2WD is similar. . cleanall partsthoroughlyin solventor carburetorcleaner,and drythem with compressedair. . Blow out all passages. . When removingthe transmissionend cover,replacethe following: - End cover gasket - Lockwasher - O-rings 6 x 1.0 rhm EOLTS - Shaftlocknuts - Conicalspringwashers - Sealingwashers
A/T GEARPOSMON SwlTCH COVER
A/T GEARPOSITION
ENDCOVERGASKET A/T GEARPOSMON SW|TCH HARNESSCLAMP MAINSHAFTLOCKNUT CONICALSPRINGWASHER 1STCLUTCHASSEMBLY THRUSTWASHER THRUSTNEEDLEAEARING NEEDI.TBEARING SUB.SHAFTLOCKNUT
PARKPAWL PAWL
O.RINGS
lt1/ sroe Y plwl
f
L/'SPRING
Locx wASHER 7// ?ARKsrop 9/ couNTERsHAFr o-- Ay' LOCKNUT LocKNUr G-€
PAwL 'sHAFr
CONICALSPRING WASHER
\
\
!€\ -l!€'
SUB.SHAFT1STGEAR MAINSHAF?'ST GEAR
I"EVER SPRING
MAINSHAFT1ST GEARCOLLAR
/
..t,"o, "oo CONICALSPRING WASHCR
PARKGEAR Y CLUTCH
SEALINGWASHERS
lST GEAR NEEDLEBEARING
LINEAOLT
COUNTERSHAFT lST GEARCOLLAR
ATF COOI.fB LINES LINEBOLT
14-186
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SEALINGWASHERS
1.
R e m o v et h e A / T g e a r p o s i t i o n s w i t c h h a r n e s s cramp. Removethe y'VTgear position switch cover. Removethe bolt securingthe ly'T gear positionswitch harnessclamp on the end cover,then removethe A/T gear positionswitch. Removethe 12 bolts securingthe end cover.then removethe cover. Slip the specialtool onto the mainshaftas shown.
PIN 8 mm pin, commercially
SUB-SHAFT LOCKNUT Replace.
MAINSHAFT LOCKNUT Replace. COUNTERSHAFT LOCKNUT 2\ Replace.
Irot)
CONICALSPNINGWASHERS Replace.
6. 7.
Engagethe parkpawlwith the parkgear. Cut the locktabsof eachshaft locknutusing a chiselas shown. Keepall chiseledparticlesout of the transmisston.
M=tt"
9. Removethe lock pin that was installedto hold the sub-shaft. 10. Removethe specialtool from the mainshaft. 11. Removethe 1stclutch,mainshaft1stgearassembly, and mainshaft1stgearcollar. '12. Removethe sub-shaft1stgear. 13. Removethe park pawl, pawl spring,pawl shaft.and pawl stoP. 14. Removethe park leverfrom the controlshaft. 15. Using a universaltwo jaw puller, removethe park g e a r , o n e - w a yc l u t c h ,a n d c o u n t e r s h a f 1t s t g e a l assemblv. PULLER available) {Commercially
Align the hole of the sub-shaft1st gear with the hole of the transmissionhousing.then insert a pin to lock the sub-shaftwhile removingthe sub-shaftlocknut. Removethe locknutsand conicalspring washersfrom eachshaft. NOTE: Mainshaftand countershaftlocknuts have lefthandthreads. Cleanthe old countershaftlocknut.lt is used to installthe pressfit parkgear on the countershaft.
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1SYGEAR Removethe needlebearingand countershaft1stgear co ar. 1 1 . Removethe ATFcoolerlines,
14-187
Transmission Housing Removal NOTE: . The illustrationshowsthe 4WDautomatictransmission; the 2WD is similar, . Cleanallpartsthoroughlyin solventor carburetorcleaner.and drythemwith compressedair. . Blow out all passages. . When removingthe transmissionhousing,replacethe lollowing: - Transmissionhousinggasket - Lockwasher - O-rings TRANSMISSIONHOUSINGMOUNTINGEOLT
TRANSMISSIONHANGER
TRANSMISSIONHOUSING
REVERSE GEANCOLLAR REVERSE GEAR
CONNECTOR BRACKET
LOCKWASHER
MAINSHAFTSPEED SENSOR
REVERSE SHIFT
MAINSHAFT SUB.ASSEMBLY
TRANSMISSIONHOUSING GASKET
DIFFERENTIAL ASSEMBLY
TOROUECONVERTER HOUSING
O-RING t4wDl
TRANSFERASSEMBLY t4wDt
10 x 1.25mm BOLTS
l4wo)
14 -18 8
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Removethe countershaftreversegearcollar,needle bearing, and countershaftrevsrse gear from the countershaft,
1 . Removethe transferassemblyfrom the torque converterhousing.(4WD) Removethe mainshaftspeedsensorfrom the transmissionhousing.
7.
Removethe lock bolt securingtho reverseshift fork, t h e n r e m o v e t h e r e v e r s es h i f t f o r k a n d r e v e r s e selectortogether.
8.
Removethe countershaftsub-assemblvand maintogether, shaftsub-assembly
9.
Removethe differential assembly.
Removethe transmissionhousing mounting bolts, transmissionhanger,and connectorbracket. 4.
Align the spring pin on the control shaft with the transmissionhousinggrooveby turningthe control shaft.
SPRINGPIN
I n s t a l lt h e s p e c i a lt o o l o v e r t h e m a i n s h a f t .t h e n removethe transmissionhousingas shown.
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14-189
TorqueConverterHousing/ValveBody Removal NOTE: . The illustrationshowsthe 4WDautomatictransmission; the 2WD is similar. ' cleanall partsthoroughryin sorventor carburetorcreaner,and drythem with compressedair. . Blow out all passages. . When removingthe valvebodies,replacethe following: - Lockwasher - O-ring ATF FEEDPIPE
SERVODETENT BASE 137 - 98 models only)
DOWELPIN 6x1.0mm '97 - 98 models:
LOCK.UPVALVE BOOY
2 Bolts '99 - 00 modeb: 1 Bolt
LOCK.UPSEPARA PLATE
ATF STRAINER
REGULAIORVALVE BOOY DOWELPIN 6x1.0mm 37 - 98 models: 7 Bolts 'gg - 0Omodels: 8 Bolts
COOLERRELIEFVALVE
TOROUECONVERTER CHECK VALVE
SERVOBODY 137 - 98 modelsl
STATOR SHAFT O.RING
SERVO SEPARATOR PLATE 5x1.0mfi 3 Bolts
6x 1.0 5 Bolts
SECONDARY VALVEBODY
MAIN VALVEBODY DOWELPIN
ATF PUMPORIVEN GEARSHAFT ATF PUMPDRIVEN GEAR
14-190
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\ CONTROL LEVER MOUNTINGBOLT {awD)
SECONDARY SEPARATOR PLATE
1 . Removethe control lever mounting bolt trom the torque converterside of the torque converterhousing. (4WD)
14, Cleanthe inlet opening of the ATF strainer thoroughly with compressedair, then checkthat it is in good condition,and the inletopeningis not clogged or damaged.
Removethe ATF feed pipes from the servo body, secondaryvalvebody,lock-upvalvebody,and main valvebody. For'97 - 98 models: Removethe two boltssecuringthe ATF strainerand servodetentbase,then removethe strainerand the base. For'99 - 00 models; Removethe ATFstrainer{one bolt). 4. For'97 - 98 models: Removethe seven bolts securingthe servo body, then remove the servo body and separatorplate' For'99 - 00 models: Removethe eight bolts securingthe servo body, then removethe servobody and separatorplate' 5 . B e m o v et h e t h r e e b o l t s s e c u r i n gt h e s e c o n d a r y valve body, then remove the secondaryvalve body' stop shaft bracket,and separatorplate. 6. Removethe eight bolts securingthe ATF lubrication plate and lock-upvalve body, then removethe ATF lubricationplate,lock-upvalve body' and separator plate.
INLET OPENING
1 5 . Test the ATF strainer by pouring clean ATF through the inlet opening,and replaceit if it is clogged or damaged.
7. Removethe one bolt securingthe regulatorvalve body,then removethe regulatorvalvebody' 8. Removethe stator shaft and stop shaft. 9. Removethe detentspringfrom the detentarm, then remove the control shaft from the torque converter houslng. 10. Removethe detentarm and detentarm shaft from the main valvebody. 1 1 . R e m o v et h e f i v e b o l t s s e c u r i n gt h e m a i n v a l v e body,then removethe main valvebody. When removingthe main valve body, do not let the eight checkballsfall out. 1 2 . R e m o v et h e A T F p u m p d r i v e n g e a r s h a f t , t h e n removethe ATF PumPgears. 13. Removethe main separatorplate with two dowel prns.
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14-191
Valve Body Repair NOTE:This repair is only necessaryif one or more of the valvesin a valve body do not slidesmoothlyin their bores.Usethis procedureto free the varves. '1.
5.
S o a k a s h e e t o f # 6 0 0 a b r a s i v ep a p e r i n A T F f o r about30 minutes.
2.
Carelullytap the valve body so the stickingvalve drops out of its bore. lt may be necessaryto use a small screwdriverto pry the valve free. Be careful not to scratchthe bore with the screwdriver.
,l
Inspectthe valve for any scutf marks.Use the ATFsoaked#600 paper to polish off any burrs that are on the valve,then wash the valvein solventand dry it with compressedair.
4.
Roll up half a sheet of ATF-soaked #600 paper and insertit in the valve bore of the stickingvalve. Twist the paper slightly,so that it unrolls and fits the bore tightly,then polishthe bore by twistingthe paperas you push it in and out.
Coatthe valvewith ATF,then drop it into its bore, lt shoulddrop to the bottomof the bore underits own weight. lf not, repeatstep 4, then retest.lf the valve still sticks,replacethe valvebody.
w
N O T E :T h e v a l v e b o d y i s a l u m i n u ma n d d o e s n , t requiremuch polishingto removeany ourrs.
1.
14-192
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R e m o v et h e # 6 0 0 p a p e r . T h o r o u g h l y w a s h t h e entire valve body in solvent,then dry it with compressedar.
Removethe valve.and thoroughlyclean it and the valve body with solvent. DrV all parts with compressedair,then reassemble usingATFas a lubricant.
Valve Assembly NOTE; Coatall partswith ATF beforeassembly. .
.
Set the spring in the valve,and installit in the valve b o d y . P u s ht h e s p r i n g i n w i t h a s c r e w d r i v e rt,h e n installthe springseat.
l n s t a l tl h e v a l v e ,v a l v es p r i n g ,a n d c a p i n t h e v a l v e body.and securewith the roller.
SEAT
u>o VALVE EODY
Installthe valve,spring,and cap in the valve body. Pushthe caD,then installthe cliP.
VALVE BODY
VALVE
CAP
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14-193
ValveGaps Description C a p s w i t h o n e p r o j e c t e dt i p a n d o n e f l a t e n d a r e i n s t a l l e dw i t h t h e f l a t e n d t o w a r d t h e i n s i d eo f t h e valvebody. Capswith a projectedtip on each end are installed w i t h t h e s m a l l e rt i p t o w a r d t h e i n s i d eo f t h e v a l v e b o d y .T h es m a l lt i p i s a s p r i n gg u i d e .
TOWARDOUTSIDEOFVALVEAODY
Capswith hollow ends are installedwith the hollow end awayfrom the insideof the valveooov. Capswith notchedends are installedwith the notch towardthe insideof the valvebodv. Capswith flat ends and a holethroughthe centerare installedwith the smaller hole toward the inside of the valvebody.
TOWAROOUTSIDEOFVALVEBODY
EEEE TOWARDINSIDEOF VALVEBODY
C a p sw i t h o n e p r o j e c t e dt i p a n d a h o l l o w e n d a r e installedwith the tip toward the inside of the valve body.The tip is a springguide. Capswith one projectedtip and flat end are installed with the tip toward the insideof the valve bodv. The tip is a spring guide. The groove is a valve cao clio g ui d e .
TOWARD OUTSID€ OF VALVE BOOY
TOWARDI'{SIDEOF VALVEEOOY
14-194
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TOWAROINSII'C OF VALVE BODY
Capswith flat ends and a groovearoundthe cap are installedwith the groovedside toward the outsideof the valvebody.
TOWARDOUTSIO€OFVAIVE BODY
TOWARDINSIDEOF VALVEBOOY
ATFPump Inspection 1.
I n s t a l tl h e A T F p u m p g e a r sa n d A T F p u m p d r i v e n g e a r s h a f t i n t h e m a i n v a l v e b o d y L u b r i c a t ea l l p a r t sw i t h A T F , a n d i n s t a l lt h e A T F p u m p d r i v e n gearwith its groovedand chamferedsidefacingup
Measurethe side clearanceof the ATF pump drive and drivengears.
2.
ATF Pump Gears Side {Radial}Cloarance: Standard (Newl: ATF Pump Drive Gear 0.105- 0.1325mm {0.004- 0.005in} ATF Pumo Driven Gear 0.035- 0.0625mm {0.0014- 0.0025in)
ATF PUMP ORIVE
MAIN VAI-VEBOOY
fl L /
ATF PUMP DRIVEGEAR
ATF PUMP DRIVENGEAR Inspeclteeth{or wear and damage
I n s p e c tt e e t h f o r w e a r a n d d a m a g e ,
3.
MAIN VALVE AOOY
Removethe ATF pump driven gear shaft Measure the thrust clearanceof the ATF pump driven gearto-valvebody. ATF Pumo Drive/DrivenGearThrust (AxiallClearance: Standard (N€w): 0.03- 0.05 mm {0'001- 0 002 inl ServiceLimit: 0.07 mm 10.003in)
ATF PUMP ORIVENGEAR
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14-195
Main Valve Body Disassembly/lnspection/Reassembly NOTE: . Do not usea magnetto removethe checkballs;it may magnetizethe balls. t clean all partsthoroughlyin solventor carburetorcleaner,and dry them with compressed ai.. Blow out all passages. . Replacethe valvebody as an assemblyif any partsare worn or damageo. . C h e c k a lvl a l v e s f o r f r e em o v e m e n tl .f a n y f a i l t o s l i d e f r e e l y , s e e V a l v e B o d y R e p a i r o n p a g e . t 4 _ 1 9 2 . . Coatall partswith ATF during reassembly.
I-2 SHIFTVALVE VALVECAPCLIP 2ND ORIFICE CONTROLVALVE SPRINGSEAT
@ U K
BALLS,8
ACCUMULATOR CHOKE
VAI-VE FELI€FVALVE
MAIN VALVEBOOY Inspectfor wear, scratches, and sconng.
sERVOCONInOL
:,/\^._.^,
14-196
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CHECKBALL
i)L )
CHECKBALLS
lo lST ACCUMULATOR CHOKE
CHECKEALL
MAIN VALVEBODY (Sectionalview)
SPRINGSPECIFICATIONS
U n i t :m m ( i n ) Standard {New)
No.
o @ @ @
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Springs Reliefvalvespring Modulatorvalvespring CPBvalvespring 1-2shift valvespring 2nd orificecontrolvalvespring Servo control valve sPring
Wire Dia. 1 . 1( 0 . 0 4 3 ) 1.4(0.055) 0.9 (0.03s) 0.9 (0.035) 0.7 (0.028) 1.0t0.039)
o.D. 8.6 (0.339) 9.4 (0.370) 8 . 1( 0 . 3 1 9 ) 7.6 (0.299) 6.6 (0.260) 8 . 1{ 0 . 3 1 9 )
FroeLength 3 7 . 1( 1 . 4 6 1 ) 35.0(1.3781 41.2 \1.8581 4 1 . 3( 1 . 6 2 6 ) 34.8(1.370) 5 2 . 1( 2 . 0 5 1 )
No. of Coils
'13.4 10.9
20.8
14-197
SecondaryValve Body Disassembly/lnspection/Reassembly NOTE: ' clean all partsthoroughlyin solventor carburetorcleaner.and dry them with compressed air. Blow out aUpassages, . Replacethe valvebody as an assemblyif any partsare worn or damaged. t checkall valvesfor free movement.rf anyfair to sridefreery.seevarveBody Repair page on 14-192. . Coatall partswith ATFduring reassembly. . The CPCvalveis installedin the secondaryvalve body,held in placeby the lock bolt.
t*-1
VALVECAP
2.3 SHIFTVALVE
@,..t'tr.,
,rr'^'//u "/
./
3-' SHIFTVALVE
ilTH EXHAUSTVALVE
SECONOARY VALVEBODY Inspectfor wear, scratches,and scorang.
N"*,"o"*
3.4 ORIFICECONTROLVAL
VALVESLEEVE ROLLER
SPRINGSPEC!FICATIONS U n i t :m m ( i n ) No.
o @
o
@
Standald {Nswl
Springs 3 4 shiftvalvespring 2-3shift valvespring 4th exhaustvalvespring 3-4 orificecontrolvalvespring
14-198
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Wire Dia.
o.D.
0.9 (0.035) 0.9 (0.035) 0.9{0.035) 0.6 {0.024}
7.6 (0.299) 7.6 (0.299) 6.1 (0.240t 6.6 (0.2601
FreeLength 57.Oi.2.2441 57.O12.244J 3 6 . 4( 1 . 4 3 3 ) 37.9(1.492)
No. of Coils 26.A 26.8 19.5 31.6
RegulatorValve Body Disassembly/lnspection/Reassembly NOTE: o Cleanall parts thoroughlyin solventor carburetorcleaner,and dry them with compressedair. Blow out all passages. . Replacethe valvebody as an assemblyif any partsare worn or damaged. . Checkallvalvesforfreemovement.lf anyfail toslidefreely,seeValveBody Repairon page l4-192. '1. Holdthe regulatorspringcap in placewhile removingthe stop bolt. The regulatorspringcap is spring loaded Once the stop bolt is removed,releasethe springcap slowly so it does not pop out. is the reverseorderof disassembly. Reassembly
2.
NOTE: . Coatall partswith ATF during reassembly. . Align the hole in the regulatorspringcap with the hole in the valve body,then pressthe spring cap into the valve body,and tightenthe stop bolt. SPSING CAP REGULATOR
STOPBOLT 6x1.0mm 12N.m11.2
8.? tbt.fil
REGULATOR VALVEBODY lnspectfor wear,scratches, ano scoflng.
REGULATOR VALVE
Standard {New}
No,
o @ @ ,6
a,
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Springs wire Dia. RegulatorvalvespringA Regulatorvalvespring B Statorreactionspring Coolerreliefvalvespring Torque convertercheckvalve spring '97 Model '98 - 00 Models Lock-upcontrolvalvespring
o.D.
F ee Length
1 . 8( 0 . 0 7 1 ) 1 . 8( 0 . 0 7 1 ) 4 . 5( 0 . 1 7 7 ) 1.0{0.039)
14.7(0.579) 9.6 (0.378) 35.4(1.394) 8 . 4{ 0 . 3 3 1 )
87.8(3.457) 44.0t1.7321 3 0 . 3( 1 . 1 9 3 ) 3 3 . 8( 1 . 3 3 1 )
1.1(0.043) 1.2lO.O47l 0.7 t0.028)
8 . 4( 0 . 3 3 1 ) 8 . 4( 0 . 3 3 1 ) 6.6 (0.260)
36.4(1.433) 32.4 11.2761 38.0(1.496)
No. ot Coils
'11.0 1.9 't2.0 12.7 14.'l
14-199
ServoBody Disassembly/lnspection/Reassembly NOTE: ' cleanall partsthoroughly in solventor carburetorcleaner,and dry them with compressedair, Blow out all passages. . Replacethe valve body as an assemblyif any partsare worn or damaged. . Coatall partswith ATF during reassembly.
ACCUMULATOR COVER
3ROSUBACCUMULATOR
O-RING Feplace. 1STACCUMULATOR PISTON
@"-.t
SPR|NGRETATNER
-tP l@
fi, il
,/
g
3RDACCUMULATOR
\_)
SERVO RVOVAL\VE/SHIFT IRKSHAFT FORK S
O.RING Replace.
SNAPRING SNAPRING
SPRINGSPECIFICATIONS U n i t :m m { i n ) No.
Standard lNewl
Springs Wire Dia,
o @ J6
@ .A \o,
o @ @
1staccumuiatorspring 4th accumulatorspringA 4th accumulatorspring B 3rd accumulatorspringA 3rd accumulatorspringB 2nd accumulatorspringC 2nd accumulatorspringA 2nd accumulatorspringB 3rd sub accumulatorspring
14-200
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2.1 (0.083) 2.6 {0.102) 2 . 3( 0 . 0 9 1 ) 2 . 8( 0 . 1 1 0 ) 2.1 (0.083) 2.2 (0.087l2.4 (0.094) r.6 (0.063) 2 . 7{ 0 . 1 0 6 )
o.D. 16.0(0.6301 17.0(0.669) 't0.2 t0.402] 17.5(0.689) 3 1 . 0( 1 . 2 2 0 ) 1 4 . 5{ 0 . 5 7 1 ) 29.0 11.1421 9.0 (0.354) 17.0(0.669)
FreeLongth 89.r (3.508) 88.4(3.480) 5 1 . 6( 2 . 0 3 1 ) 94.3(3.713) 38.2(1.504) 68.0{2.677) 39.0fi.535) 20.7(0.815) 39.0(1.535)
No. of Coil3
14.2 13.8 15.9 2.6 13.9 2.9 o.l
6.3
Lock-upValve Body bly Disassembly/lnspection/Reassem NOTE: . Cleanall partsthoroughlyin solventor carburetorcleaner,and dry them with compressedair. Blow out all passages. . Replacethe valvebody as an assemblyif any partsare worn or damaged. . C h e c k a lvl a l v e s f o r f r e em o v e m e n tl .f a n y f a i l t os l i d ef r e e l y s, e e V a l v eB o d yR e p a i r o np a g e1 4 - 1 9 2 . . Coatall partswith ATF duringreassembly.
LOCK.UPSHIFTVALVE
'\
\
\ ,^
/
\-.xlO
@-tr \"o...*
,As'.
LOCK-UPVALVEEODY Inspectlor wear,scratches, and scoring.
VALVECAP
LOCK-UPTIMINGVAL
\uo.*"or".,,
SPRINGSPECIFICATIONS
Unit:mm (in)
Standard lNewl No.
O (
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Springs Lockup shiftvalvespring Lock-uptiming valvespring
Wire Dia.
0.9(0.035) 0.9(0.035)
o.D. 7.6 (0.299) 8 . 1( 0 . 3 1 9 )
Fle€ Length
73.1 t2.902), 8 1 . 4( 3 . 2 0 5 )
No. of Coils
32.0 47.8
14-201
Mainshaft Disassembly/lnspection/Reassembly NOTE: . Lubricateall partswith ATFduring reassembly. .Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement, . Beforeinstallingthe O-rings.wrap the shaftsplineswith tapeto preventdamagingthe O-rings. . Locknuthas left-handthreads. . Installthe conicalspringwasherin the directionshown. . Inspectconditionof the sealingrings.lf the sealingrings are worn, distorted,ordamaged,replacethem (seepage 142041. LOCKNUTIFLANGENUT) 19 x 1.25mm 78 N.m {8.O kgf.m,58 lbl.ftl Replace. Left-hand threads
CONICAL SPRINGWASHER Replace.
lST CIUTCH ASSEMBI.Y
SNAP RING
o-Rtt{Gs THRUSTNEEDLE B€ARING
THRUST WASHEB
Replace. THRUST WASHCR
4TH GEAR
THRUST NEEOI€ BEARIl{G I{EEDLEBEARIIIG
MAINSI{AFT Check splinesfor excessive wear ano damage. Check bearingsurfacetor scoring, scratchesand excessivewear.
BEARII{GS
rST GEAR COLLAR TXBUST 1{EEDLE BEARIl{G 4TH GEAR COLLAR 2ND/4TH CLUTCX
o-Brr{Gs THRUSTWASHER,36.5 r 55 mm Selective part
THRUSTNEEDLE SEARING 2NO GEAR SEALINGRltrlG, 29 mm
NEEDLEEEARING THRUST NEEDI-E BEARING Install the sealing ring mating faces as shown
NEEDLEEEARING www.emanualpro.com
14-202
SET RING
lST GEAR
TnANSMtSSIOt{ HOUSII{GBEARII{G
Inspection Clearance Measurement 1.
2.
3.
Removethe mainshaftbearingfrom the transmission housing lsee page 14-227l..
Tightenthe mainshaftlocknutto 29 N.m (3.0kgf.m, 22 tbf.ft). The mainshaftlocknuthas left-handthreads.
Assemblethe mainshaftparts,but do not installthe O-rings,
CONICALSPRINGWASHER
29 N.m (3.Okst.m, 22 lbt.frl lST CLUTCHASSEMELY THRUST WASHER 1ST GEAB COLLAR TRAI{SMISSION HOUSIf{G BEARING SNAP RII{G THRUST WASI{ER GEAR COLLAR
Hold 2nd gear againstthe 2nd clutch,then measure the clearancebetween2nd gear and 3rd gearwith a feelergauge. Take measurementsin at leastthree places,and usethe averageas the actualclearance. STANDARD:0.05- 0.13 mm (0.002- 0.005in) 3RD GEAR
2'{D GEAR
2[{D/4TH CLUTCH ASSEMALY THRUST WASHER .5r55mm Selective part
THBUST IIEEDLE EEARII{G 2ND G€AR EEARIt{G TI{RUST NEEOLE BEARII{G
FEELERGAUGC THRUSTWASHER. 36.5 x 55 mm
MAII{SHAFT
(cont'd)
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14-203
SealingRings
Mainshaft Inspection(cont'dl
Replacement
I t t h e c l e a r a n c ei s o u t o f s t a n d a r d ,r e m o v e t h e thrustwasherand measureits thickness.
The sealingrings(35 mm and 29 mm) are syntheticresin with chamferedends.Checkthe conditionof the sealing rings,and replacethem only if they are worn, distorted, or oamageo. NOTE:Apply ATFto all partsduringassembly. 1.
For a better fit, squeezethe sealing ring together slightlybeforeinstallingthem.
Selectand install a new washer,then recheckthe clearance, and makesure it is within standard. THRUSTWASHER36.5 x 55 mm No.
Part Number
Thickness
1
9 0 4 4 1- P G 4 , 0 1 0
4 . 0 0m m ( 0 . 1 5 7 in)
2
90442-PG4-010
4 . 0 5m m ( 0 . 1 5 9 in)
90443-PG4-010
4 . 1 0m m { 0 . 1 6 1i n )
90444-PG4-010
4 . 1 5m m { 0 . 1 6 3i n )
90445-PG4-010
4 . 2 0m m ( 0 . ' 1 6i5n )
6
90446-PG4-010
4 . 2 5m m { 0 . 1 6 7i n )
1
90447-PG4-010
4 . 3 0m m ( 0 . 1 6 9i n )
8
90448-PG4-010
4 . 3 5m m ( 0 . 1 7 1i n )
I
90449-PG4-010
4 . 4 0m m ( 0 . 1 7 3i n )
10
90450-PG4-000
4 . 4 5m m ( 0 . 1 7 5i n l
Installnew sealingrings on the mainshaft. After installingthe sealingrings, verify the following: . . .
The sealingringsare fully seatedin the groove. The sealingringsare not twisted. T h e c h a m f e r e de n d s o f t h e s e a l i n g r i n g s a r e properlyjoined.
SEALINGRING Installthe sealingring matingfacesas shown.
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14-204
Countershaft Disassembly/lnspection/Reassembly NOTE: . Lubricateall pans with ATF beforereassembly. .Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement. . Beforeinstallingthe O-rings,wrap the shaftspllneswith tapeto preventdamagingthe O-rings. . Locknuthas left-handthreads. . Installthe conicalspringwasherin the directionshown.
R€VERSEGEAR
LOCKNUTIFLANGENUTI 23 x 1.25mm 103-0-103N.m t 1 0 . 5- 0 - 10.5 kgl.m, 7 5 . 9- 0 - 75.9 lbt.lr)
CONICAL SPRING WASHER Replace.
Replace. Lelt.hand threads
NEEOLEBEARING REVERSE SELECTOR REVERSE SELECTOR HUB lST GEAR COUNTERSHAFT Check splinesfor excessive wear and damage. Check bearingsurfacefor scoring, scratchesand excessivewear.
4TH GEAR NEEDLEEEARING
I{EEDLEBEARING
OISTANCECOLLAR. 28 mm Selective part
lST GEARCOLLAR
2NO GEAR
TRANSn SSTON HOUSI G BEARING
3RD GEAR NEEDLEBEARING 3RD GEARCOLLAR THRUSTNEEOLEBEARING SPLINEDWASHER 3RO CLUTCHASS€MBLY
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14-205
Gountershaft Disassembly/Reassembly 1.
Removethe reverseselectorhub and countershaft 4th gear using a universaltwo-jaw lor three-jaw) puller as shown. Placea shaft protector between t h e p u l l e ra n d c o u n t e r s h a ftto p r e v e n td a m a g i n g the countershaft.
2.
Assemblethe parts on the countershaftas shown below. NOTE; . Lubricateall partswith ATF during reassembly. . B e f o r e i n s t a l l i n gt h e O - r i n g s .w r a p t h e s h a f t s p l i n e sw i t h t a p e t o p r e v e n td a m a g i n gt h e O rings.
{ C o m m e r c i a l l ya v a i l a b l e )
4TH GEAR BEARI'{G DISTANCECOLLAR, 28 mm Selectiveoart
REVERSE SELECTOR HUB
GEAR
THRUST ]{EEOL€AEARIIIG
SEARII{G .TH GEAR
GEAR COLLAR THRUST I{EEDLEEEARII{G WASHER 3RO CLUTCH ASSEMBLY
O-RINGS Replace.
14-206
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Inspection 3.
Installthe reverseselectorhub on the countershaft sub-assembly, and pressthe hub using the special tool and a pressas shown.
DRIVERto mm l.D. 07746- 0030100
ClearanceMeasurement NOTE: Lubricateall partswith ATF duringassembly. 1.
Removethe countershaftbearing from the transmissionhousinglsee page14-227).
2.
Assemblethe countershaftparts using the special tool and a pressas describedon this page. Do not installthe O-ringsduring inspection.
R€VERS€SELECTOR HUB GEAR NEEDLEBEARING
REVERSE SEI.ICTOR HUB
DISTANCECOLLAR, 28 mm Selective part
2NO GEAR
COUNTERSHAFT SU&ASSEMBLY
THRUST NEEDLEBEARING GEAR NEEOLEBEARING GEAR COLIAR THRUSTNEEDLEBEARING WASHER
CLUTCHASSEMBLY
(cont'd)
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14-207
Countershaft Inspection(cont'd) 3.
I n s t a l lt h e c o u n t e r s h a fst u b - a s s e m b lpy a r t s ,t h e n i n s t a l l t h ep a r kg e a ru s i n ga p r e s sa n da c o l l a r .
4.
Tightenthe locknutto 29 N.m (3.0 kgf.m,22 lbf.ft). The countershaftlocknuthasleft-handthreads.
Measurethe clearancebetweenthe 2nd gear and the 28 mm distancecollarwith a feelergauge.
5.
NOTE:Takemeasurementsin at leastthree places, and usethe averageas the actualclearance. 0.10- 0.18mm (0.004- 0.007in) STANDARD:
LOCKNUT Le{t-hand threads
2NO GEAR
OISTANCECOLLAR, 28 mm
CONICALSPRING WASHER
PABKGEAR/ONE.WAY CLUTCH/1STGEAR ASSEMBLY NEEDLEBEANING lST GEARCOLLAR TRANSMISSIONHOUSING AEARING
REVERSE GEAR COLLAR
COUNTERSHAFT SUB.ASSEMBLY
6.
FEELER GAUGE lf the clearanceis out ot standard,removethe distancecollar,and measureits width.
7.
Selectand installa new distancecollar,then recheck.
DISTANCECOLLAR,28mm No.
8.
14-208
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Part Number
widrh
1
90503-PCg-000
3 9 . 0 0m m ( ' 1 . 5 3i5n )
2
90504-PCg-000
3 9 . ' 1m 0 m ( 1 . 5 3 9i n )
?
90505-PCg-000
3 9 . 2 0m m { 1 . 5 4 3i n )
90507-PCg-000
3 9 . 3 0m m ( l . 5 4 7i n )
90508*PCg-000
3 9 . 0 5m m ( l . 5 3 7i n )
90509-PCg-000
3 9 . 1 5m m ( l . 5 4 1i n )
7
90510-PCg-000
3 9 . 2 5m m { 1 . 5 4 5i n )
8
90511-PCg-000
3 8 . 9 0m m { L 5 3 1i n )
9
90512-PCg-000
3 8 . 9 5m m ( 1 . 5 3 3i n )
After selectinga new distancecollar. recheckthe clearance and makesureit is within standard.
One-way Glutch Disassembly/lnspection/Reassem bly 1.
Separatecountershaft1st gear from the park gear by turningthe parkgear in the directionshown.
3.
Inspectthe oartsas follows; PARKGEAR InspectIor wear andsconng.
PARKGEAR
COUNTERSHAFT lST GEAR
2.
ONE.WAYCLUTCH Inspectfor damage and taultymovement,
Removethe one-wayclutchby prying it up with the tip of a screwdriver.
COUNTERSHAFT IST GEAR
ONE.WAYCLUTCH Installin this direction. lST GEAR Inspectfor wear and scortng.
4.
After the parts are assembled, hold countershaft lst gear. and turn the park gear in the direction shown to be sure it turns freely. Also make sure the park gear does not turn in the opposite direction.
ONE.WAYCLUTCH lST GEAR
,ISTGEAR COUNTERSHAFT SCREWDRIVER
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14-209
Sub-shaft Disassembly/lnspection/Reassembly NOTE: . Lubricateall partswith ATF beforereassembly. . Inspectthe thrust needlebearingsand the needlebearingsfor gallingand rough movement. . Beforeinstallingthe O-rings,wrap the shaftsplineswith tapeto preventdamagingthe O-rings.
TRAi{SMTSStONtl()UStNG
IST.HOLOCLUTCH ASSEMBLY 6 x 1.0 mrr 12 1{.m ll.2 ksl.m, 8.7 lbt.ftl
o,Rtl{GS Replace. TI{RUST WASI{ER
SUB.SHAFT Check splines tor excessive wear ano damage, Check bearing surlace for scoring, scralches and excessive wear-
THFUST TEEOLC BEARI G I{EEDLE B€ARI G
t{EEDLEBEARING STOP
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14-210
Disassembly/Reassembly 1.
Removethe ATF guidecap by pushingthe sub-shaft insidethe transmissionhousing. R e m o v et h e 1 s t - h o l dc l u t c ha s s e m b l yb y p u l l i n g , then removingthe sub-shaft. Installnew O-ringson the sub-shaft. NOTE:Wrap the shaft splineswith tape to prevent damagingthe O-rings. P l a c et h e s u b - s h a f ti n t h e t r a n s m i s s i o nh o u s i n g , and installthe'lst-holdclutchassembly, I n s t a l lt h e n e w A T F g u i d e c a p u s i n g t h e s p e c i a l tools.Installit in the directionshown.
ATTACHMENT, 32x35mm 07746- 0010t00
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14-211
Sub-shaftBearings Replacement NOTE:Lubricateall partswith ATF beforereassembly. 1.
4.
Installa new needle bearing in the housing using the sOecialtools and a oressas shown.
E x p a n dt h e s n a p r i n g w i t h s n a p r i n g p l i e r s .t h e n push the bearing out of the transmissionhousing usingthe specialtools and a pressas shown.
c I
32x35mm 077/46- qt10t(x, ATTACHMENT, ai:lx 68 mm 07746 - 00105q)
E x p a n dt h e s n a p r i n g w i t h s n a p r i n g p l i e r s ,t h e n insert the ball bearing part-way into the housing using the specialtools and a pressas describedin step 1. Installthe bearingwith the groove facing outsidethe housing.
Removethe needlebearingstop. Removethe needlebearingfrom the transmission housingusinga drift.
Releasethe pliers,then push the bearingdown into t h e h o u s i n gu n t i l t h e s n a p r i n g s n a p si n p l a c e aroundit. 7.
After installingthe ball bearingverifythe fottowing: . .
The snap ring is seatedin the bearingand housIng grooves. The ring end gap is correct.
ENDGAP:0-7mm l0 - 0.28 inl
SNAPRING
14-212
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Glutch lllustratedlndex 3RDCLUTCH CLUTCHPISTON RETURNSPRING NETAINER CLUTCHPLATES Standardthicknoss: RING 2.00 mm 10.079inl
CLUTCHDISCS Standardthickne$: 1.94mm (0 0?6 inl
SNAPFING
lST CLUTCH CLUTCHDISCS Standardthicknca3: inl 1.9amm 10.076
SNAPRING
CLUTCHDRUM
CHECKVALVE
(cont'd)
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14-213
Clutch lllustratedIndex(cont'dl 2ND/4THCLUTCH
CLUTCHPLATES Stendardthickness: OISCSPRING 2.00 mm {0.079in)
I
[*
CLUTCH
I
2ND CLUTCH CLUTCHPISTON
sPl
I
Repl6ce.
uoavEnr" CLUTCHPLATES Standardthicknesai 2.00 mm {0.079inl
SNAPRING
14-214
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lST-HOLDCLUTCH
thickness:
RETURNSPRING
cLUTCHPISTON O.RINGS
/
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14-215
Clutch Disassembly l.
Removethe snap ring, then removethe clutch end plate,clutchdiscsand plates.
3.
I n s t a ltlh e s p e c i atlo o l sa s s h o w n . CLUTCHSPNING COMPRESSOR ATTACHMENT 07LAE- PX40100
SCREWORIVER
SNAP RING
-'=*.=:--
'..p 2.
Removethe discspring.
CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX4010Oor 07HAE- PL50100
1ST,2ND, 4TH lST-HOLDCLUTCH: DISCSPRING CLUTCH COMPRESSOR AOLTASSEMBLY 07GAE- FGao2OO or OTGAE. PG4O2OA
CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX40t00 CLUTCHDBUM
3RDCLUTCH: DISCSPRING
CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX4010Oor 07HAE- PL50100 CLUTCHSPRING COMPRESSOR BOLTASSEMBLY 07GAE- PG0200 or OTGAE- PG4O2OA
14-216
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CAUTION: lf either end ot the specialtool issetover an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged. B€ sure the specialtool is adiusted to have lull contact with the spring retainer.
Do not s6t h6re.
5.
Removethe snap ring, Then removethe specialtools, springretainerand returnspring.
SPRIlIG RETAINER
Wrap a shop rag aroundthe clutchdrum, and apply air pressureto the ATF passageto removethe piston. Placea finger tip on the other end while applying arr pressure. OSHA.APPROVED SPRINGRETAINER
4.
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Compressthe returnspring.
14-217
Glutch Reassembly NOTE: . Clean all parts thoroughly in solvent or carburetor cleaner,and dry them with compressedair. . Blow out all passages. o Lubricateall parts with ATF before reassembly. 1.
3.
Installth€ pistonin the clutchdrum. Apply pressure and rotate it to ensure proper seating, Lubricatethe pistonO-ringwith ATF betoreinsta ing the piston. NOTE:Oo not pinchthe O-ringby installingthe pis_ ton with too muchforce.
Inspectthe checkvalve;if it's loose,replacethe pis_ ton.
CLUTCH DRUM
CHECK VALVE
2.
4.
Installnew O-ringson the clutchpiston.
Installthe return spring, and spring retainer,then positionthe snap ring on the retainer.
SI{AP RING
SPAI'{G RETAIIIER
REIURN SPRING
CLUTCH DRUM
PtsTot{
14-218
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5.
CAUTION:It sither end of the spscial tool is sot over an area of the spring retain€l which is unsup' ported by the return spring, the retainer may be damaged. Be sure the specialtool is adiusted to have full contaqt with th€ spring ratainel.
Installthe specialtoolsas shown
CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX40100
CLUTCHSPRING COMPRESSOR BOLTASSEMALY 07GAE- PG{0200or OTGAE- PG|(IMA
Do notsethere.
TOOL SPECIAL
CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PXaOI0o
CLUTCHSPRING COMPBESSOR AOL| ASSEMALY 07GAE- PG/9t200ot OTGAE- PG/(,20A
Set here.
CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX40100or O?HAE- PL5O1OO
SPRINGRETAINER
6.
Compressthe returnspring.
CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX4010O ol 07HAE- PL50100
(cont'd)
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14-219
Clutch (cont'd) Reassembly 7.
Installthe s n a pr i n g .
1 0 . Soakthe clutchdiscsthoroughlyin ATF for a mini_
m u m o f 3 0 m i n u t e s . B e f o r ei n s t a l l i n gt h e p l a t e s and discs,make sure the insideof the clutchdrum is free of din or otherforeignmatter
' t 1 . Starting
with a clutch plate, alternatelvinstall the clutch platesand discs.Installthe clutch end plate with its flat sidetowardthe disc.
CLUTCHEI{D PI.ATE Installin this directior.
S AP RIIG 8.
Removethe specialtools.
9,
Installthe discspring in the directionshown.
1ST,2ND, 4TH, lST-HOLDCLUTCH:
otsc sPfitl{c
CLUTCH
CLUTCHEI{D PLATE
12. Installthe snap ring.
SCREWDRIVER 3RD CLUTCH:
Dlsc sPRrrtc
CIUTCH ORUM
14-220
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13. Measurethe clearancebetweenthe clutchend plate and top disc with a dial indicator.Zerothe dial indicatorwith the clutchend platelowered,and lift it up to the snap ring. The distancethat the clutch end plate movesis the clearancebetweenit and the top dtsc. NOTE:Takemeasurementsin at leastthree places' and usethe averageas the actualclearance.
lST CLUTCHEND PLATES 'I
2 2 5 5 1 P 5 6- N 0 0
2
3
22552-P56-N00 22553 - P56 N00
5
22554-P56-NOo 2 2 5 5 5 P 5 6- N 0 0
8
22556 P56- N00 22557 - P56 N00 2 2 5 5 8- P 5 6 N 0 0
I
2 2 5 5 9- P 5 6 N 0 0
10
22s60- P56 N00
6 7
Clutch End Ptate-to-TopDisc Clearance: Clutch 'l st 2nd 3rd 4th lst-hold
ServiceLimit 0.650.400.400.400.50-
0.85mm (0.0260.60mm (0.0160.60mm (0.0160.60mm (0.0160.80mm (0.020-
0.033in) 0.024in) 0.024in) 0.024in) 0.031in)
Mark
I
-
:
I
Parl Number
Thickness
22558-P56-N00
10
22559-P56-N00 2 2 5 6 0- P 5 6 N 0 0
in) 2 . 9m m ( 0 . 1 1 4 3 . 0m m ( 0 . 1 1 8i n )
22561 PDM22562- PDM22563 PDM22564 PDM-
3 . 1m m ( 0 . 1 2 2i n l
000 000 000 000
3 . 2m m { 0 . 1 2i6n ) 3 . 3m m ( 0 . 1 3i 0n ) 3 . 4 m m ( 0 . 1 3 4i n )
2 2 5 6 5 P D M- 0 0 0 22566 PDM- 000
3 . 5m m ( 0 . 1 3i8n ) 3 . 6m m 1 0 . 1 4i n2 )
22567-PDM-000
in) 3 . 7m m ( 0 . 1 4 6
3RDCLUTCHEND PLATES
I
Part Number 2 2 5 5 8 P 5 6- N 0 0
9
2 2 5 5 9 P 5 6- N 0 0
10
22560 P56- N00
11
22561 PD[4 - 000
12 t3
- PDM 000 22562
'14
22564-PDN4-000 22565-PD[,l-000 22566 PDM- 000 - PoM- 000 22567
't1
-
2 . 9r n m ( 0 . 1 1 4i n ) 3 . 0m m ( 0 . 1 1 8i n )
8
15
--l----T
2 . 7 m m ( 0 . 1 0 6i n ) 2 . 8m m ( 0 . 1 1 0i n )
22556-P56-N00 22557 P56- N00
Mark
MARK
2 . 5 m m { 0 . 0 9 8i n ) 2 6 m m ( 0 . 1 0 2i n )
1
6
17
NOTE: lf the thickestclutch end plate is installed, but the clearanceis still over the standard,replace the clutchdiscsand clutchplates.
2 3 m m ( 0 . 0 9 1i n ) 2 . 4 m m ( 0 . 0 9 4i n )
2 . 6m m ( 0 . 1 0i2n ) 2 . 7m m ( 0 . 1 0i6n ) 2 . 8m m ( 0 . 1 1i0n )
12 13
1 4 . lf the clearanceis not within the servicelimits,select a new clutchend platefrom the followingtable
2 . 1m m ( 0 . 0 8i3n ) in) 2.2mm (0.087
2ND and 4TH CLUTCHEND PLATES
'11
SNAPRING
Thicknass
Mark
22563-PDM-000
Thiclness 2 . 8m m ( 0 . 1 1 0i n l 2 . 9m m ( 0 . 1 1 4i n )
3 . 0m m ( 0 . 1 1i 8n ) 3 . 1m m ( 0 . 1 2i2n ) in) 3.2mm (0.126 3 . 3m m ( 0 . 1 3i0n ) 3 . 4m m ( 0 . 1 3 4i n ) 3 . 5 m m ( 0 . 1 3 8i n ) 3 . 6m m ( 0 . 1 4 2i n ) 3 . 7m m { 0 . 1 4 6i n )
lST-HOLDCLUTCHEND PLATES Thickness
2255r-PS5-003
2 . 1 m m ( 0 . 0 8 3i n )
2 2 5 5 2- P S 5 - 0 0 3
2 . 2 m m { 0 . 0 8 7i n )
3
22553 PS5- 003
in) 2.3mm (0.091 2 . 4 m m ( 0 . 0 9 4i n ) 2 . 5 m m ( 0 . 0 9 8i n )
6
2 2 5 5 4 , P S 5- 0 0 3 2 2 5 5 5 P S 5- 0 0 3 2 2 5 5 6 P S 5- 0 0 3
7
22557- PSs 003
rnictness
2 . 6m m { 0 . 1 0 2i n ) 2 . 7m m ( 0 . 1 0 6i n )
CLUTCHEND PLATE
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14-221
Differential lllustratedIndex 'lWD:
2WDl
SETRING,80 mm part Selective
SETnlNG,80 mm Sel6ctive part
10x 1.0mm 103N.m (10.5kgt.m, ?5.9 tbtftl
FINALORIVENGEAR lnspectfor excessivewear, Installin this direction.
A ,U
1 0x 1 . 0m m 103N.m {10.5kg[.m, 75.9 tbt.ftl Left-handthreads
,gBc
FINALORIVENGEAR Inspectfor excessivewear, Installin thls direction.
BALLBEABING Inspectfor rough
BALLBEARING Inspectfor rough
DIFFERENTIAI. CARRIER Inspectfor cracks.
DIFFERENTIAI. CARRIER lnspectfor cracks. TRANSFERSHAET DNlvE GEAR Inspectfor excessive
ROLLER,5 x 10 mm
SPEEDOMETER DRIVEGEAR Installin this direction.
SPEEDOMETER DRIVEGEAR Installin this direction.
SNAPRING Installin this direction. BALLBEARING
SNAPRING Installin this direction.
BALLBEARING Inspectfor rough movement,
14 -2 2 2
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BacklashInspection 1.
BearingReplacement
Placethe differentialassemblyon V-blocks.
NOTE:Checkbearingsfor wear and rough movement. lf bearingsare OK, removalis not required.
lnstallthe driveshaftand intermediateshaft on the differentialassemblY.
1.
Checkthe backlashof both piniongears.
Removethe bearingsusinga bearingpuller. PULLER BEARING (Commercially available)
STANDARD:0.05- 0.15 mm (0.002- 0.006in) DIALINDICATOR
ASSEMBLY OIFFEBENNAL
l n s t a l l n e w b e a r i n g s u s i n g t h e s P e c i a lt o o l snown. PRESS
It the backlashis out of standard, replacethe difterentialcarrier.
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14-223
Differential DifferentialCarrierReplacement NOTE:The illustrationshows the 4WD automatictransmissiondifferential; the 2WDdifferentialis similar. 1.
Installthe final drivengearon a new differentialcarrier with its chamferedside facing the carrier and the transferdrive gear (4WD),
Removethe snap ring from the differentialcarrier.
Tightenthe boltsto the specifiedtorque. N O T E : T h e 2 W D d i f f e r e n t i a tb o l t h a s l e f t - h a n d threads, 1 0x 1 . 0m m 103N.m 110.5 kd.m, 7s.9 rbr.ft)
FINALDRIVENGEAR
Removethe 5 x 15 mm roller (4WD)or 5 x 10 mm roller(2WDland the speedometerdrive gear. SPEEDOMETER DRIVEGEAR
TRANSFERSHAFT
RoI I FP 5 x 15 mm (/tWD)
{4WDl
5 x 10mm {2WDl
Installthe speedometerdrive gear with its chamfered side facingthe carrier.Align the cutout on the bore of the speedometerdrive gear with the 5 x 15 mm roller(4WD)or 5 x 10 mm roller(2WD). 7.
A l i g n t h e h o o k e de n d o f t h e s n a p r i n g w i t h t h e spring pin in the pinion shaft.then installthe snao ring in the differentialcarriergroove SNAP RING Installin this direction.
Hookedend
PINIONSHAFT
Removethe bolts securingthe final drivengear and the transfershaft drive gear (4WD),then replacethe differentialcarrier.
14-224
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SPRINGPIN
GROOVE
Oil SealReplacement 1.
Removethe oil sealfrom the transmissionhousing.
3.
lnstallthe oil seal in the transmissionhousingusing the specialtools as shown.
DRIVER 077a9- 0010000
OIL SEAL Replace.
ATTACHMEMT
079r?- slx[ax)
R e m o v et h e o i l s e a l f r o m t h e t o r q u e c o n v e r t e r housing.
4.
Installthe oil seal in the torque converterhousing usingthe specialtoolsas shown.
-.]. OIL SEAL Replace.
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TOROUECONVERTER HOUSING
14-225
Differential Side ClearanceInspection 1.
Instsllthe 80 mm set ring in the transmissionhousIng,
4.
Tap on the transmissionhousingside of the diffsr entialassemblywith the specialtool to seatthe differentialassemblv. DBIVERilo m.n LO. 0t746 - 0030100
SET RING,80 mrn
Measurethe clearancsbetweenthe 80 mm set ring and the bearingouter racewith a feelergauge, Installthe differentialassemblyin the torque converterhousingusingthe specialtool.
STANDARD:0 - 0.15 mm (0 - 0.006inl
FEEI..ER GAUGE lf the clearanceis out of standard,removerne set ring and measurs its thickness. 7.
Selectand instslla new 80 mm set ring. SETRING,80 mm Part Numbor
Installthe transmissionhousingon the torque converter housing,and tighten the transmissionhousing mountingbolts (seepages14-252and t4-253).
90414-689-000 90415-689-000 90416-689-000 90417-689-000 90418-689-000 90419-PH8-000
Thicknoss 2.50mm (0.098in) 2.60mm (0.102in) 2.70mm (0.106inl 2 . 8 0m m ( 0 . 1 1 0 in) 2 . 9 0m m ( 0 . 1 1 4i n ) 3.00mm (0.t'18inl
TOROUE:4a N.m l/r.5 kgf.m, 33 tbt.ftl Recheckthe clearance,and make sure it is within standard.
14-226
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HousingBearings Transmission Mainshaft/CountershaftBearingsReplacement 1.
Expandeach snap ring with snap ring pliers,then coat the new bearingswith ATF and insert them part-way into the housing using the specialtools and a pressas shown. Installthe bearingswith the groovefacingoutsidethe housing.
Expandeach snap ring with snap ring pliers,then push the bearingsout of the transmissionhousing usingthe specialtools and a pressas shown. Do not removethe snap rings unlessit's necessary to cleanthe groovesin the housing.
R e l e a s et h e p l i e r s ,t h e n p u s h t h e b e a r i n g sd o w n i n t o t h e h o u s i n gu n t i l t h e r i n g s s n a p i n p l a c e a r o u n dt h e m .
077/49- 0010000
ATTACHMENT . Mainshaft BearingInstallation: x 75 mm ATTACHMENT,72 07746- 0010600 . CountershaftBearing Instsllation: ATTACHMENT,52 x 68 mm 077'16- 0010500
MAINSHAFTBEARING
DFIVER 077a9- 001(xx)o ATTACHMENT
4.
After installingthe bearings,verifythe following: T h e s n a p r i n g s a r e s e a t e di n t h e b e a r i n ga n d housrnggrooves. . The snap ringsdo not bind. . The ring end gapsare correct, .
ENDGAP:0-7rnm l0 - 0.28in)
ATTACHMENT . Mainshaft Bearing Romoval: ATTACHMENT,72 x 75 mm 077/16- 0010600 . CountqrshaftBearing Removal: ATTACHMENT,62 x 68 mm 07746- 0010500
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SNAPRING
14-227
TransmissionHousingBearings Sub-shaftBearingReplacement 1.
Expand the snap ring with snap ring pliers, then push the bearingout of the transmissionhousing usingthe specialtools and a pressas shown.
E x p a n dt h e s n a p r i n g w i t h s n a p r i n g p l i e r s ,t h e n coat the new bearingwith ATF and insert it partway into the housingusing the specialtools and a pressas shown. lnstallthe bearingwith the groove facingoutsidethe housing.
Do not removethe snap ring unlessit,s necessary to cleanthe groovein the housing.
Releasethe pliers,then push the bearingdown into the housinguntilthe ring snapsin placearoundit.
DRIVER 07743- 0010mo
ATTACHMENT, {i:l x 68 mm 07746- 0010500 GROOVE
After installingthe bearing,verifythe following: ATTACHMEI{T, 5:l x 68 mm 07r{5 - @10500
SNAP RI]TG
. . .
DRIVER 07749- tDl(xx)o
The snap rjng is seatedin the bearingand hous_ ing grooves. The snap ring does not bind. The ring end gap is correct,
ENDGAP:0-7mm
ATTACHMENT, 6:l x 68 mm 077a6- (X,r0500
SNAPRING
14-228
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TorqueGonverterHousingBearings MainshaftBearing/OilSeal Replacement 1.
R e m o v et h e m a i n s h a f b t e a r i n ga n d o i l s e a l u s i n g the soecialtool.
3.
Installa new oil sealflush with the torqueconverter housing.
07749- 0010000 SLIDEHAMMER, 3/8" - 16 (Commercially available)
ATTACHMENT, ADJUSTABLEEEARING - 40 mm PULLER,25 07736- A010008or 07736- A01000A
07?46- 0010m0
Installa new mainshaftbearinguntil it bottoms in the torqueconverterhousing.
ATTACHMENT, 62x68mm 07746- 0010500
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14-229
TorqueGonverterHousing Bearings
GontrolLeverAssembly
CountershaftBearingReplacement
Replacement
1.
Checkthe conditionand movementof the control lever assembly,lf the control lever assemblybinds or does not move smoothly.replaceit.
Removethe countershaftbearingusing the special tool.
SLIOEHAMMER, 3la" -16 (Commercially available)
ADJUSTABLE BEARING - 40mm PULLER,25 07736- A0100OB ol 07736- A01m0A
1.
Removethe 6 x 1.0mm bolt and lockwasher.
2.
Removethe changeshafttrom the torqueconverter housing.
3.
Removethe controlleverassemblyfrom the control shaft.
4.
Installthe new controlleverassemblyin the reverse order of disassembly,until it bottoms in the torque converterhousing.
COUNTERSHAFT BEARING
Installthe ATF guide ptate. I n s t a l la n e w c o u n t e r s h a fbt e a r i n g i n t h e t o r q u e converterhousing.
DRIVER 077i19- 001m00
LOCKWASHER Replace.
ATF GUIDEPLATE
14-230
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ParkStop
Reverseldler Gear
ustment Inspection/Adi
lnstallation 1.
't. Setthe parkleverin the E position.
lnstallthe reverseidler gear'
Measurethe distancebetweenthe park pawl shaft and the parkleverrollerpin as shown. 72.9- 73.9mm {2.87- 2.91in) STANDARD:
',.A\ Measuring
\t/
PARKSTOP
lnstallthereverseidler gear shaftholderand needle bearinginto the transmissionhousing,then tighten the bolts. 6 x 1.0 mm 12 N.ft ll.2 kgl']n, a.7 rbl.frl
PARKPAWLSHAFT
lf the measurementis out of standard,selectand i n s t a l lt h e a p p r o p r i a t ep a r k s t o p f r o m t h e t a b l e below. PARKSTOP
PARKSTOP Mark 1
Part Number
Lt
L2
2 4 5 3 7 - P A g - 0 0 3 1 1 . 0 0m m (0.433in)
11.00 mm (0.433in)
2 4 5 3 8 - P A g - 0 0 3 1 0 . 8 0m m (0.425in)
10.65mm (0.419 in)
2 4 5 3 9 - P A g - 0 0 3 1 0 . 6 0m m (0.417 in)
1 0 . 3m 0m (0.406 in)
After replacingthe park stop. make sure the distanceis within standard.
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14-231
TransferAssembly lllustrated Index
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O TRANSFERHOUSING O o-RINGReplace. O TRANSFERHOUSINGROLLERBEARING @ TRANSFERSHAFT O TAPEREDROLLERBEARINGOUTERRACE @ TAPEREDROLLERBEARING O TRANSFERSHAFTCOLLAR @ THRUSTSHIM,25 mm Selectivepart €) TRANSFERDRtvE GEAR(HYPoIDGEAR} @ coNtcAL SPRtNGWASHERReptace, SHAFTLOCKNUT,22x 1.25mm Left-handrhreads,replace. @ TRANSFER (D TAPEREDROLLEREEARING @ TAPEREDROLLEREEARINGOUTERRACE (} THRUSTSHIM,68 mm Selectivepart @ O-RINGReplace. coVER A @ TRANSFER (} TRANSFERCOVERB @ o-RINGReplace. (9 TRANSFERDRIVENGEARSHAFT(HYPOIDGEAR) @ THRUSTSHIM,35 mm Selectivepart @ TAPEREDROLLERBEARING SPACERReptace. @ TRANSFER OUTERRACE @ TAPEREDRoLLERBEARTNG @ TAPEREDROLLERBEARINGOUTERRACE @ TAPEREDBOLLERBEARTNG @ olL SEALReplace. FLANGE @ COMPANION @ o-RINGReplace. @ BACK-UPRING @ coNtcAL SPRtNGWASHERReptace. DRIVENGEARSHAFTLOCKNUT,22x 1.25mm Replace. @ TRANSFER
TOROUESPECIFICATIONS Boh/Nut No.
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Torque Value
Size
6A 8C 22L
1 2 N ' m ( 1 . 2k g f . m , 8 . 7l b f . f t ) 24 N.m (2.4kgf.m,17 lbnft) 1 1 8N . m( 1 2 . 0k g i m , 8 7 I b i f t )
6x1.0mm 8 x 1 . 2 5m m 22 x 'l.25mm
22H
132 216 N.m (13.5 22.0kgf.m, 98 - 159lbift)
2 2 x 1 . 2 5m m
Remarks
Transfershaft locknut: Left handthreads Transferdriven gear shaft locknut Tighteningtorque:dependingon Total StartingTorquevalue
14-233
TransferAssembly Inspection N O T E : T o p r e v e n td a m a g et o t h e t r a n s f e rh o u s i n g , always use soft jaws or equivalentmaterialsbetween the transferhousingand the vise.
TransferGear (Hypoid gear) Tooth Contact Inspection 5,
Trsnsfer Gear (Hypoid gear) Backl8shM€asurem€nt
Removetransfercover B, then apply PrussianBlue to both sides of the transfergear teeth lightly and
1 . S e t a d i a l i n d i c a t o ro n t h e c o m p a n i o nf l a n g e a s snown. 2.
Measurethe transfergear backlash. STANDARD:0.06 - 0.16 mm {0.02- 0.06 in) DIALINDICATOR
TRANSFERDRIVEG€AR
6.
Rotatethe companionflangein both directionsuntil the transfergear rotatesone full turn in both directions.
7.
Checkthe transfergear tooth contact pattern.The pattern should be centered on the gear tseth as snown.
8.
lf the statrting torque measurementor the tooth contact pattern are not correct, disassemblethe transferassembly,replaceworn or damagedparts, and reassembleit.
COMPANIONFLANGE
Total Starting Torque Meagurgm€nt 3,
Rotatethe companionflange severaltimes to seat the taperedrollerbearing.
4.
M e a s u r et h e s t a r t i n gt o r q u e ( c o m p a n i o nf l a n g e side)usinga torquewrenchas shown, STANDARD: 2.68- 3.,17N.m (27.3- 35.,1kgf.cm,23.7- 30.7 lbf.inl TRANSFER SHAFT
14-234
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Disassembly 1.
P u t a 1 4 m m A l l e nw r e n c hi n t h e g e a r s i d e o f t h e transfer shaft, then secure the Allen wrench in a benchvise.
Removethe transfercoversA and B.
Removethe transfershaft locknut and the conical spring washer.The transfershaft locknut has left handthreads.
1a mm ALLENWRENCH
5.
Removethe transfer shaft, transfer drive gear, 25 mm thrust shim, transfershaft collar,and tapered rollerbearingfrom the transferhousing. TRANSFERSHAFT
2.
Cutthe locktabs of the locknutusinoa chisel.
LOCKTAB
THRUSTSHIM, 25 mrn Selectivepart
CONICALSPRING WASHER Replace.
(cont'd)
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14-235
TransferAssembly Disassembly(cont'd) Securethe transfer housing in a bench vise with soft iaws. To preventdamageto the transferhousing, always use soft jaws or equivalentmaterials betweenthe transferhousingand the vise. 7.
I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g e , then loosenthe transferdrivengearshaft locknut.
9. Removethe transferdriven gear shaft,then remove the transfer spacer from the transfer driven gear shaft.
TRANSFER DRIVEN GEAR SHAFT
COMPANION FLANGE HOI.DER 07RAB- TB4lll0A or OTRAB- TB&TOB
HOLDER HAITDI..E 07JAB_ (x)1020a Removethe transferdrivengear shaft locknut,conical spring washer, back-upring, O-ring.and companionflange.
1 0 . Removethe oil seal and the taperedroller bearing from the transferhousing.
OILSEAL Feplace-
O.RING Replace.
TAPEREOROLLER BEARING
BACK-UP RING CONICAL SPRINGWASHEN Replace. TRANSFERHOUSING
GEARSHAFTLOCKNUT Replace.
14-236
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TransferDriveGearBearing Replacement
TransferDrivenGearShaft BearingReplacement
NOTE:Coatall partswith ATFduring reassembly.
NOTE: Coat all parts with ATF during reassembly.
1.
1.
Removethe taperedrollerbearingfrom the transfer drive gear usingthe specialtools and a press.
Removethe taperedrollerbearingfrom the transfer drivengearshaft usinga pressand a collar.
B€ANf{GSEPARATO 0 - 1112' (Comm6rcially availablel
(Commercially available) Installthe new taperedroller bearingin the transfer drivegear usingthe specialtoolsand a press.
2.
Installthe 35 mm thrust shim on the transferdriven gear shaft,
3,
Installthe new taperedrollerbearingon the transfer d r i v e n g e a r s h a f t u s i n g t h e s p e c i a lt o o l s a n d a press. PNESS
I
ATTACHMENT, l()x50mm 07LAD- PWSo6o1
n GEAR
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DRIVERiO mm l.D. 0t7a5 - 00:I)100
ru
ATTACHMENT. 35 mm l.D. 0t715 - 0030400
14-237
TransferAssembly TransferHousingRollerBearing Replacement
TransferCoverA BearingOuter
NOTE;Coatall partswith ATF du.ing reassembly.
NOTE:Coatall partswith ATF during reassembly.
1.
1.
Removethe roller bearingfrom the transferhous Ing.
RaceReplacement Removethe taperedroller bearingouter racefrom t r a n s f e rc o v e r A b y h e a t i n gt h e c o v e r t o a l m o s t 212"F llOO"Clusing a heat gun. Do not heat the coverover 212"F(100"C).
Installthe 68 mm thrustshim in transfercoverA. Installthe new roller bearingusingthe specialtools and a press.
ATTACHMENT, 62x68mm 07746- 0010500
TRANSFERHOUSING
14-238
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Installthe tapered roller bearing outer race using the specialtools and a p.ess.
TransferHousingBearingOuterRaceReplacement NOTE: Coat all parts with ATF during reassembly. 1.
Bearing Outer Rac6Locations and SpecialTool Applications
Removethe taperedroller bearingouter racefrom the transferhousing. HOUSING TRANSTER vi.w Sacttonal
ATTACHMENT, 62x68mm 077a5- @105dt
ATTACHI'E'{T, {i:l x 6t mm 07746 - rDl05rr0 ATTACHMENT, 52x55mm 07t46 - dtroa{x,
TRANSFERHOUSING
Install th€ new tapered roller bearing outer race usingthe specialtoolsand a press.
DRIVER 077$ - 0010(ro0
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14-239
TransferAssembly Reassembly NOTE: . While reassembling the transferassembly: . Checkand adjustthe transfergeartooth contact. . Measureand adjustthe transfergear backlash. . Checkand adjustthe taperedroller bearingstaning torque. . Coatall pans with ATFduring reassembly. . R e p l a c et h e t a p e r e dr o l l e rb e a r i n ga n d t h e b e a r i n g outer raceas a set if eitherpart is replaced. . Replacethe transferdrive gear and the transferdriven gearshaftas a set if eitherpart is replaced.
EXAMPLE: C: EXISTING35 mm THRUSTSHIM Thickness: C=1.05mm
X: REPLACEMENT 35 mm THRUSTSHIM Thickness:X=??mm
Number: A=+2
Numbe.: B=-'l
Outline of Assembly 1 . Selectthe 35 mm thrusi shim. Psrtorm this procedute if the transter driven g€ar shaft or the tapered roller bearing on the transfer driven gear shaft is replaced. 2.
Prea$emble the parts to check and adiust transtel gear backlashand transfer gear tooth contact.
3 . Disassemblethe parts, then assemble the transler driven gsar shaft and its related pans. 4.
Measure and adjust the starting torque oI the transfer driven gear shaft tapered roller bearing.
5.
Assemblethe transfer shaft and its related parts.
6.
Measureand adiust the total starting torque.
35 mm Thrust Shim Selection L
Selectthe 35 mm thrust shim if the transferdriven gearshaftor the taperedrollerbearingon the transfer drivengearshaft is replaced. Calculate t h e t h i c k n e s so f t h e 3 5 m m t h r u s t s h i m usingthe formula below.
F o R M U L A :-+* - + c = x A: Numberon the existingtransferdrivengear shaft B; Numberon the replacementtransferdriven gear shaft C: Thicknessofthe existing35 mm thrustshim X : T h i c k n e s sn e e d e df o r t h e r e p l a c e m e n3t 5 m m t h r u s ts h i m N O T E : T h e n u m b e r o n t h e t r a n s f e rd r i v e n o e a r shaftis shown in 'll100mm.
14-240
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Ar EXISTINGTRANSFER DRIVENGEARSHAFT
B: REPLACEMENT TRANSFER DRIVENGEARSHAFT
"x = A - B . c100 100 2 - 1 '100 100 = 0.02+ 0.0'l+ 1.05 =1.08{mm) S e l e c t3 5 m m t h r u s t s h i m t h i c k n e s so f l 0 8 m m (0.043in). lf the taperedroller bearingon the transfer drivengear shaftis replaced. M e a s u r et h e t h i c k n e s so f t h e r e p l a c e m e nbt e a r i n g and the existingbearing,and calculatethe difference of the bearjngthickness.Adjust the thicknessof the existing35 mm thrust shim by the amount of difference in bearingthickness,and selectthe replacement 3 5 m m t h r u s ts h i m . THRUSTSHIM,35 mm Shim No.
c D F H
Part Number
41361- PS3- 000 41362-PS3-000 41363-PS3-000 41364-PS3-000 41365-PS3-000
0.75 mm {0.030in} 0.78 mm (0.03'1in) 0.81 mm (0.032in)
0.84mm (0.033an)
0.87 mm (0.034in) 4 1 3 6 7 - P S 3 - 0 0 0 0.90 mm (0.035in) 4 1 3 6 8 - P S 3 - 0 0 0 0.93 mm (0.037in) 41366-PS3-000
M
41369-PS3-000 41370-PS3-000 4 r371- PS3- 000 41372-PS3-000 41373-PS3-000
N
41374-PS3-000
K
Thickness 0 . 7 2m m ( 0 . 0 2i8n )
0.96mm 10.038 in) 0.99 mm (0.039in) 1 . 0 2m m ( 0 . 0 4 0i n 1 . 0 5m m ( 0 . 0 4 1i n 1.08mm (0.043in '1.11 m m 1 0 . 0 4 i4n
Transfer Gear BscklashInspectionand TransferGear Tooth Contact Inspection 2.
5.
Installthe transferdriven gear shaft in the transfer housing.Do not install the transfer spaceron the transferdrivengearshaft in this step.
Installthe 35 mm thrust shim on the transferdriven g e a r s h a f t ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g usingthe specialtools and a press.
TRANSFER
DRIVER{0 mm LD. - 0030100 077146
TRANSFER DRTVEN GEARSHAFT
;;. 745- 0O304O0 u,
6.
Installthe companionflange,conicalspringwasher, and locknut on the transfer driven gear shaft. Do not install the O-ring and the back-upring on the transfergear shaftin this step.
Placethe taperedrollerbearingon the bearingouter race of the companionflange side of the transfer housrng.
TRANSFERHOUSING
I n s t a l lt h e n e w o i l s e a l o n t h e t r a n s f e r h o u s i n g usingthe specialtools.
OIL SEALDRIVER ATTACHMENT 07JAD- PH80101
COMPANION FLANGE
{cont'd)
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14-241
TransferAssembly (cont'd) Reassembly 7.
Securethe transfer housing in a bench vise with soft jaws, then installthe specialtool on the companion flange. To preventdamageto the transfer housing,alwaysuse soft jaws or equivalentmaterials betweenthe transferhousingand the vise. Tighten the locknut while measuringthe starting '1.39 torque so the startingtorque is within 0.98N.m (10.0- 14.2kgf.cm,8.68 12.3lbnin).
9.
I n s t a l lt h e t r a n s f e rs h a f t i n t h e t r a n s f e rh o u s i n g , then installthe taperedrollerbearing,transfershaft collar.25mm thrust shim, transferdrive gear,conical springwasher,and locknuton the transfershaft. NOTE: . Coat the threads of the locknut. and the shaft with ATF beforeinstallingthe locknut. . Do not stakethe locknutin this step.
NOTE: Coat the threads of the locknut, and the shaft with ATF beforeinstallingthe locknut. Do not stakethe locknutin this step. STARTINGTOROUE: 0.98- 1.39N.m {10.0- 14.2kgrf.cm,8.68- 12.3lbf'inl
TRANSFER
COMPANION FLANGE HOLDER
THRUSTSXIM, 25 mm Selectivepan
TRANSFERDRIVE GEAR CONICALSPRING WASHER Replace. 07JAB- @1020A
14-242
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1 0 . Put a 14 mm Allen wrench in the gear side of the transfer shaft, then secure the Allen wrench in a benchvise.
1 3 . Rotatethe companionflange severaltimes to seat the taperedrollerbearing. 1 4 . Set a dial indicatoron the companionflange,then
1 1 . Tightenthe transfershaftlocknut. NOTE: . The transfershaftlocknuthas left-handthreads. . Do not stakethe locknutin this step.
measurethe transfergear backlash. STANDARD: 0.06- 0.16mm {0.02- 0.06inl DIAL INOICATOR
TOROUE:118 N'm 112.0kgf.m, 87 lbf.ftl TOROUEWRENCH
FLANGE COMPANION 1 5 . l f t h e m e a s u r e m e n ti s n o t w i t h i n t h e s t a n d a r d . removethe transfershaft locknutand replacethe 25 m m t h r u s t s h i m . S e l e c ta n d i n s t a l la n e w 2 5 m m thrust shim. then recheckthe measurement. Do not use more than two 25 mm thrust shims to adiust the transfergear backlash. THRUSTSHIM,25 mm Shim No.
1 2 . Temporarilyinstallthe transfercoverA without t h e O-ring. TRANSFERHOUSING
I
2 4 6 7
11
29421- P1C- 000
14
tt
g 9-r'r.ru-g
2.00 mm (0.079in)
2 9 4 2 2 - P 1 C - 0 0 0 2.03mm 10.080 in) 2 9 4 2 3 - P ' 1 C - 0 0 0 2.06 mm (0.081in) 29424-P1C-000 2.09mm 10.082 in) 2 9 4 2 5 - P 1 C - 0 0 0 2 . 1 2m m ( 0 . 0 8 i3n ) 2.'15mm (0.085in)
16
29426-P1C-000
17 18
29427- P1C-O00 2 . 1 8m m ( 0 . 0 8 6i n ) 29428-PlC-000 2.21 mm (0.087in) 2 9 4 2 9 - P 1 C - 0 0 0 2.24mm {0.088in)
19
el
1.88mm (0.074in)
10
TRANSFERCOVERA
/Fr E
29417-PlC-000
2 9 4 1 8 - P 1 C - 0 0 0 1 . 9 1m m { 0 . 0 7 5i n ) 2 9 4 1 9 - P 1 C - 0 0 0 1.94mm (0.076in) 2 9 4 2 0 - P t C - 0 0 0 1 . 9 7m m ( 0 . 0 7 i8n )
d
g
Part Numbor Thickness 2 9 4 1 1 - P 1 C - 0 0 0 1.70mm (0.067in) 2 9 4 1 2 - P 1 C - 0 0 0 1.73mm (0.068in) 2 9 4 1 3 - P 1 C - 0 0 0 1.76mm (0.069in) 2 9 4 1 4 - P 1 C - 0 0 0 1.79mm (0.070in) 2 9 4 1 5 - P l C - 0 0 0 1.82mm (0.072in) 2 9 4 1 6 - P 1 C - 0 0 0 1.85mm (0.073ini
N.m 12.4 24 N.m 24 12.4|kgt.m, 17 lbf.ftl
(cont'd)
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14-243
TransferAssembly (cont'dl Reassembly 16. Apply PrussianBlue to both sides of the transfer gearteethlightlyand evenly.
19. lf the transfergear tooth contactis incorrect,adjust the transfergear tooth contactwith a 35 mm or 25 m m t hr u s ts h i m . NOTE: . To selecta 35 mm thrust shim, referto page 14, 240. . D o n o t u s e m o r e t h a n t w o 3 5 m m s h i m st o adjustthe transfergeartooth contact. . To selectthe 25 mm thrust shim, refer to page 14-243. . D o n o t u s e m o r e t h a n t w o 2 5 m m s h i m st o adjustthe transfergeartooth contact.
1 7 . Rotatethe companionflangein both directionsuntil the transfergear rotatesone full turn in both directions. 1 8 . Checkthe transfergeartooth contactpattern.
CORRECT TOOTHCONTACT PATTERN
NCONRECTTOOTH CONTACTPATTERN
TOE CONTACT
HEELCONTACT
FLANKCONTACT
FACECONTACT
14-244
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Toe Contact U s e a t h i c k e r3 5 m m t h r u s t s h i m t o m o v e t h e transferdriven gear shaft toward the transferdrive gear. Becausethis movement causesthe transfer gear backlashto change,move the transferdrive gear away from the transferdriven gear shaft to adjustthe transfergear backlashas follows: . I n c r e a s et h e t h i c k n e s so f t h e 2 5 m m t h r u s t shrm. . R e d u c et h e t h i c k n e s so f t h e 6 8 m m t h r u s t shim by the amount of increasedthicknessof the 25 mm thrustshim. Heel Contact U s e a t h i n n e r3 5 m m t h r u s t s h i m t o m o v e t h e transfer driven gear shaft away from the transfer d r i v e g e a r .B e c a u s et h j s m o v e m e n tc a u s e st h e transfer gear backlashto change,move the transfer drive gear toward the transferdriven gear shaft to adjustthe transfergearbacklash asfollows: . R e d u c et h e t h i c k n e s so f t h e 2 5 m m t h r u s t shim. . I n c r e a s et h e t h i c k n e s so f t h e 6 8 m m t h r u s t shim by the amount of reducedthicknessof t h e 2 5 m m t h r u s ts h i m . Flank Contaqt Use a thinner thrust shim to move the transfer drive gear toward the transferdriven gear shaft. Flankcontactmust be adjustedwithin the limits o f t h e t r a n s f e rg e a r b a c k l a s h l. f t h e b a c k l a s h e x c e e d st h e l i m i t s ,a d j u s t a s d e s c r i b e du n d e r Heel Contact. FaceContaqt Use a thickerthrust shim to move the transfer drive gear away from the transfer driven gear shaft. Facecontactmust be adjustedwithin the limits of the transfergear backlash.lf the backl a s h e x c e e d st h e l i m i t s , a d j u s t a s d e s c r i b e d underToe Contact.
20. Removethe partson the transfershaft,and remove the transfershaftfrom the transferhousinq. TRANSFERSHAFT
TRANSFERHOUSING
23. Removethe transterdrivengear shaftand the companionflange, 24. Installthe new transferspaceron the transferdriv e n g e a r s h a f t ,t h e n i n s t a l lt h e m i n t h e t r a n s f e r housrng. TRANSFERDRIVEN GEARSHAFT
TAPEFEDROLLER BEARNG
TFANSFERSPACER lnstallin this direction. Replace.
TRANSFER COLLAR THRUSTSHIM,25 mm Selectivepan
TRANSFERDRIVE GEAR
CONICALSPRING WASHER Replace.
Replace.
Transf€r Driven Gear Shaft Starting Torque Inspsction and Adjustment
25. Installthe companionflange, O-ring,back-upring. 21. Secure the transfer housing in a bench vise with soft jaws, To preventdamage,alwaysuse soft jaws or equivalentmaterialsbetweenthe transferhousing and the vise. 2 2 . I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g e , then removethe transferdriven oear shaft locknut and the conicalspringwasher.
conical spring washer and locknut on the transfer drivengear shaft. NOTE: . C o a t t h e t h r e a d so f t h e l o c k n u t ,a n d t r a n s f e r shaftwith ATF beforeinstallingthe locknut. . Installthe conicalspring washerin the direction shown,
COMPANION FLANGE HOLDER 07RAB- TB,010Aol 07RAB- TB,010B
TRANSFERHOUSING
O.RING Replace. CONICALSPRING WASHER Replace.
BACK.UPRING
LOCKNUT Replace.
(cont'd)
www.emanualpro.com
14-245
TransferAssembly (cont'd) Reassembly Secure the transfer housing in a bench vise with soft jaws. To preventdamage,alwaysuse soft jaws or equivalentmaterialsbetweenthe transferhousing and the vise.
28. Stakethe locknutinto the transferdriven gear shaft usinga 3,5 mm punchas shown.
27. I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g e , then tighten the transferdriven gear shaft locknut while measuringthe startingtorque of the transfer drivengearshaft. STARTINGTOROUE: 0.s8- 1.39N.m {10.0- 14.2kgf.cm,8.68- 12.3lbf.in) TIGHTENINGTOROUE: 132- 216 N.m {13.5- 22.0 kgf.m, 98 - 159 lbf.ft) NOTE; . Rotatethe companion flange several times to seatthe taperedrollerbearing,then measurethe startingtorque, . l f t h e s t a r t i n gt o r q u e e x c e e d s1 . 3 9 N . m ( 1 4 , 2 kgf.cm, 12.3 lbf.in), replacethe transfer spacer a n d r e a s s e m b l et h e p a r t s . D o n o t a d j u s t t h e torquewith the locknutloose. . lf the tightening torque exceeds216 N.m (22.0 kgf.m,159 lbf'ft),replacethe transferspacerand reassemble the parts. . W r i t e d o w n t h e m e a s u r e m e no t f the starting torque: it is used to measurethe total starting rorque.
0.7- 1.2mm {0.03- 0.05 inl PUNCH 3.0- 3.5 mm 1 0 . 1-2 0 . 1 {i n l
.,.,.,\
\
t)
t
--/./
Point to be staked.
29. Install the transfer shaft in the transfer housing, then installthe taperedroller bearing,transfershaft collar,25 mm thrust shim,transterdrive gear,conical springwasher,and transfershaft locknuton the transfer shaft, NOTE: . Coatthe threadsof the locknutand translershaft with ATF beforeinstallingthe locknut. . Installthe conicalspring washer in the direction snown. TRANSFERSHAFT
COi'PANIOI{FLANGE HOLDER 07MB - TBi(tloA ot O'RAB - TB,.|}IOB
TRANSFERHOUSII{G
THRUSTSHIM.25 mrt| Selectivepart
TOFOUE WRENCH HOLDERHANDLE 07JAB- 001020A
CONICALSPRING WASHER Replace. Replace.
14-246
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30. Put a 14 mm Allen wrench in the gear side of the transfer shaft. then secure the Allen wrench in a benchvise. Tightenthe transfershaft locknut.{The locknuthas left-handthreads,)
Total Starting Tolqu€ Insp€ctionand Adiustment 32. TemDorarilvinstalltranstercover A without the Oflng.
HOUSING
TOROUE:118 N.m (12.0kgf.m, 87 lbt.ft)
TMNSFER COVERA
e € v E-
8x1.25mm r? bt'ftl 24 N'm {2.i1kgt'm,
14 mm ALI-ENWRENGH 5J.
al
Stakethe locknuton the transfershaft using a 3.5 mm ounch.
Securethe transfer housing in a bench vise with soft jaws, then rotatethe companionflangeseveral times to fit the tapered roller bearing.To prevent damage,alwaysuse soft jaws or equivalentmaterials betlveenthe transferhousingand the vise.
34. Measurethe total startingtorque.
0.7- 1.2.nm {0.0:1-0.C5in} PU CH 3.0 - 3.5 rnm
TOTALSTARTINGTOROUE: 1.70- 2.08N.m {17.3- 21.2kgl.cm,15.0- 18.i1lbf.in} + Transler Driven Gear Sh8ft Starting Torque Value lwroto down in step 27).
(cont'd)
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14-247
TransferAssembly Reassembly(cont'dl 35. RemovetaansfercoverA.
36. lf the measurementis out of specification,remove t h e 6 8 m m t h r u s t s h i m f r o m t r a n s f e rc o v e r A b y h e a t i n gt h e c o v e rt o a l m o s t2 1 2 " F( 1 0 0 " Cu) s i n ga heat gun. Do not heat the cover higher than 212"F ( 1 0 0 ' C ) .L e t t h e c o v e r c o o l t o r o o m t e m p e r a t u r e beforeadjustingthe startingtorque, go to lf the measurementis within the specification, step 40.
37. Selectthe 68 mm thrustshim. THRUSTSHIM,58 mm Shim No.
ZY
23977- P1C- O20 23978-P1C-020 23941 PW5- 000
zz c
23942-PWs-000 23943- PWs 000
D
23944-PW5-000
E
23945 PWs- 000 23946 PWs- 000 23947 PWs- 000
F G
23948-PW5-000 23949 PW5 000 J K L
1.92mm (0.076in 1.95mm (0.077in
23957-PW5-000
23958,PWs 000
s
23959-PW5-000 23960 PW5- 000 2396'1 PW5- 000
23962 PWs 000 X
23963- PW5 000 23964- PW5 000 23965 PW5- 000
z
23966 PWs 000 23967-PWs-000
AC AD M BZ
cz DZ
EZ
14-248
1.74mm (0.069ini 1.77mm (0.070ini 1 . 8 0m m ( 0 . 0 7 i1n ,
23953 PWs- 000
R
AB
1.65mm {0.065in} 1.68mm (0.066in) 1.71mm (0.067in)
1.86mm (0.073in 1.89mm (0.074in
o
T U
1.53mm 10.060 in) '1.56mm {0.061in) 1.59mm 10.063 in) 1.62mm (0.064in)
23951- PWs- 000 23952 PW5- 000
P
o
1.50mm (0.059in)
2 3 9 5 0 - P W s - 0 0 0 1.83mm {0.072ini
23954 PW5- 000 23955 PW5 000 23956- PWs 000
N
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Thickness
2 3 9 7 4 - P 1 C - O 2 0 1.41mm (0.056in) 2 3 9 7 5 - P 1 C - O 2 0 1.44mm (0.057in) '1.47mm (0.058in) 23976-P1C-020
B
HEATGUN
Part Number
zv zw zx
1.98mm (0.078in 2.01mm (0.079in 2.04mm (0.080in 2.07mm (0.081in 2.10mm (0.083in 2 . 1 3m m ( 0 . 0 8 i4n 2 . 1 6m m ( 0 . 0 8 i5n 2 . 1 9m m ( 0 . 0 8 i6n 2.22mm (0.087in 2.25mm (0.089in 2.28mm (0.090in 2.31mm (0.091in 2.34mm (0.092in
2.37mm (0.093in) 2 3 9 6 9 - P W s - 0 0 0 2.40mm (0.094in) 23970-PW5-000 2.43mm (0.096in) 23941 PW8 000 2.46mm (0.097in)
23968-PWs-000
23942-PW8-000 23943- PW8 000 23944 PW8- 000 23945-PW8-000
2.49mm (0.098in) 2.52mm (0.099in) 2 . 5 5m m ( 0 . 1 0 i0n ) 2 . 5 8m m ( 0 . 1 0 i2n )
3 8 . I n s t a l lt h e 6 8 m m t h r u s t s h i m u s i n g t h e s p e c i a l tools.
PRESS
DRIVER 07743- 0010000
40. Installthe new O-ringson transfercoversA and B, then installthecoverson the transferhousing
6x1.0mm 12 N.m 11.2kgt.D, 8.7 rbf.ftl
TRANSFENCOVERB
Replace.
O.RING AEARINGOUTERRACE
Replace.
ATTACHMENT, 62x68mrr| 077a6- (x)10500
39. After replacingthe 68 mm thrust shim. recheckand m a k e s u r e t h e t o t a l s t a r t i n gt o r q u e i s w i t h i n t h e specification.
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8 r 1.25rnm 24 N.m 12.4kgl.m, 17 lbf'ftl
Transmission Reassembly NOTE: . The illustrationshowsthe 4WDautomatictransmission;the 2WDis similar. . Cleanall partswith ATF. . Replacethe followingparts: - O-rings - Lockwashers - Gaskets - Sealingwashers - Locknutsand conicalspringwashersof eachshaft SERVO DETENT
6x1.0mm ATF FEEDPIPE ATF LUBRICATION PLATE
/
ATF FEEDPIPES BASE (37 -98 modebonlyl 1 4 5m m 6x1.0mm
DOWELPIN
2 Bolts '99 - 00 models: 1 Bolts
LOCK.UPVALVE BODY
ATF STRAINER
ATF FEEOPIPE
LOCK.UPSEPARATOR PLATE 40 mm
'-\t
REGULATOR VALVE BODY DOWELPIN
j
coNrRoL
I
SHAFT
VALVESPRING COOLERBELIEFVALVE TOROUECONVERTER CHECKVALVE
6x1,0mm '97 - 98 models:
'112mmll,
6x1.0mm 18olts DETENT ARM SHAFT
r l T
7 Bolts '99- 00 models:8Bolts SERVOBODY ('97- 98 models)
STATORSHAFT O.RING STOPSHAFT CHECKBALLS18'
SERVO SEPARATOR PLATE 6x1.0mm 3 Bolts
ATF FEEDPIPE 1 1 2m m
STOPSHAFT BRACKET
6x1.0mm 5 Eolts
)
/
105.8 SECONDARY VALVEBODY
/,,!.,::
MAIN VALVEEOOY
(./ ,/
ATF PUMP DRIVEN GEARSHAFT
afF FEEO ptpEs
ATF PUMPDRIVEN d---.-
OOWELPIN 8x40mm SECONDARY SEPARATOR PLATE --.CONTROLI.EVERMOUNTINGBOLT 6x1.0ftm 14 N.m (1.4 kgt.m, 10 tbf.ft) (4WD)
SERVO BODY ('99- 00models)
EP,--!ir{+*a\
x*hi
ATF PUMP DRIVEGEAR DOWELPIN
14-250
www.emanualpro.com
r
fpffi4i
MAIN SEPARATOR PLATE
_ \zl TOBOUE
HOUSING
1 . Installthe suction pipe collar and the ATF magnet {2WD)in the torque converter housing, if necessary. lnstallthe main seDaratorDlateand the two dowel pins on the torqueconverterhousing, Installthe ATF pump drive gear.ATF pump driven gear,and ATF pump drivengear shafton the torque converterhousing.InstalltheATF pump drivengear with its groovedand chamferedsidefacingdown. ATF PUMP GEAR
ATF PUMP D{IVEf{ GEARSHAFT
8. Installthe servo body and separatorplate on the secondaryvalve body ('97 - 98 models: seven bolts, '99 - 00 models:eight bolts). 9 . lnstallthe servo detentbase ('97- 98 modelsonly) and the ATF strainer('97 - 98 models:two bolts,'99 00 models:one boltl.
1 0 . Tightenthe five bolts on the main valve body to 12 N'm (1.2kgf.m,8.7 lbf.ft). 1 l . Makesure the ATF pump drive gear and ATF pump d r i v e n g e a r s h a f t m o v e s m o o t h l y .l f t h e y d o n ' t , loosenthe bolts on the main valve body,and disassemblethe valve bodies.Realignthe ATFpump driven gear shaft and reassemblethe valve bodies,then retightenthe boltsto 12 N.m (1.2kgim, 8.7 lbf.ft). CAUTION: Failureto align the ATF pump driven gear shaft corroctly will rosult in a seizsd ATF pump drive gear or ATF pump drivon gear shaft.
ATF PUi'P ORIVENGEAR Grooved and chamtered side faces separator plate.
MAIN S€PAR/ATOR PLATE
Loosely install the main valve body with five bolts. Makesurethe ATFpump drivegearrotatessmoothly in the normaloperatingdirection,and the ATF pump driven gear shaft moves smoothly in the axial and normal operatingdirections. Installthe secondaryvalve body, separatorplate, and two dowel pins on the main valve body. Do not installthebolts.
5.
o.
Installthe control shaft in the housing along with the manualvalve.
7.
lnstall the detent arm and arm shaft in the main valve body, then hook the detentarm spring to the detentarm. SEBVOSEPARATOR PLATE
ATF PUMP DRIVEGEAR
ATF DBIVENGEAR
GEAR SHAFT
Installthe stator shaft and stop shaft
1 3 . Installthe bolts and the stop shaft bracketon the secondaryvalve body, then tighten the bolts (three bolts). 1 4 . Installthe torqueconvertercheckvalve,coolerrelief
valve,and valvespringsin the regulatorvalve body, then install the regulatorvalve body on the main valvebody {one boltl. 1 5 . Installthe lock-upvalve body, separatorplate,two dowel pins and lubricationplate(eightbolts).
DETENTARM SHAFT
CONTROL SHAFT
OETENTARM OETENTARM SPRING
MANUAL VAIVE
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1 6 . Installtheone ATFfeed pipe in the main valvebody, the three ATF feed pipes in the secondaryvalve, the three ATF feed pipes in the servo body and the one ATF feed pipe in the lock-upvalve body. NOTE:lnstallthe 105.8mm ATF feed pipe with its filter side away from the secondaryvalve body; the filter is on the 105.8mm ATF feed pipe, which is (cont'd) onlv on the '98 - 00 models,
14-251
Transmission (cont'd) Reassembly TRANSMISSION HOUSINGMOUNNNG BOLT 10 x L25 4,1N.m {/ 4WD: 19 2WD: 18 TRANSMISSIONHANGER
t
f, 6xl.0mm 12 N.m (1.2 kgl.m,
8.7rbt.ft)
llf, g il /
l
MAINSHAFTSPEED SENSOB
COUNTERSHAFT BEVERSEGEAB
LOCKWASHER MAINSHAFT SUB.ASSEMBLY
REVERSE SHIFT FORK
DOWELPIN 14x 20 rnm
NEEDLEBEARING REVERSE SELECTOR
OOWELPIN 14x25mm TRANSMISSIONHOUSING GASKET
DOWELPIN 14x25mm
COUNTERSHAFT SUB.ASSEMBLY DIFFERENTIAL ASSEMBLY
TRANSFESASSEMBLY (4wDl
14-252
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1 7 . Installthe sub-shaftassemblyin the transmission housing(seepage 14-210and 14-2'111. 1 8 . lnstall the ATF magnet (4WD) in the transmission housing,if necessary.
Installthe reversegear with the collar and needle bearingon the countershatt. 2 4 . Align the spring pin on the control shaft with the transmissionhousinggroove by turningthe control shaft. SHAFT CONTROL SPRING PIN PIN SPRING
1 9 . Installthe reverseidler gear and gear shaft holder (seepage 14-231). 20. Installthe differentialassemblyin the torque converterhousing.
21. A s s e m b l et h e m a i n s h a f ta n d c o u n t e r s h a f ts u b then install assembly(seepage 14-206and 14 207],, them togetherin the torqueconverterhouslng.
COUNTERSHAFT SUB-ASSEMBLY
TRANSMISSION HOUSING 25. Placethe transmissionhousingon the torque conv e r t e r h o u s i n gw i t h a n e w g a s k e ta n d t h e t h r e e dowel pins, Make sure that the mainshaftspeed sensor is not i n s t a l l e do n t h e t r a n s m i s s i o nh o u s i n g b e f o r e h o u s i n go n t h e t o r q u e i n s t a l l i n gt h e t r a n s m i s s i o n converterhousing. 2 6 . I n s t a l lt h e t r a n s m i s s i o nh o u s i n g m o u n t i n g b o l t s alongwith the transmissionhangerand the connector bracket,then torque the bolts in two or more steosin the seouenceshown.
Turn the shift fork so the large chamferedhole is facing the fork bolt hole. then installthe shift fork with the reverseselectorand torque the lock bolt. Bendthe locktab againstthe bolt head.
NOTE:The illustrationshows the 4WD automatic transmission.The 4WD has 19 transmissionhousing mountingbolts;the 2WD has 18 bolts. TOROUE:44 N.m {,[.5kgf.m, 33 lbf'ft) TNANSMISSION
SHIFI FORK LOCK WASHER Beplace. 'l.O mm 6 r 4 N.m (1.4 ksl.m. 1O lbt.ft)
Large chamfered hole
{cont'd)
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14-253
Transmission (cont'd) Reassembly Install the mainshaft speed ssnsor (with new Oring)on the transmissionhousing.
28. I n s t a l lt h e p a r k l e v e r o n t h e c o n t r o l s h a f t , t h e n installthe lock bolt with a new lock washer.Do not bend the lock tab of the lock washer in this step; bend it after checkingthe park pawl engagementin step45.
33. Install the old locknut and the old conical spring washeron ths countershaft. Tightenthe old locknut to seat the park gear to the specifiedtorque,then remove th€ washer and locknut. The locknut has left-handthreads. Do not use an impact wrench. Always usea torquewrenchto tightenthe locknut. TOROUE:103 N.m {10.5kgf.m, 75.9 lbnft)
Assemblethe one-wayclutchand the park gear on the countershaft1stgear(seepage l4-2Og). Lubricatethese pans with ATF: . Countershaft threads . Old locknutthreadsand flat end . Old conicalspringwasher . Park gear contact area with conical spring wasner
3 1 . Installthe countershaft1st gear collar,needlebearing, and the countershaft1st gear/parkgear assembly on the countershaft. Installthe park pawl shaft. pawl spring, pawl. and p a w l s t o p o n t h e t r a n s m i s s i o nh o u s i n g ,t h e n engagethe pawl with th€ parkgear. PARKGEAR PARXGEAR
ONE.WAYCLUTCH
PAWL STOP
I I
a
34. Slip the specialtoolontothe mainshaft.
LOCK BOLT
PAWLSHAFT
BEARING COUNIERSHAFT COUNTERSHAFT lST GEARCOLLAR
14-254
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MAINSHAFT 07GAB- PF50101or 07GAB- PF501q)
5C.
Installthe sub-shaftlst gear on the sub-shaft.
36. Installthe mainshaft1st gear collar, mainshaft1st gear,needlebearing,thrust needlebearing,and the thrustwasheron the mainshaft. Wrap the shaft splineswith tape to preventO-ring damage,then installnew O-ringson the mainshaft ,te
4 1 . T i g h t e nt h e l o c k n u t st o t h e s p e c i f i e dt o r q u e . Mainshaftand countershaftlocknutshave left-hand threads.Do not use an impactwrench.Always use a torquewrenchto tightenthe locknuts. LOCKNUTTOROUE: 78 N.m (8.0 kgf'm, 58 lbf'ft) MAINSHAFT: 103 N.m (10.5kgf.m, 75.9 lbf'ft) COUNTERSHAFT: 93 N.m {9.5 kgf'm, 69 lbf'ft| SUB-SHAFT:
lnstallthe1stclutchassemblvon the mainshaft MAINSHAFT SU8-SHAFT LOCKNUT LOCXNUT Left-handthreads PIN COUNTENSHAFT 8 mm pin, LOCKNUT commercially threads Left-hand available
lST CLUTCH ASSEMELY SUB.SHAFT lST GEAR
.A/.b"' "wt
O.RINGS THRUSTWASHER IHRUST NEEDLE BEANING NEEDLEBEARING MAINSHAFT 1ST GEAR
CONICALSPBINGWASH€RS lnstallin this directionMAINSHAFT 1STGEAR COLLAB
39. A l i g n t h e h o l e o f t h e s u b - s h a f tl s t g e a r w i t h t h e hole of the transmissionhousing,then insert an 8 mm pin to hold the sub-shaftwhile tighteningthe sub-shaftlocknut.
42. Stake each locknut using a 3.5 mm punch.
0.7- 1.2mm {0.03- 0.05inl PUNCH 3.0- 3.5mm - 0.1ilinl 10.12
40. Install new conical spring washers and new locknuts on each shaft.Installthe washersin the direction shown.
LOCKNUT Pointto be staked.
(cont'd)
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14-255
Transmission Reassembly lcont'd) Set the parklever in @ position,then verifythat the parkpawl engagesthe parkgear.
47. Install the control lever assemblv on the control shaft. (4WDl
44. lf the pawl does not engagefully, checkthe distance b e t w e e nt h e p a r k p a w l s h a f t a n d t h e p a r k l e v e r rollerpin (seepage 14-231). Tightenthe lockbolt and bendthe locktab.
6 r 1 . Om m
1o tbf'frl
6x1.0mm 14 N.m 11.4kg{.m, 10 tbf.ftl PARKGEAR PARKPAWL
46. Installthe end coverwith two dowel pins and a new gasket {twelve bolts). TOROUE:12 N.m (1.2 kgf.m, 8.7 tbf.ft)
CONTROL LEVER ASSEMBLY
48. Set the A/f gear position switch to E] position. NOTE: The Aff gear position switch cticks in N] position,
6 x 1.0mm EOLTHOLE {Usedin step50.)
END COVER A/T GEARFOSMON SWNCH
14-256
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49. Set the control shaft to E position,and installthe A,/Tgear positionswitchon it. CONTROLSHAFT
Installthe transferassemblywith a new O-ring.Do not allow dust or otherforeignparticlesto enterthe transmission. {4WD)
,. ((,,, l( *
N
Cleanthe areaswhere the transferassemblycontacts the transmissionwith solvent or carburetor cleaner,dry with compressedair, then coatthe contact areaswith ATF. (4WD)
O.RING Replace-
N
$*\.t+-
'gtt - 00 MoDELS {6 position3}
T
50. I n s t a l lt h e A / T g e a r p o s i t i o n s w i t c h c o v e r , t h e n installthe harnessclamps of the AviTgear position switch harnesson the end cover and the transmiss i o nh o u s i n g .
6x1.0mm 12 N.m 11.2kgt.m, 8.7 tbf.ftl
10 r 1.25mm a,aN'm 14.5kgt'm, 33 lbf'ftl
lnstallthe cooler lineswith the line bolts and new sealingwashers.
6xl.0mm 12 N.m 11.2kgf'm, 8,7
TOROUE:28 N.m 12.9kgif'm.21 lbf'ft) 54. Installthe ATF dipstick. CONTROLSHAFT
55. lnstallthe breathercap on the breatherpipe so its arrow pointsto the transmissionhanger.
HARNESSCLAMP
HARNESSCLAMP
TRANSMISSION
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14-257
TorqueConverter/DrivePlate
6 x 1.0 rnin 12 N..t| {1.2 kgt.m, 8.7 lbt.frl
12 x 1.0mm 74 .m (7.5 lgt.m, 54 tbt.ft) Torque in I crisscross oattern.
o 0o
DBIVCPTATE
14-258
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Transmission lnstallation 1.
Flushthe ATF cooler as describedon page 14-264 and 14-265. Installthe torque converterassemblyon the mainshaftwith a new O-ring. lnstallthe starteron the transmissionhousing,and installthe 14 mm dowel pins in the torqueconverter housing.
6.
Install the transmission housing mounting bolt (front side). TRANSMISSIONHOUSINGMOUNNNG BOLT {FRONTSIDE) 12x 1.25mm 6,1N m (6 5 kgl m, 47 lbf'ftl
44 N.m {{.5 kgf.m, 33 rbf.f0
14 mm DOWELPIN
7.
Installthe transmissionmount bracket.Tightenthe bolt loosely,then tighten the nuts to the specified torque,and tightenthe bolt to the specifiedtorque. 12 x 1,25mm 6,aN.ft (6.5kgtm,47 rbf.ft)
t@ P l a c et h e t r a n s m i s s i o no n a j a c k , a n d r a i s e i t t o enginelevel. Anach the transmissionto the engine,then install the rear engine mounting bolts and the transmission housingmountingbolt (rearsidel.
TRANSMISSIONMOUNT BRACKET
REARENGINEMOUNTINGBOLTS la x 1.5mm 8:l N.m (8.5 kgf.m, 61 lbf.ftl
12 x 1.25 mm 74 N.m (7.5 kgf.m, s{ tbtftl
MOUNTINGBOLT{REARSIDEI 12x 1.25mm 6il N.m 16.5kgd.m,47 tbt.ttl
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TBANSMISSIONMOUNT
(cont'd)
14-259
Transmission Installation(cont'dl 8. Installthe transmissionhousingmountingbolts.
1 3 . C o n n e c t h e A T F c o o l e r h o s e st o t h e A T F c o o l e r lines(seepage14-266). .
ATF COOLER LINE
'i'l'r
' , : , . )-
10 x 1.25mm 44 N.m (4.5kgf.m, 33 tbtftl
TRANSMISSION HOUSING MOUNTING BOLTS 12x 1.25mm 54N.m16,5kgf.m,a7lbtftl
FRotrtT MOUNT/ARACKET
't4. Install the rightfront mounvbracket.
9. Removethe transmissionjack. 10. Attach the torque convenerto the drive plate with eight bolts. Rotatethe crankshaftas necessarvto tightenthe bolts to 'll2 of the specifiedtorque,then to the final torque, in a crisscrosspattern. After tightening the last bolt. check that the crankshaft rotatesfreelv. 6x1.0mln 12 N.m (1.2tgt m, 8.t lbf.frl
CLAMP 12x 1.25mm 64 N.m 16.5kg{.m, a7 tbt.ftl
DRIVEPLATE
1 5 . Installnew set rings on the ends of the intermediate shaftand the driveshaft. 1 6 . Cleanthe areaswhere the intermediateshaft con_ tacts the transmission{differential)with solvent or carburetorcleaner,and dry with compressedair. Then installthe intermediateshaft in the differen_ tial, While installingthe intermediateshaft,be sure not to allow dust or other foreign paniclesto enter the transmission.
8 x 1.25mm 2a N.m 12.5kgf'm, 18 tbt.ftl 6x1.0mm 12 N.m {1.219{.m, 8.7 tbtft,
STIFFENER 12 x t.25 mm 34 N.m 13.5kgf.rn,25 lbf.ft)
44 N.rn (4.5kgt m, 33 lbtftl
1 1 . Installthe torque convenercover and the rear stiff_ ener. 1 2 . Tightenthe crankshaftpulleybolt as necessary(see section5).
14-260
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l0 x 1.25mm 39 N.m 14.0kgt.n, 29 tbf.ftl
SETRING Replace.
INTERMEDIATE SHAFT
17. Installthe right and left driveshafts(seesection18). While installingthe right driveshaftin the differential, be sure not to allow dust or other foreignparticlesto enterthe transmission. NOTE: . Cleanthe areaswhere the right driveshaftcontacts the transmission(differential)with solvent or carburetorcleaner,and dry with compressed air. . Turn the right and left steeringknucklefully outward, and slide the right driveshaftinto the differentialuntil you feel its spring clip engagethe side gear. Slidethe left driveshaftinto the intermediateshaft until you feel the spring clip of the intermediate shaftengagethe left driveshaft,
19, Installthe propellershaft to the transferassembly by aligningthe referencemarks(4WD). MARKS REFERENCE
8 x 1.25mm 32 N.m (3.3 kgt'm,2ir blft) Feplace. \
@_
18. Installright damper fork, then installthe right and left ball joints on each lower arm with the castle nutsand new cotterpins (seesection18).
DAMPERPINCHBOLT 10 x 1.25mm 43 N.m 14.{kgf.m, 32 rbr.ftl
SHAFT PROPELLER 20. lnstallthe shift cable. 4WD: I n s t a l lt h e s h i f t c a b l e w i t h t h e c o n t r o l p i n , t h e n secureit with the snap Din. Do not bend the shift cableexcessivelv.
DAMPER FORX
SELF.LOCKING NUT 12 x 1,25mm 6/t N m (6.5kg{.m,a7 lbtft) Replace.
Replace.
CONTROL LEVER
CASTLE 12 x 1.25mm 49 - 59 N.m 15.0- 6.0 kgl m, 36 - {3 lbtftl
SHIFTCAALE COVER
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8 x 1.25mm 22 N.m 12.2l'glm, 16 rbt.ftl
(cont'd)
14-261
Transmission Installation(cont'dl 2WD: Installthe controlleverwith a new lockwasherto the controlshaft.Donot bendtheshiftcableexcessivelv.
24. Installthesplashshieldand guard bar,
SHIFTCABLE
8 r 1.25mm 22 N.m |'2.2 kgt.m, 16 rbf.ft)
8 x 1.25 24 N.m {2.akgl.m, 17 tbt.ftl
SI{IFT CAELE COVER
LOCKWASHER Replace.
6 x 1.0 mm 14 N.m 11.4kgt.m, 10 tbr.frl
6r1.0|r|m 9.8N.ml1.0lgf.m,7.2tbtftl
25. Connectthe mainshaftspeedsensor,the shift con-
22. Installexhaustpipe A.
23. Connectthe primaryheatedorygen sensor(primary HO2S) connector.
SHIFTCONTROLSOLENOID VALVECONNECTOR
GASKETS Replace.
SELF.LOCKING 8 x 1.25mm 22 N.m {2,2kgt.m, l5 lbt.ftl
14-262
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GUAROBAR
trol solenoidvalve,and the linearsolenoidconnec_ tors,
lnstalltheshift cablecover.
10 x 1.25m.n 5r N.m {5.5 kgf.m, 40 tbtftl Replace.
SPLASHSHIELD
SELF-LOCKING NUT 8 ! 1.25mm 16 N.m {1.6kgf.m, 12 lbf.ftt Replace.
26. Connectthe vehiclespeed sensor(VSS).the countershaft speed sensor. and the A,/Tgear position switch connectors,
VEHICLESPEEO
28. Instailthe transmissionground cable terminal on t h e t r a n s m i s s i o nh a n g e r ,a n d i n s t a l lt h e r a d i a t o r hoseclampon the transmissionhanger, 29. Connectthe startercablesto the starter,and install the harnessclamDon the clamDbracket.Makesure the crimpedside of the startercablering terminalis facingout. CLAMPBRACKET
STARTEB CABLE
SPEED SENSOA CO'{NECTOR STARTER CAAtf,
2 7 . Connectthe lock-upcontrol solenoidvalve connec-
30. I n s t a l lt h e a i r c l e a n e rh o u s i n ga s s e m b l ya n d t h e intakeair duct.
t o r , t h e n i n s t a l lt h e h a r n e s sc l a m p o n t h e c l a m p bracket.
3 1 . Refillthe transmissionwith ATF (seepage 14-161).
HARNESSCI-AMP RADIATORHOSE CLAMP
Connectthe batterypositiveterminaland negative terminal. Setthe parkingbrake,Startthe engine,and shift the transmissionthroughall gearsthreetimes.
34. Checkthe shift cable adjustment (see page 14-271]-. C h e c kt h e t r o n t w h e e l a l i g n m e n ta n d a d j u s t i t i f needed(seesection18).
TRANSMISSION GROUNDCAB1I TERMINAL
LOCK-UPOONTROL SOLENOIDVALVE CONNECTOR
Let the engine reachnormal operatingtemperature (the radiatorfan comeson) with the transmissionin E or N position,then turn it off and checkthe ATF level{seepage14-160). 37. Performa roadtest (seepage 14-157and 14-158).
6x1.0mm 12 N'm (1.2kgi.m, 8.? tbtftl
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14-263
Transmission CoolerFlushing To prevent in;ury to face and eyos, atways @@ wear safety glassesot a face shield when using the tlansmission flusher.
7. With the water and air valvesoff, attachthe water and air suppliesto the flusher.(Hotwaterif available.)
This procedureshould be performedbeforereinstalling the transmission. L
Checkequipmentfor wear and cracksbeforeusing. Replaceany worn or crackedcomponents.
2.
Usingthe measuringcup.fill the tankwith 21 ounces {approximately213lull) ol biodegradableflushing fluid (J35944- 20). Do not substitutewith any other f l u i d . F o l l o wt h e h a n d l i n gp r o c e d u r eo n t h e f l u i d contaaner. S e c u r et h e f l u s h e r f i l l e r c a p , a n d p r e s s u r i z et h e flusherwith compressedair to 550 - 829 kpa (5.6_ 8 . 4 5 k g f / c m , ,8 0 - 1 2 0 p s i )T. h e a i r l i n e s h o u l d b e equippedwith a water trap to ensurea dry air system.
8 . Turn on the water valve for 1Oseconds.lf water does not flow through the cooler, it is completely plugged,cannotbe flushed,and must be replaced.
Hangthe flusherunderthe vehicle. 5.
Attachthe flusherdischargehose to the return line of the transmissioncoolerusinga clamp. Connectthe drain hoseto the inlet line on the transmissioncoolerusinga clamp. IMPORTANT: Securelyclampthe oppositeend ofthe drainhoseto a bucketor floor drain.
Depressthe triggerto mix the flushingfluid into the water flow. Usethe wire clip to hold the trigger down. 1 0 . While flushingwith the water and flushingfluid for two minutes,turn the air valve on for five seconds every 15- 20 secondsto createa surgingaction. AIR PRESSURE: MAX 845 kpa(8.45kgf/cmr,t20 psi) 1' I. Turn the water valve off. Releasethe trigger,then reversethe hosesto the cooler so you can flush in the oppositedirection.Repeatsteps8 through 10.
12. Releasethe trigger,and rinsethe coolerwith wate. for one minute. 1 3 . Turn the water valve off, and the water supplyoff. DISCHARGE HOSE
1 4 . Turn the air valve on for two minutes,or until no
moistureis visibleleavingthe drain hose.Residual m o i s t u r e i n t h e c o o l e r o r l i n e s c a n d a m a g et h e transmission. Removethe flusherfrom the cooler line.Attachthe drain hoseto a container.
t
Air lp Water TnAI{SrfiSStoN coot"€R FLUSHER {Comm.rcidly.v.il.bt.l K.r -Moor. J38,t{15.A or aquival.nt
14-264
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to.
Installthe transmission,and leave the drain hose attachedto the coolerline.
1 7 . Makesurethe transmissionis in E position. F i l l t h e t r a n s m i s s i ow n i t h A T F ,a n d r u n t h e e n g i n e for 30 secondsor until approximately0.951 {1.0US qt., 0.8 lmp qt.) is discharged.
TOOL MAINTENANCE 1.
€mpty and rinse the flusher after each use. Fill the flusherwith water and pressurizeit, then flush the dischargelineto ensurethat the unit is clean.
1 8 . R e m o v et h e d r a i n h o s e ,a n d r e c o n n e ctth e c o o l e r returnhoseto the transmission(seepage14-266).
2.
lf dischargeliquiddoes not foam, the orificemay be blocked.
1 9 . Refillthe transmissionwith ATF to the proper level ( s e ep a g el 4 ' 1 6 1) .
3.
To clean,disconnectthe largecouplingnut from the flusher.
FILLERCAP
FILTER
COUPLING NUT
I - 0 - - D -@q I
\
II
\ ORIFICE
O.RING
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4.
Removethe in-linefilterfrom the dischargesideand cleanit if necessary.
5.
The fluid orificeis locatedbehindthe filter. Clean it with the pick stored in the bottom of the tank handle,or blow it cleanwith air.
6.
Reassemble all parts.
14-265
ATFCoolerHoses Gonnection '1. Connectthe ATF
coolerhosesto the ATF coolerlines.then securethem with the cliDs.
2. Facethe tabs of the clips of the transmissionside toward the radiator,and facethe tabs of the ATF coolerside downward.
CLIP F a c et a b s t o w a r d r a d i a t o r .
ATF COOLERLINE
ATF COOLERLINE
TRANSMISSION
6-8mm (0.2- 0.3 inl
ATF COOLER
HOSECLAMP
2-rlmm 10.1- 0.2inl
CLIP Facetabs downward.
14-266
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Shift Lever Removal/lnstallation SRS componentsare located in this area. Reviewthe SRS componentlocations,precautions,and procedures in the SRSsection(24)beforeperformingrepairsor servrce.
R e m o v et h e f l a n g e n u t s a n d b o l t s s e c u r i n gt h e steeringcolumn,then lowerthe steeringcolumn.
22 N.m (2.2kgf.m, 16 lbt.ftl
1.
Removethe instrumentpanel lower cover and the columncovers(seesection171.
2.
Shift to N position,then removethe lock pin from the cableadjuster.
3.
Separatethe shift cablefrom the cableadjuster,Do not bendthe shift cableexcessively.
ADJUSTERROD
SHIFTCABLE
NUTS FLANGE 16N m (1.6kgl m, 12lbt'ftl Disconnectthe shift lock solenoidand the park pin switchconnector. Removethe bolts securingthe shift leverassembly, then removethe shift leverassembly. 7.
lnstallthe shift lever assemblyin the reverseorder of removal. NOTE; . Make sure the lock pin is seatedsecurelyin the cableadjuster. . Replacethe lock pin if it does not snap over the cableadjustersecurely. Checkthe cableadjustmentafter installingthe shift lever(seepage14-27'l).
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14-267
Shift Lever -'97 - 98 Models Disassembly/Reassembly SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations.precautions.and proceduresin the SRS section(24)beforeperformingrepairsor service. Apply siliconegreaseto theseparts' . Movablepartsof the shift lever, . Movablepartsof the shift lock mechanism. . Slidingsurfaceson the detentof the controlcheckerand detentguide.
SHIFTLOCKSOLENOID SPRING SCREW 2.5 N.m {0.25kgtm, 1.8 lbtftl
SHIFTLOCK
SHIFTLOCKSOLENOID PLUNGER
SCREW 2.5 N.m {0.25kg{.m, 1.8rbf.ft)
SHIFTLOCK EXTENSION
DETENTSPFING
STOP
SHIFTLEVER CONTROLBRACKET
DETENTGUIDE 9.3 N.m 10.95kgtm, 6.8 tbrft)
PARKPIN SWITCH CONNECTOR SHIFTLOCK RELEASELEVER SPRING 9.3 N.m {0.95kgf.m, 6.8 tbf.ftl
SHIFTLEVER LINK 9.3 N.m (0.95kgt.m, 6.8 tbf.ftl
SHIFTCAALE
7 N.m {0.7 kgf.m.5 tbt.fr}
14-268
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KNOB I N.m 10.9kgt.m, 7 rbf.ftl
-'99 - 00 Models Disassembly/Reassembly SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,and proceduresin the SRS section(24)beforeperformingrepairsor service. Apply siliconegreaseto theseparts: . Movablepartsof the shift lever. . Movablepartsof the shift lockmechanism. . Slidingsurfaceson the detentof the controlcheckerand detentguide. NOTE:Adjustthe clearancebetweenthe O/Dswitchwires and the edge ofthe shift levercontrolbracketafter reassembly (seepage 14-270). SHIFTLOCK RELEASE LEVER SHIFTLOCKSOLENOID
SHIFTLOCKSOLENOID SPRING SCREW 2.5 N.m {0.25kgf.m,1.8lbtft) SHIFTLOCKSOLENOIO PLUNGER
SCREW 2.5 N.m (0.25kgl.m, 1.8 lbl.ft) DETENTSPRING
SHIFTLOCKEXTENSION
SHIFTLEVERCONTROL BRACKET
STOP
PARKPIN SWITCH_
DETENTGUIDE
o/DswtTcH CONNECTOB
9.3 N.m {0.95kgf.m, 6.9 lbl.ftl SCREW 2.5 N.m {0.25kgt m, 1.8 tbf.ftl
SHIFTLOCKBELEASE LEVERSPRING PARK PIN
9.3 N.m {0.95kgl.m, 6.9 lbtfr) HARNESSCLAMP ERACKET
swrTcH
SCREW 2.5 N.m {0.25kgf.m, 1.8 tbl.f0 9.3 N.m 10.95kgtm, 6.9 tbf.ft)
CONTROLCHECKER
LOCKNUT 7 N.m {0.7kgl.m, 5 tbf.ftl
SHIFTLEVER BUSHING
SHIFTLEVERKNOB 6 - 1 2N . m {0.6- 1.2 kgt'm, 4 - 8.7 tbnft)
o/DswtTcH www.emanualpro.com
14-269
Shift Lever Over-Drive(O/DlSwitch Wire Clearance Adjustment-'99 - 00 Models NOTE: Be sure to adjust the clearancebetween the O/D switch wires and the shift lever control bracket after replacingthe O/D switch and park pin switch,and after reassemblingthe shift lever. lf there is the slack in the wires or the wires are kept tight, the wires may have Dreaks. 1.
Shiftthe shift leverinto E positron.
2.
Pull or push the wires to adjust the clearance betweenthe wires and the edge of the shift lever controlbracketto 13 mm (0.5in).
Securethe wireswith the harnessclamp. Move the shift leverto eachposition,and verifythat there is a clearancebetweenthe wires and bracket in eachposition. lf the wires are kept tight in any position,read.iust the clearance. Installthe shift lever assemblyon the steeringcolumn. 7.
SHIFTLEVERBRACKET
14-270
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Move the shift lever to each position, and make sure that the wires are kept away from any parts suchas the steeringcolumn.
DetentSpringReplacement 1.
Installthe detent spring on th€ shift lever control bracket,and installthescrewloosely.
4.
Put the detent spring roller in E position on the detentguide,then tightenthe screwto the specified torque,
Shift the shift lever to E position. lnssrt a 0.5 mm (0.02 in) wire gap gauge between the control chockerdetent and the shift lever,then hold the shift lever againstthe El position in the controlchecker.
'97 - 98 Modeb: SPRING DETENT
SHIFI LEVER
2.5 N.m 10.25kgf.m, 1.8lbl.ftl
GAPGAUGE
SCREW 2.5 N.m 10.25kgl.m, 1.8lbtftl
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14-271
Shift Gable Adjustment SRScomponentsare locatedin this area.Reviewthe SRS componentlocations,precautions, and proceduresin the SRSsection(241beforeperformingrepairsor service. 1.
Release the steeringtilt lever.
2.
Removethe accesscover from the lower column cover.
4. Checkthat the hole in the cable adjusteris aligned with the hole in the adjusting rod. There are two holes in the cableadjuster.They are positioned90" apart to allow cable adjustmentsln l/4 turn increments.
CABLEADJUSTER LOCKPIN AOJUSTING
noo
K\ffi
6-,> /* 1 snenrftc Y TILTLEVER
Cabls Too Short
Cable Too Long
Exact Alignment
I
ACCESSCOVER
ADJUSTER 7 N.m(0.7kg{.m, 5 tbf.ft) 3.
lf not perfectlyaligned, loosenthe locknut on the shittcable.and adjustas required.
Shift to E position.then removethe lock pin from the cableadjuster.
Tightenthe locknut. 7 . Installthe lock pin on the adjuster.lf you feel the lock pin bindingas you reinstallit, the cable is still out of adjustmentand must be readjusted. M a k e s u r e t h e l o c k p i n i s s e a t e ds e c u r e l yi n t h e a d j u s t e r .R e p l a c et h e l o c k p i n i f i t d o e s n o t s n a p over the cableadjustersecurely. a
Move the shift leverto eachgear,and verifythat the A/T gear position indicator follows the A"/Tgear position switch.
1 0 . S t a r t t h e e n g i n e ,a n d c h e c kt h e s h i f t l e v e r i n a l l gears.lf any gear does not work properly,refer to troubleshooting on page 14-'153 thru 14-156. ' l1 . Insertthe ignition key into the key cylinderon the upper column cover, and verify that the shift lock teverreteases.
14-2 7 2
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Replacement SRScomponentsare locatedin this area.Reviewthe SRS componentlocations,precautions, and proceduresin the SRSsection{24}before performing repairsor service.
Removethe shift cablecover.
1.
Removethe instrumentpanel lower cover and the columncovers(seesection17).
4WD: Removethe snap pin and control pin,then separate the shiftcablefrom the controllever.
2.
Shift to E position,then removethe lock pin from the cableadiuster.
Removethe shiftcable.
CONTROLPIN CABLEADJUSTER
SHIFTCABLE
LOCKPIN
LOCKNUT 29 N.m {3.0 kgl.m, 2j2lbf.trl
ADJUSTING SHIFTCABLE ROO BRACKET
L o o s e nt h e l o c k n u t ,t h e n r e m o v et h e s h i f t c a b l e from the shift cablebracket.
SHIFT
COVER
t r 1.25mm 22 N.n 12.2*glrn. 16tbf.trl
2WDi Removethe control lever, then separatethe shift cablefrom the controlshaft.
R e m o v et h e n u t s e c u r i n gt h e s h i f t c a b l e h o l d e r , then removethe shiftcable.
SHIFT CABI-E
CONTROL SHAFT
STUOBOLT
8 x 1.25mm 22 N.m 12.2 kgl-m, 16 tbf.frl
6x1.0mm 12 N.m {1.2 kgf.m, 8.7tbtfrl
SHIFTCABLE COVER LOCKWASHER
6x LOmm 14 N.m {1.4kgf.m,
10 tbt.lrl
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(cont'd)
14-273
Shift Gable Replacement(cont'd) 7.
Removethe nuts securingthe shift cable holder, then removethe shiftcable. GROMMET
STUDBOLT
SHIFTCABLE
f-'
6x 1.0mm 12 N.m 11.2kgtm, 8.7 tbf.ftl
I n s t a l lt h e s h i f t c a b l e l n t h e removat. NOTE: . Do not bent the shift cable excessivelywhen installingit. . Make sure the lock pin is seatedsecurelyin the cableadjuster. . Replacethe lock pin if it does not snap over the cableadjustersecurely. Checkthe cableadjustmentafterinstallingit.
14-274
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Differential Rear Differential S p e c i aT l o o l s. . . . . . . . . . ...........15-2 Description R e a rD i f f e r e n t i a .l . . . . . . . . . . . . . . . . . . . . . . . 1 . .5. .-.4. . . . H y d r a u l i cF l o w . . . . . . . . . . . . , . .1 5 - 6 Real-time4WD-DualPump System T r o u b | e s h o o t i n .9. . . . . . . . . . . . . . . . . . . . . . . 1 . .5. .-.1. .0. . RearDifferentialAssembly T r o u b l e s h o o t i n .g. . . . . . . . . . . . . . . . . . . . . . . 1 . .5. .-.1. .3. . Maintenance D i f f e r e n t i aFl l u i d . . . . . . . . . . . . 15-14 Rear DifferentialAssembly l l l u s t r a t e dI n d e x . . . . . . . . . . .. 15-15 Removal/lnstallation ....15-16 DifferentialCarrierAssembly L e a kR e p a i r . . . . . . . . . . . . . . .1 . .5. .-.1 8 OilSeals R e p l a c e m e n.t. . , . . . . . . . . . . . . . . . . . . . . . . . . .1. 5 . .-.1. .9. . . . RearDifferentialAssembly Disassembly . . . . . . . . . . , . . . .1. 5. .-,2 0 Reassembly . . . . . . . . . . . . . . .1. .5. .-.2 3
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SpecialTools
Ret. No.
o @ aa @ /il tol
Tool Number J - 38592 07GAD- PH7020'1 07JAB- 0010204 OTRA_ BT B 4 0 l O B 07749 0010000 07965- 6920101
otv
Oescription TransferCaseOil Seallnstaller SealDriver H o l d e rH a n d l e F l a n g eH o l d e r Driver Hub Dis/Assembly Tool
1 1 1 1 1 1
6\
@
15-2
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PageReler€nce
15-20 15-19 tc-zt, z9
15-21,25 15-19 15-19
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15-3
Description RearDifferential Outline The Real-time4WD-DualPump Systemmodel has a hydraulicclutchand a differentialmechanismin the rear differential assembly.Under normalconditions,the vehicleis driven by the front wheels.However,dependingon to the drivingforce of the front wheels and the road conditions.the systeminstantlytransmitsappropriatedrivingforce to the rear wheels without requiringthe driverto switchbetween2WD (trontwheel drive)and 4WD(fourwheel drive).The switchingmechanism between2WD and 4WDis integratedinto the reardifferentialassemblyto makethe systemlight and compact. forcewhen brakingin a forwardgear.This allowsthe ln addition,the dual-pumpsystemswitchesoff the rear-wheel-drive brakingsystemto work properlyon modelsequippedwith an Anti-lockBrakingSystem(ABS). Construction The rear differentialassemblyconsistsof the torque control differentialcase assemblyand the rear differentialcarrier assembly.The torque control differentialcase assemblyconsistsof the differentialclutch assembly,the companion flange,and the oil pump body assembly.The reardifferentialcarrierassemblyconsistsof the differentialmechanism.The differentialdrive and drivengearsare hypoidgears. The oil pump body assemblyconsistsof the front oil pump, the rear oil pump,the hydrauliccontrolmechanism,and the clutch piston.The clutch piston has a disc spring that constantlyprovidesthe differentialclutchassemblywith a preset torqueto Dreventabnormalsound. The clutchguide in the differentialclutchassemblyis connectedto the propellershaft via the companionflange,and it receivesthe drivingforce lrom the transferassembly.The clutchguide rotatesthe clutchplate and the front oil pump in the oil pump body. The clutchhub in the differentialclutchassemblyhas a clutchdisc that is splinedwith the hypoid drive pinion gear.The hypoiddrivegear drivesthe rearoil pump. The front and rearoil pumpsare trochoidalpumps.The rearoil pump capacityis 2.5 percentlargerthat the front oil pump to handlethe rotationdifferencebetweenthe front and rear wheelscausedby worn front tires and tight corner braking. The oil pumps are designedso the fluid intakeworks as a fluid dischargewhen the oil pumps rotatein reverse.Genuine HondaCVTfluid is usedinsteadof differentialfluid. Operation Whenthere is a differencein rotationspeedbetweenthe front wheels(clutchguide)and rearwheels(hypoiddrivengear), hydraulicpressurefrom the front and rear oil pumps engagesthe differentialclutch,and drive force from the transler assemblyis appliedto the rearwheels. The hydraulicpressurecontrolmechanismin the oil pump body selects4WD mode when the vehicleis startedabruptly, or when acceleratingin a forward or reversegear (causingrotationdifferencebetweenthe front and rear wheels).or when brakingin reversegear {whendecelerating). lt switchesto 2WD modewhen the vehicleis drivenat a constantspeed in forwar! or reversegear (whenthere is no rotationdifferencebetweenthe front and rearwheels),or when brakingin a fo rward gear (whendecelerating). To protectthe system,the differentialclutchassemblyis lubricatedby hydraulicpressuregeneratedby the oil pumps in both 4WDand 2WD modes.Also,the thermalswitchrelievesthe hydraulicpressureon the clutchpistonand cancels4WD mode if the temDerature of the differentialfluid risesabovenormal.
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REARDIFFERENTIAL ASSEMBLY TOROUECONTROLOIFFERENTIAL OIFFERENTIAL CARRIER OILPUMPBODY HYPOIDDRIVE PINIONGEAR
OIFFERENTIAL CLUTCH ASSEMBLY
DIFFERENTIAL CLUTCHGUIDE HYPOIDRINGGEAR
COMPANIONFLANG€ CLUTCHHUB REAROIL PUMP CLUTCHPLATE
FRONTOIL PUMP HOUSING DIFFERENTIAICLUTCHDISC
HYDRAULICCONTROLSYSTEM DISCSPRING CLUTCHPISTON
FRONTOIL PUMP REAROII- PUMP
DIFFEREMT|AL CLUTCH ASSEMBI-Y THERMALSWITCH
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RELIEFVALVE
OIL STRAINER
15-5
Description HydraulicFlow Forward Start and Accelerationl4WD) Duringa forwardstartand forwardacceleration, the dual pump systemcan engagefour wheeldrive. lf the front wheelsspin fasterthan the rearwheels,the front oil pump spinsfasterthan the rearoil pump.The front pump draws fluid through checkvalve B and dischargesit. Some of the dischargedfluid is drawn in the by the rear oil pump. The remainingfluid will passthroughcheckvalve E into the clutchpiston.There,hydraulicpressureis regulatedby two orifices. The regulatedhydraulicpressureat the clutchpistonpushesthe platesand discsof the clutchtogetherto form a connection. The engagedclutchthen passesdrivingforcefrom the transferassemblyto the rearwheels,producing4WD.
oRrFtcEs
FRONTOIL PUMP
REAROILPUMP
Forward Driving at Constant Speed lzWD) When drivingforwardat a constantspeed(cruising), the dual pump systemfunctionsin two wheeldrive mode. The rotationspeedof the front and rearwheelsis the same,so the speedof the front and rearpumps is alsothe same. Fluid dischargedby the front oil pump is drawn in by the rear oil pump and is circulatedthrough the system.Because there is no pressurebuilt up at the clutchpiston,the clutchdoes not engage,and the vehicleremainsin 2WD (frontwheel drive).
FRONTOIL PUMP
15-6
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Forward Decelerationl2WDl the dual pump systemfunctionsin two wheeldrive mode. Duringforwarddeceleration, the speedof the rearwheels may exceedthe speedol the front wheelsduring decelerBecauseof brakingcharacteristics, ation.lf so, the rearoil pump spinsfasterthan the front oil pump. d .e c a u s teh e r ei s n o F l u i dd i s c h a r g ebdy t h e r e a ro i l p u m p i s s i m p l yd r a w n i n a g a i nb y t h e r e a rp u m p a n d r e c i r c u l a t e B pressurebuilt up at the clutch piston.the clutch piston does not engage,and the vehicleremainsin 2WD (front wheel drive). REAROILPUMP
ReverseStart and Acceleration(4WD) the dual pump systemcan engagefour wheeldrive. Duringreversestartand reverseacceleration, lf the front wheelsspin fasterthan the rear wheels,the front oil pump spinsfasterthan the rear oil pump. The front oil pump drawsin fluid throughcheckvalveA and dischargesit. {Notethat in reverse,the directionof the pumps is the opposite of that duringforwarddriving.) Some of the fluid that is dischargedby the front oil pump is drawn in by the rear oil pump. The remainingfluid passes throughcheckvalveF into the cylinderof the clutchpiston,where it is regulatedby two orifices. The regulatedhydraulicpressureat the clutchpistonmay forcethe platesand discsof the clutchtogetherto form a connectlon.The engagedclutchpassesdrivingforcefrom the transferassemblyto the rearwheels,producing4WD.
oRtFtcEs
FRONTOIL PUMP
{cont'd)
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15-7
Description HydraulicFlow (cont'dl ReverseDriving at Constant Speed l2WD) when driving in reverseat a constantspeed,the dual pump systemfunctionsin two wheeldrive mode. The rotationspeedof the front and rearwheelsis the same,so the speedof the front and rearpumps is alsothe same, Fluiddischargedby the front oil pump is drawn in by the rearoil pump and is circulatedthroughthe system.But,because the there is a differencein the capacitybetweenthe two pumps,fluid flows through checkvalve E, and then through oriIices.This fluid lubricatesand coolsthe clutchassemblyand bearings. ls this condition,only a low pressureis built up at the clutchpiston.Thereforethe clutchdoes not engage,and the vehicle remainsin 2WD (frontwheeldrive).
ReverseDecelerationl/tWDl Duringreversedeceleration, the dual pump systemcan engagefour wheeldrive. When deceleratingin reversedirection,the speedof the rear wheels may exceedthe speedof the front wheels (due to enginebraking).In this condition,the rearoil pump drawsfluid throughcheckvalvesB and C. Fluid dischargedfrom the rearoil pump then flows throughcheckvalveE to the clutchpiston.There,pressureis regulatedby two orifices. The regulatedhydraulicpressureat the clutchpiston may forcethe platesand discsof the clutchtogetherto form a con, nection.The engagedclutchpassesdrivingforcefrom the transferassemblyto the rearwheels,producing4WD.
oRtFtcEs
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REAROIL PUMP
Thermal Switch Operation l2WD) fluid is in contactwith the clutchpistonand the thermalswitch. During4WDoperation,pressure-regulated lf the temperatureof the fluid in the differentialgoes too high, the thermalswitch pushesopen the reliefvalve R. This causesthe pressurein the clutchpistonto drop, and 4WD mode is disengaged.
THERMALSWITCH
RELIEFVALVE
RelietValve Operation When the fluid pressuregoes higherthan the reliefvalvespringforce,checkvalve R opens.Pressureappliedat the clutch pistonis held constant.This featureadds stabilityby preventingthe rearwheeldrive systemfrom experiencingexcessive to rque.
RELIEFVALVE
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15-9
Real-time4WD-DualPumpSystem (AutomaticTransmissionl Troubleshooting When starting and accelerating in forward gesrs {4WD model
When starting and accelerating in revGrsggear {4WD model
1.
L i f t u p t h e v e h i c l es o a l l f o u r w h e e l sa r e o f f t h e ground (seesection1).
1.
2.
Makea mark on eitherNo. ' I o r N o . 2 p r o p e l l e r shaft.
PROPELLER SHAFT
L i f t u p t h e v e h i c l es o a l l f o u r w h e e l s a r e o f f t h e ground (seesection1).
Makea mark on eitherNo. 1 or No. 2 propeller shaft. PROPELLER SHAFT
Startthe engine,and let it run until it warms up (the radiatorfan comeson at leasttwice).
Startthe engine.and let it run until it warms up (the radiatorfan comeson at leasttwicei.
With the engineat idle.shiftto the E position.
With the engineat idle,shift to the E position.
A p p l y t h e p a r k i n gb r a k ef i r m l y . a n d m e a s u r et h e time it takesthe propellershaftto rotate10 times. . lf the measuredtime is more than 10 seconds, the 4WDsystemis normal. . l f t h e t i m e i s l e s st h a n 1 0 s e c o n d s t, h e r e i s a problem in 4WD system. Checkthe differential f l u i d . l f t h e d i f f e r e n t i af l u i d i s n o r m a l ,r e p l a c e the torquecontroldifferentialcasekit.
A p p l y t h e p a r k i n gb r a k ef i r m l y , a n d m e a s u r et h e time it takesthe proDellershaftto rotate10times, . lf the measuredtime is more than 10 seconds, the 4WDsystemjs normal. . l f t h e t i m e i s l e s st h a n 1 0 s e c o n d s t, h e r e i s a problem in 4WD system. Checkthe differential fluid. lf the differentialfluid is normal, reolace the torquecontroldifferentialcasekit.
15-10
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(ManualTransmissionl Troubleshooting When starting and acceleratingin forward gears (4WD mode) 1.
L i f t u p t h e v e h i c l es o a l l f o u r w h e e l s a r e o f f t h e ground{seesection1)
2.
Startthe engine,and let it run until it warms up (the radiatorfan comeson at leasttwlce).
3.
W i t h t h e e n g i n ea t i d l e , s h i f t i n t o 1 s t g e a r a n d releasethe clutch. Applythe parkingbrakefirmlY . .
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lf the enginestalls,the 4WDsystemis normal. lf the enginecontinuesrunning,there is a problem in 4WDsystem.Checkthe differentialfluid. lf the differentialfluid is normal,replacethe torque controlditferentialcasekit.
When starting and acceleratingin reversegear (4WD model 1.
L i f t u p t h e v e h i c l es o a l l f o u r w h e e l s a r e o f f t h e ground (seesection1).
Startthe engine,and let it run until it warms up (the radiatorfan comeson at leasttwice) 3.
With the engine at idle, shift into reversegear and releasethe clutch. Apply the parkingbrakefirmlY . .
lf the enginestalls,the 4WDsystemis normal. lf the enginecontinuesrunning,there is a problem in 4WD system.Checkthe differentialfluid lf the differentialfluid is normal,replacethe torque controldifferentialcasekit.
Real-time4WD-DualPumpSystem Troubleshooting(AutomaticTransmission/Manual Transmission) Whon d6c6l6ratingin a torward gear {2WD mode}
When deceleratingin reversegear (4WD mod€)
1.
1.
Blockthe front wheels,raisethe left rearwheel.and supportit with a safetystandas shown.
WHEELCHOCKS
Hold the tire and turn it counterclockwise continuouslvfor more than one rotation.
lf the rotation of the wheel does not gradually feel heavywhile rotating,the 2WD systemwhen decelerating in a forwardgear is normal. lf the rotationof the wheelgraduallyfeelsheavy, there is a problem in the system.Checkthe differentialfluid, lf the fluid is normal,reDlacethe torouecontroldifferentialcasekit.
15-12
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Blockthe front wheels.raisethe left rearwheel,and suppo( it with a safetystandas shown.
WHEELCHOCKS
Hold the tire and turn it clockwisecontinuouslvfor more than one rotation.
lf the rotation of the wheel gradually feels heaw. the 4WD systemwhen deceleratingin reversegear is normal, lf the rotationof the wheeldoes not graduallyfeel heavy,there is a problem in the system.Check t h e d i f f e r e n t i afl l u i d . l f t h e f l u i d i s n o r m a l . reolacethe torquecontroldifferentialcasekit,
RearDifferentialAssemblY Troubleshooting Most problemsin the unit are to be diagnosedby identifyingnoisesfrom the gearsor bear'ngs' components' care shouldbe takenduringdiagnosisnot to confusedifferentialnoiseswith thosefrom otherdrivetra'n Symptom
Remedy
ProbableCause
Will not go into 4WD mode
. Fluidleveltoo low . Incorrectfluid type
. Add fluid . Replace
Will not returnto 2WD mode
Incorrectfluid type
Drainand fill the differential
Gearor bearingnoises
Overheating F l u i dl e a k
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Fluidleveltoo low Incorrectfluid type Damagedor chippedgears . Fluidleveltoo low . Incorrectfluid type Fluidleveltoo high Cloggedbreatherhose Worn or damagedoil seal Damagedsealingwasher Loosemountingboltsor inadequatesealing
Add fluid Drain and fill the differential Replacethe differential carrier assemory . Add fluid . Drain and fill the differential
Lowerto properlevel Cleanor replace Replace Replace torqueor aPPIYsealant Recheck
15-13
Maintenance DifferentialFluid !@ section 1). 1.
2.
Make sure lifts are placed properly lsee
With the vehicleon levelground,inspectdifferential f l u i dw i t h e n g i n eO F F . Removethe oil filler plug, then checkthe leveland conditionof the fluid.
C l e a nt h e d r a i n p l u g , t h e n r e i n s t a l il t w i t h a n e w washer, and refill the differentialwith the recommendedfluid to the properlevel. NOTErlf you disassembly the differential, checkthe fluid levelagain after the 4WD systemcheckis finished.Add fluid if necessary. Reinstallthe oil filler plug with a new washer.
Proper Level
Fluid Capacity 1.0/ {1.1US $, 0.9 lmp qt) at tluid change 1.2/ {1.3US $, 1.1lmp qt) at oyerhaul Recommended fluid: GenuineHondaCVT Fluid
o|I FII.IIR PI-UG 4t N.m la.8kgl.m,35 lbl.ftl
T h e f l u i d l e v e lm u s t b e u p r o t h e f i l l h o l e .l f i t i s below the hole, add the recommendedfluid until it runs out, then reinstallthe oil filler plug with a new wasner. 4.
l f t h e d i f f e r e n t i atll u i d i s d i r t y , r e m o v et h e d r a i n p l u g ,a n d d r a i nt h e f l u i d .
DMIN PLUG a7 N.m 14.8kgl.m, 35 lbt.ftl
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1 5 -1 4
RearDifferentialAssembly lllustratedIndex
6xl.0m 12 N.m (1.2 kgf m,8.7 lbt'ftl DOWELPINS COMPANIONFLANGE O.RING Replace. BACK-UPRING LOCKNUT,24 mm Replace. 118N.m (12.0kgtm. 87 rbt ft)
6x1.0mm 12 N.m 11.2kgt'm,8.7 lbf'ft| OIL SEAL Replace.
PRESSURE PLATE
CLUTCHHUB/PLATES/DISCS CLUTCH DIFFERENNAL ASSEMBLY
OIL PUMPDRIVESHAFT
THBUSTNEEDLE AEARING
""t",at\(
'd' CLUTCHGUIDE
OILPUMP PIN
e MAGNET
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OIL STRAINER
15-15
RearDifferentialAssembly Removal/lnstallation Make sure tifts are ptaced property lsee l!!@ section 11. 1.
Drainthe differentialflujd (seepage 15-14).
2.
Mark the propellershaft and companionflange of the rear differentialassemblyso they can be reinstalledin theiroriginalpositions. PROPELLERSHAFT
5,
Placea transmissionjack underthe rear differential assembly,then removethe right mountingbracketB andthe left mountingbracket8.
COMPA'{IONFLANGE
12 POtt'lT BOLI 8 x 1.25mm 32 N.m 13.3tgf.m. 2a lbtft,
Mark
Removethe breathertube from the breathertube fitting. BREATHER TUBEflTNNG
Removethe propellershaftfrom the reardifferential assemory. Removethe reardifferentialdamper.
12x 1.25mm 5,1N.m 15,5kgf.m, iO tbf.fO
15-16
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7.
Insertthe edge of the screwdriverinto the groove locatedunder the differentialhousing Pry out the driveshaftinboardiointwith a screwdraver. NOTE:Take care not to damagethe differentialoil sealand differentialring when prying out the differentialinboardjoint.
DIFFERENTIAL
10. Remove the rear difterentialmounting bracketA from the reardifferentialassembly. 12 x 1.25 fifi
N.m {7.0 lgf.m. 5l lbl.tt) REARDIFFERENTIAL MOUNTINGBRACKETA
REANDFFERENTI,AL ASSEMBLY
1 1 .Installthe rear differentialassemblyin the reverse orderof removal.
8.
Removethe mountingboltsand the washers.
Notetheseitemsduringreassembly . lnstallthe breathertube to the breathertube joint properly. . Duringthe propellershaft installation,align the m a r k s o n t h e p r o p e l l e rs h a f t a n d c o m p a n i o n flange. . Reiillthe rear differentialwith the recommended fluidto the properlevel{seepage15-14).
DRIVESHAFT
BOLTS MOUNTING '10x 1.25mm ,19N'm (5 0 kgf m, 36 lbtftl Lower the rear differentialassemblyon the transmissionjack,then removethe reardriveshaftsfrom the rear difterentialassembly.
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15-17
DifferentialCarrierAssembly LeakRepair '1. Remove t h e b o l t s i n a c r i s s c r o s so a t t e r n .t h e n removethe differentialhousing. I x 1.25mm 22 N.m 12.2kgl.m, 16 tbtftl
2.
I n s t a ltlh e o i l s e a l s( s e ep a g e1 5 - 1 9 ) . DIFFERENTIAL HOUSING
Apply liquid gasketto the sealingsurfaceof the ditferentialhousing,and notetheseitems: . Use liquidgasket(P/N08718- 000'1). . R e m o v ea n y d i r t o r f l u i d f r o m t h e s e a l i n gs u r lace. . lf 20 minutes have passedafter applying liquid gasket,reapplyit beforeyou assemblethe housings. Allow it to cure at least 30 minutes after assemblybeforefilling differentialwith ftuid. DIFFERENTIAL HOUSING
15-18
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Installthe differentialhousing.then torquethe bolts in a crisscrosspatternin severalsteps.
Oil Seals Replacement 1.
Removethe oil sealsfrom the differentialhousing.
2.
Installthe oil sealssquarelyusingthe specialtools. Be carelulnot to damagethe lip ol the oil seals.
Right side: Rightside:Installationdepth of the oil seal is 9 mm (0.35in) belowthe edgeof the differentialhousing.
OILSEAL
HUB DIS/ASSEMBLYTOOL 07965- 6920101 OIL SEAL
Left side:
Left side: Installthe oil seal flush with the edge of the differentialcarrierassembly.
OIL SEAL
(cont'd)
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15-19
Oil Seals
RearDifferentialAssembly
Replacement(cont'd)
Disassembly
3.
1.
Removethe oil seal from the toroue control differentialcase.
Removethe breathertube,the drain plug and the oil f i l l e rp l u g .
BREATHER TUBE
OIL FILI.IRPLUG
DRAIT{PLUG
Installthe oil sealsquarelyusingthe specialtool. carefulnot to damagethe lip of the oil seal. Raisethe locknuttab from the groove of the clutch guide, making sure that the tab completelvclears the grooveto preventdamagingthe clutchguide.
L(rcKNUT,24 mm Replace.
15-20
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3.
Installthespeclaltoolson the companionflange,
7.
R e m o v et h e l o c k n u t ,t h e d i s c s p r i n gw a s h e r ,t h e back-upring,the O-ringand the companionflange.
HOIIIER HANDTI o'JAB - OO102nA
@r/ v-.,.
LOCKNUT,24 mm Feplace. DISCSPRINGWASHER,24 mm
ao/
BACX.UPRING
rA*..-
O.N|NG Replace.
U
zzft
h\@fr\
COMPANIONFLANGE
8 x 1.25mm
32 N m {33 tgt m,24lbf ftl so that its tab Loosenthe locknutcounterclockwise comesout from the groovein the clutchguide. LOCKNUT,24 mm
8.
5.
Tightenthe locknuttill its tab alignswith the groove.
6.
Removeany dirt from inside of the groove in the clutchguide,then loosenthe locknut.
Removethe torque controldifferentialcaseand the dowel pins.
LOCKNUT.2,1mm
Tab
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(cont'd)
Rear DifferentialAssembly Disassembly(cont'dl 9 . R e m o v et h e s h i ma n dt h e c l u t c hq u i d e .
1 1 . R e m o v et h e t h r u s tn e e d l eb e a r i n ga n d t h e o i l p u m p driveshaft.
d"HIM'30mm
CLUTCHGUIDE
and the pressure 1 0 . Removethe clutchhub/plates/discs prare.
1 2 . Removethe oil pump body assembly,the oil pump pin,the magnet,and the oil strainer.
OIL PUMPBODYASSEMBLY CLUTCHHUB/PLATES/OISCS
k
ffi -:*
_zz
PRESSURE PLArE
MAGNET
@-
OIL PUMPPIN
OIL STRAINER Inspectfor damage or clogging.
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15-22
Reassembly 1.
Apply CVTfluid to the rubberof the oil strainer,then installthe oil strainer,the magnet,and the oil pump pin to the differential carrier.
3.
Tightenthe oil pump body assemblymounting bolts.
4.
I n s t a l lt h e o i l p u m p d r i v e s h a f tb y a l i g n i n g t h e p r o jection of the oil pump driveshaftwith the groove of the front oil pump in the oil pump body assembly.
MAGNET THRUSTNEEDLEBEABING
-n
OIL PUMPPIN
lnstallin thisdirection. Projection
CWfluid
6x1.0mm 12 N.m 11.2kg{.m,8.7 lbl.ft}
DIFFERE]TTIALCARRIER ASSEMBLY
2.
Alignthe oil pump pin with the grooveof the rearoil pump in the pump body assembly, then installthe oil pump body assemblyto the differential carrierassemoty. OIL PUMP BODYASSEMBLY
5.
Installthe thrust needlebearing. Installthe pressureplate assemblyby aligningthe projectionof the pressureplate with the groove of the oil pump driveshaft. PRESSURE PLATE
OILPUMP DRIVESHAFT
( c o n t ' d)
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15-23
RearDifferentialAssembly (cont'dl Reassembly 7.
then alignthe proInstallthe clutchhub/plates/discs, jectionof the plateswith the discs.
sHlM, 30 mm ,/ .A-\,/r \-7
10. lnstallthe dowel pins and toroue controldifferential case. TOROUECONTNOL 6x1.0mm 12 N.m 11.2tgf m,8.7lbt.ftl
CLUTCHGUIDE
CLUTCHHUA/PLATES/
Dtscs
8.
Installthe c l u t c hg u i d ea n dt h e 3 0 m m s h i m .
9.
A p p l y l i q u i d g a s k e tt o t h e s e a l i n gs u r f a c eo f t h e t o r q u e c o n t r o l d i f f e r e n t i a lc a s e ,a n d n o t e t h e s e rlems: . Use liquidgasket(P/N08718- 0001). . Removeany dirt or fluid from the sealing surface. . lf 20 minutes have passedafter applying liquid gasket,reapplyit beforeyou assemblethe housings. Allow it to cure at least 30 minutes after assemblybeforefilling differentialwith fluid.
11. Installthe companionflange,O-ring,back-upring, discspringwasher,and the locknut. NOTE:Apply CW fluid to the O-ring. ,24mm DISCSPRINGWASHER, 2a mm
TOBOUE CONTROL DIFFERENNAL
@+-_alcr-upnwc
/r-
lnstallin this direction.
K@#/ COMPANIONFLAI{GE
---
15-24
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Apply liquidgaskot
1 2 . I n s t a l tl h e s p e c i a tl o o l s t o t h e c o m p a n i o nf l a n g e , then tightenthe locknutto specifiedtorque.
14. lnstallthe breathertube.
TOROUE:118N.m (12.0kgf-m,87lbf'ft) BREATHER TUAE HOLDEBHANDLE 07JAB- @1020A OIL FILI..ERPLUG 47 N.m 14.8kgf.m, 35 tbt frl
WASHENS Replace.
DRAIN PLUG 4? N'm l4.E tgf.m, 35 lbf'ftl I x I .25 mm 32 N'm (3.3kgt m, 24 lbtftl
t5.
Stakethe locknuttab into the groove in the clutch guide.
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Installthedrain plug and the oilfiller plug with wasners.
Driveshafts Special Tools.......... ........... 16-2 Driveshafts Inspection ...................... l6-3 FrontDriveshafts Removal ....16-3 Disassembly ................... 16-5 Reassembly .................... 16-g Installation ..................... 16-17 IntermediateShaft Removal ....16-19 Disassembly ................... 16-19 Reassembly .................... 16-20 Installation ..................... 16-21 RearDriveshafts Removal .... 16-22 Disassembfy ................... 16-22 Reassembfy .................... 16-24 Installation ..................... 16-29 PropellerShaft Inspection . 16-29 RemovaUlnstallation ....16-30
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R€f. No.
o @ \D'
o @ @
T
Tool Number 07JAF- SH20400 07LAD- PW50601 07MAC- S100200 07746- 0010300 07746- 0010400 07746- 0030400 07749- 0010000 07965- SD90100 07xAc - 0010200
o
D€scription Attachment Attachment,40x 50 mm LD. B a l lJ o i n tR e m o v e r , 2 m 8m Attachment,42 x 47 mm Attachment,52 x 55 mm Attachment,35 mm l.D. Driver Suppon Base T h r e a d e dA d a p t e r , 2 4 x 1 . 5m m
arl
!.,
o)
16-2
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Otv 1 'l 1 1 1 1 ,l 'I 1
PageRolsrenca 16-16 16-18 16-4 16-16 1 6 - 1 71, 8 16-17 1 7 ,1 8 16-16 16-7
Driveshafts
Front Driveshafts
Inspection
Removal
Boot Damago Check the boots on the driveshaft for cracks, damago, leakinggrease,and loose boot bands.lf any damagsis found, replacethe boot and boot bands.
1 . Loosenthe wheel nutsslightly.
Looso Splines Turn the driveshaftby hand,and make sure th€ splin€s and joint are not excessivelyloose.lf damageis found, replacethe inboardjoint.
?
Raisethe front of the vehicle,and suppon it with safetystandsin the properlocations(seesection1). Removethe wheel nuts and front wheels.
Twisting or Crscking Make sure the driveshaftis not twisted or crackod. Replaceit if necessary. DRIVESHAFT SPINDLENUT 24 x 1.5mm Replace.
FRONTWHEEL
lf the right driveshaftis to be removed, drain the transmission fluid {sees€ction13or 14).lt is not necessaryto drain the transmissionfluid when the left driveshaftis removed. Lift up locking tab on the spindle nut, then remove the nut, 6.
Removethe self-locking nut and flangebolt, FLANGEBOLT 10 x 1.25mm
SELF"LOCKING NUT 12 x 1.25mm Replace. 7.
Remove the damper fork,
(cont'd)
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16-3
Front Driveshafts Removal (cont'd) Removethe cotterpin from the lower arm ball ioint castlenut, and removethe nut.
12. Pull on the inboardjoint, and removethe driveshaft from the differentialcase or bearingsupportas an assembly.Do not pull on the driveshaft,the inboard joint may come apart. Pull the driveshaftstraight out to avoid damagingthe differentialoil sealor the intermediate shaftouter seal.
07MAC- SLm2m Installa 12 mm hex nut on the ball joint. Makesure the hex nut is flush with the balljoint pin end,or the threadedsectionof the ball joint pin might be damaged by the specialtool.
i0. Usethe specialtool as shown in section'18to separate the ball joint and lower arm, Be caretulnot to apply pendamagethe ball joint boot, lf necessary, etratingtype lubricantto loosenthe ball joint, 1 l . Pry out the driveshaftassemblywith a pry bar, as shown, to force the set ring at the driveshaftend past the groove. Be careful not to damagethe oil sealswhen prying. PRY BAR
16-4
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Left driveshaft: Removethe left driveshaftfrom the bearingsuppon by tapping on the inboard joint of the driveshaft with a olastichammer. BEARINGSUPPORT
Disassembly 13, Pullthe knuckleoutward,and removethe driveshaft inboard joint from the differentialcase or bearing suoDort.
InboardJoint Sid€: 1,
Carefullyclamp the driveshaftin a vise with soft jaws, then remove the set ring from the inboard joint.
2.
Removethe boot bands.Take care not to damage the boot, . lf the boot band is a lockingtab type, pry up the lockingtabs with a screwdriver,and lift up the end of the band. . l f t h e b o o t b a n di s a w e l d e dt y p e o r a l o w p r o f i l e type, carefullycut the boot band with a pair of diagonalcutters. . lf the boot band is a double loop type. lift up the band bend.
KNUCKLE
Locking Tab
DRIVESHAFT
1 4 . Removethe driveshaftoutboardjoint from the front wheel hub usinga plastichammer.
PLASTICHAMMER
SET BING Replace. Welded
DRIVESHAFT
{cont'd)
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16-5
Front Driveshafts Disassembly(cont'd) Double Loop
4,
Mark the rollersand spiderto identifythe locstions of the rollerson the sDider,then removethe rollers. BEARING REMOVER (Commercially available)
DRIVESHAFT DRIVESHAFT
Mark
Removethe circlip, Mark the spider and driveshaft to identify the position ofthe spideron the shaft. 7. Mark each roller and inboard joint to identify the locationsof the rollersand groovesin the inboard joint. Thon remove the inboard ioint on the shop towel. Be careful not to drop the rollers when separatingthem from the inboardjoint.
Removethe spiderusinga bearingremover, Wrap the splines on the driveshaftwith vinyl tape to preventdamageto the bootsand dynsmicdamper,
INBOARDBOOT INBOARDJOINT Checksplinesfor wearor damage. Checkinside bore for wear. Inspectfor cracks.
DRIVESHAFT
DYNAMICDAMPER
q
16-6
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Rsmove the inboard boot and dvnamic d a m p e r . Take care not to damage the boot and d y n a m i c damDer.
DRIVESHAFT
Outboard Joint Side: 1.
L i f t u p t h e t h r e e t a b s w i t h a s c r e w d r i v e r ,t h e n remove the boot bands,Take care not to damage the boot. NOTE: . lf the boot band is a double loop type, lift up the bandbend. . lf the boot band is a welded type, cut the boot band. . l f t h e b o o t b a n di s a l o c k i n g t a b s t y p ep.r y u p t h e tabswith a screwdriver,and lift up the end of the oano.
PAINTMARK
5,
CarefullvclamDthe driveshaftin a vise. THREADED AOAPTER,2iIx 1.5 mm 07xAc - 0010200
EarClamp TAB
EAR CLAMP BAND Replace.
2.
Slidethe outboardboot to the inboardioint side.
Slidehammc..5/8'x lS Throad (Commerically, available) o.
Removethe outboardjoint using a specialtool as shown.
7.
Removethe driveshatttrom the vise
8.
Removethe stop ring from the driveshaft.
DRIVESHAFT
Wipe off the greaseto exposethe driveshaftand the outboardjoint innerrace. Markthe driveshaftat the same positionof the outboardjoint end with paint.
STOPRING Replace.
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Front Driveshafts Reassembly Notetheseitemsduringreassembly . Cleanthe disassembledparts with solvent,and dry them thoroughlywith compressedair. Do not wash the rubber partswith solvent. :Thoroughlypackthe inboardand outboardjoints and both joint bootswith the joint greaseincludedin the new driveshaftset. The'98 Canadamodel andall '99 - 00 modelsusea TPE(Thermoplastic PolyesterElastomer)outboardjoint boot. Usethe ear clamptype boot band in the outboardboot set.
o *4@] .
Greasequantity: Inboard Joint: All models 120- 130 g (i1.2- 4.6 oz) Left inboard joint splines (Al: 0.5 - 1.0 g (0.018- 0.035oz) Outboard Joint: '97 model and'98 USA model 130- 140 g (4.6-,1.9 oz) '98 Canadamodel and all '99 - 0Omodels 140150 g 14.9- 5.3 oz) SETRING Replace.
INBOARO JOINT
LEFTINBOARO JOINT
SPIOER
INBOARDBOOT
-6r
(Al SPLINES:
P a c kc a v i t y w i t h g r e a s e .
wtn grease. BANDS DYNAMICDAMPER
STOPRING Replace.
OUTBOARDBOOTITPE)*I
-611 -/
DOUELE
BAND+'
Replace.
Pack cavity with grease. EARCLAMPBAND*1
Replace.
__G1 P a c k c a v i t y wrtn grease.
OUTBOARDBOOT*' (RUBBERI
-Grj Pack cavity wtrn grease.
16-8
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*l: '98 Canadamodels,all '99-00models *2: '97- 98 models(except'98Canadamodel)
Inboard Joint Side: 1.
5.
Wrap the splineswith vinyl tape to preventdamage to the boot and dynamicdamper.
DRIVESHAFT
\
Fit the rollersto the spider. NOTE: . Reinstallthe rollersto their originalpositionson the spiderby aligningthe marks. . Hold the driveshaft pointed up to prevent the rollersfrom fallingoff.
,..',NYL rAPE
F
uu.oa.Dsoo. V6
,",^_Y,C@ I n s t a l lt h e i n b o a r d b o o t t o t h e d r i v e s h a f t ,t h e n removethe vinyl tape.Takecare not to damagethe boot. Installthe spideronto the driveshaftby aligningthe markon the spiderand the end of the driveshaft.
@+-crncr-rr
4.
Packthe inboardjoint with the joint greaseincluded in the new driveshaftset, Greasequantity: 120- 130 g {4.2- 4.6 oz) Left inboad ioint splines@:0.5 - 1.0 g (0.018- 0.m5 ozl
F i t t h e c i r c l i p i n t o the driveshaft groove. Always rotatethe circlipin its grooveto makesure it is fully seated.
(cont'd)
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16-9
Front Driveshafts Reassembly {cont'd) 7.
Left: 508 - 513 mm 120- 2O.2inl
Fit the inboard joint onto the driveshaft,and note theseitems: Reinstallthe inboardjoint onto the driveshaftby aligningths markson the inboardjoint with the markson the rollers. Holdthe driveshaftso the inboardjoint pointsup to prevent it from falling off.
Right: AT model 520 - 525 mm {20.5- 20.7 in) MT mod6l 515 - 520 mm (20.3- 20.5 inl
I
/,?:..{ t
\
Sptine airection
lffi t Y l :\
ROLLERHOLDER
I
-flm+dm@
/€\
9.
Positionthe dynamic damper to the specifications as snown. Left:299.5t 2 mm 111.8r O.l inl Right:299.5t 2 mm 111.810.1inl
Adjustthe lengthof the driveshaftsto the specifications shown. then adjustthe boots to halfway betweenfull compressionand full e)dension.Make surethe endsof the bootsseat in the groovesof the driveshaftand Ioint.
OUTBOAROJOINT
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16-10
10. Set the double loop band onto the boot or dynamic damper with the band end toward the front of the vehicle.
OOUBLELOOPBAND
1 3 . Threadthe free end of the band through the nose sectionof a commerciallyavailableboot band tool (KD-3191 o r e q u i v a l e n t )a. n d i n t o t h e s l o t o n t h e winding mandrel. '14. Place wrench a on the winding mandrelof the boot b a n d t o o l . a n d t i g h t e nt h e b a n d u n t i l t h e m a r k e d spot on the band meetsthe edgeof the clip.
BOOTBANDTOOL (KD-3191 or equivalentl
Markon band.
WINDING MANDREL
11. Pull up the slackin the band by hand. 12. Make a mark on the band 10 - 14 mm (0.4- 0.6 in) from the clip. CLIP
1 5 . Lift up 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 clip.
HAMMER
(cont'd)
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1 6 - 11
Front Driveshafts (cont'd) Reassembly 16. Unwind the boot band tool. and cut off the excess free end of the band to leavea 5 - 10 mm (0.2- 0.4 in) tail protrudingfrom the clip.
Outbosrd Joint Sids: 1.
Wrap the splineswith vinyl tape to preventdamage to the boot.
5 - 1 0m m 10.2- 0.4 in,
OUTBOARDBOOT
VINYLTAPE
1 7 . Bendthe band end by tappingit down with a hammer, NOTE; . Makesurethe band does not move, . Removeany greaseremainingon the surrounding surfaces.
2,
I n s t a l lt h e b o o t b a n d a n d o u t b o a r d b o o t , t h e n removethe vinyl tape.Takecare not to damagethe boot.
3.
Installthe stop ring into the driveshaftgroove.
DRIVESHAFT
18, Installthe new set ring.
16 -1 2
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4.
lnsertthe driveshaftinto the outboardioint until the stop ring is closeon the joint.
6.
DRIVESHAFT
Checkthe alignmentof the paint markwith the outboardjoint end.
DRIVESHAFT
1. To completelyseat the outboardjoint, pick up the driveshaftand joint. and drop them from about 10 cm (4 to 5 inches)onto a hard surface,Do not use a hammeras excessiveforce may damagethe driveshaft.
Packthe outboardjoint with the joint greaseincluded in the new joint boot set. Greasequantity: Outboard ioini: '97 model and '98 USA model 130- 140 g {,1.6- ,0.9oz} '98 C8n8d8modsl 8ndall '99- 00 models ll0 - tso g {i1.9- 5.3 ozl
DRIVESHAFT
i/,,,t|:l,r;;:,:.'i,,1;'/l (cont'd)
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1 6 - 13
Front Driveshafts Reassembly(cont'd) 8. Fit the boot ends onto the driveshaftand outboard lornt. OUTBOARDBOOTfiPE)
11. Closethe ear portion of the band with a commercially availableboot band pincersKENT-MOORE J-35910or equivalent.
OUTBOARD BOOT
OUTBOARDBOOT BOOTBAND PINCERS KENT.MOORE J-35910 or equivalent
OUTBOARD JOINT Installthe boot bands, . F o r a l l ' 9 7 m o d e l sa n d ' 9 8 USA models, go to step 13. . For'98 Canadamodelsand all '99 - 00 models, go to step 10. 10. Set the ear clamp band by threadingthe tab into the holesof the band.
EARPORTION
12. Checkthe clearancebetween the closed ear Dortion of the band, lf the clearanceis not within the standard,closethe ear portionof the bandfurther.
6.0 mm 10.24in) MAX
3.0mm {0.12in} MAX
16 -1 4
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13. Fit the boot ends onto the driveshaftand the outboardjoint.
1 5 . Pull up the slackin the band by hand. 1 6 . Mark a positionon the band 10 - 14 mm (0.4- 0.6 in.)from the clip.
CLIP
14. Fit the doublelooDboot bandsonto the boot ends 1 7 . Threadthe free end of the band through the nose sectionof a commerciallyavailableboot band tool (KD-3191 o r e q u i v a l e n t la, n d i n t o t h e s l o t o n t h e winding mandrel. BOOTBANDTOOL (Commercially available) or equivalent KD-3191
Mark spot.
(cont'd)
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16-15
Front Driveshafts (cont'dl Reassembly 1 8 . Placea wrenchon the winding mandrelof the boot b a n d t o o l , a n d t i g h t e nt h e b a n d u n t i l t h e m a r k e d spot on the band meetsthe edgeof the clip. 1 9 . Lift up the boot band tool to bend the free end of the band90" to the clip. Center-punch the clip,then fold over the remainingtail onto the clip.
21, Bendthe bandby tappingit down with a hammer. N O T E :M a k e s u r e t h e b a n d a n d t h e c l i p d o e s n o t i n t e r f e r ew i t h a n y t h i n g ,a n d t h e b a n d d o e s n o t m o v e , R e m o v ea n y g r e a s er e m a i n i n go n t h e s u r roundingsurfaces. BAND END
CLIP
20. Unwind the boot band tool. and cut off the excess free end of the bandto leavea 5 - 10 mm (0.2- 0.4 in) tail protrudingfrom the clip.
16-16
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Front Driveshafts lnstallation 1.
Installthe outboardioint into the knuckle.
4.
KNUCKLE
Cleanthe areaswhere the driveshaftcontactsthe differentialthoroughly with solvent or carburetor c l e a n e r ,a n d d r y w i t h c o m p r e s s e da i r . I n s e r tt h e inboardend of the driveshaftinto the differentialor 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 g l o c k s i n t h e groove. INBOARD JOINT
INBOARDJOINT
Replace.
OUTBOARDJOINT
Apply0.5- 1.0g (0,02- 0.04oz)of specifiedgreaseto the whole sDlinedsurfaceof the intermediateshaft. After applyinggrease.removethe greasefrom the splinedgroovesat intervalsof 2 - 3 splinesand from the set ring groove so air can bleed from the inboard ioint. SETRING Replace.
5.
lnstallthe knuckleon the lower arm. Be careful not to damagethe ball joint boot. Wipe off the greasebefore tighteningthe nut at the ball joint.Torquethe castle then tightenit nut to the lower torque specification. only far enoughto alignthe slot with the pin hole.Do lnstalla new cotterpin. not alignthe nut by loosening.
SET RING
Installa new set ring onto the driveshaftor intermediateshaftgroove.
CASTLENUT 12 x 1.25mm 49-59Nm (5.0- 6.0 kgl'm, 36 - 4:l lbl.ft)
COTTERPIN Replace. On reassembly, bendthe cotterpin
(cont'd)
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16-17
Front Driveshafts Installation{cont'd} Installthe damperfork 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 damperfork. FLANGE BOLT 10x 1.25mm € N.m{4.i1kst.n,32lbf.ftl ALtcNtNGTAB
IntermediateShaft Removal 1 . Drainthe transmissionoil or fluid (seesection13 or 14). Removethe left driveshaft(seepage16-3). Removethe threedowel bolts.
12x 1.25mm 64 N.m {6.5 kgf.m, 47 lbf.ftl Replace. 7. Loosely install the flange bolts and the new selflocking nut. 8. Apply oil to the seating surface of the new spindle nut. FRONTWHEEL
i
WHEELNUT 12 x 1.5mm 108N.m (11.0kgf.m,80lbf.ftl
Removethe intermediateshaft from the differential. Holdthe intermediateshaft horizontaluntil it is clearof the differentialtopreventdamageto the differentialoil seal.
INTERMEDIATE SHAFT
SPINDLENUT 24 x 1.5mm 245 N.m {25.0ksf.m, 181 lbf.ft)
NOTE:Attertightening. usea driftto stakethespindle nutshoulder against thedriveshaft. 9. Installa new spindlenut,then tightenthe nut. 10. Cleanthe mating surfacesof the brakedisc and the wheel. then install the front wheel with the wheel nuts, 1'1. Tighten the flange bolts and the new setf-locking nut with the vehicle'sweight on the damper. 12. Refillthe transmissionwith recommendedfluid (see section13or 14). 13. Checkthe front wheel alignment.and adjust if necessary(seesection 18).
16-18
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Disassembly NOTE:Be carefulnot to damagethe metal rings on the intermediateshaftduringdisassembly.
6.
shaft bearingout of the bearPressthe intermediate ing supportusingthe specialtoolsand a press
'1. Removethe set ring.
ORIVER 07749- 001q)00 FLOATINGRUBBER DAMPER Checkfor deterioration ano oamage,
SEAL OUTER RePlace
ATTACHMENT, tl2x 17 mm 07745- 0010300
SET RING Replace.
Removethe intermediateshatt outer seal from the bearingsupport. Removethe e)dernalcirclip. 4.
Pressthe intermediateshaft out of the shaft bearing usingthe specialtoolsand a press. Press
INTERNALCIRCLIP
+
ATTACHMENT o?JAF_ SH20it00
o
SHAFT INTERMEDIATE Checklor damage. 5.
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Remove the internal circlip.
16-19
IntermediateShaft Reassembly Notetheseitemsduring reassembly: . Cleanthe disassembledparts with solvent,and dry them thoroughlywith compressedair. Do not wash the rubber partswith solvent. . Be carefulnot to damagethe metal ringson the intermediate shaftduring reassembly.
DOWELEOLT 10 x 1.25mm 39 N.m 14.0kg'tm, 29lbf.ft)
BEARINGSUPPORTRING
EXTERNALCIRCLIP
Packthe interior of the outerseal. 2.0-3.5 g {0.07-0.r2 oz}
INTERMEDIATE SHAFTRING
INTERNALCIRCLIP
BEARINGSUPPORT
'L
Pressthe intermediateshaft bearinginto the bearing supportusingthe specialtools and a press. Prcss
t
OUTERSEAReplace.
Seat the internal circlip in the groove of the bearing support. Press
I
W-L!
SHAFT INTERMEDIATE
ATTACHMENT, 52x55mm 07746- 0010400
ATTACHMENT.35 mm l.D. 07746- 0030400 Pressthe intermediateshaft into the shaft bearing usingthe specialtools and a press.
16-20
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lnstallation Seatthe externalcirclip in the groove of the intermediateshaft.
4.
1.
Press
+ Packthe interior of the outerseal. 2.0- 3.59 {0.07- 0.12oz)
DRNER
07749- 0010000
Cleanthe areaswhere the intermediateshaft conthoroughlywith tactsthe transmission(differential) solvent or carburetorcleaner,and dry with compressedair. Insen the intermediateshaft assembly into the differential.Holdthe intermediateshaft horizontalto preventdamageto the differentialoil seal.
INTERMEOIATE SHAFT
ATTACHMENT, 52x55mm 07746- 0010400
OUTERSEAL
EXTERNAL CIRCLIP
ATTACHMENT. 40 x 50 mm l.D. 07LAD- PW50601
Installthe outer seal into the bearingsupportusing the specialtools. The seal should be flush with the bearingsupport. 6.
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shaft I n s t a l lt h e n e w s e t r i n g i n t h e i n t e r m e d i a t e groove.
2.
Installthe three dowel bolts,then torquethem.
OOWELBOLTS 10x 1.25mm 39 N.m {4.0kgf.m,29 lbtftl
16-21
RearDriveshafts Removal
Disassembly
't. Loosenthe rear wh€el nuts slightly. Raisethe rear of the vehicle,and support it with safety stands in the proper locations(seesection 1), Removethe wheel nuts and rearwheets.
NOTE: a Due to the amount of work requiredto replaceone damaged boot, it is best to replace both boots at the sametime. . Theseinstructionsare for the inboardjoint.The same procedureappliesto the outboardjoint. 1,
Removethe set ring from the inboardjoint, BOOTBAND Replace.
SPINDLENUT 22 x 1.5mm Replace.
WHEELNUT 1 2x 1 . 5m m
INBOARDJOINT
2.
Removethe boot band. -
4.
L i f t u p t h e l o c k i n gt a b o n t h e s p i n d l e n u t . t h e n removethe nut. Remove the rear driveshaftsfrom the rear differential assembly(seesection15), Removethe rear driveshaft outboard joint from the trailingarm and rear hub usinga plastichammeror a puller if necessary.
OUTBOARDJOINT
16-22
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TRAILINGARM
lf the boot band is a double loop type, raisethe band bendas shown,
DOUSLELOOPBAND Replace.
3.
Mark each roller and inboard joint to identify the locationsof rollersand groovesin the inboardjoint. Then removethe inboardjoint on the shop towel. INBOARDJOINT Checksplinesand driveshaftring for wearor damage, Checkinsideborefor wear. Inspect{or cracks,
RING DRIVESHAFT
8. Wrap the splineson the driveshaftwith vinyl tapeto preventdamageto the boots.
INEOARDBOOT Inspectfor cracking, splittingand wear.
M.rks
DRIVE SHOPTOWEL Marks
Markthe rollersand spiderto identifythe locations of the rollerson the sgider,then removethe rollers,
Remove the boot band and boot from the driveshaft. Take care not to damagethe boot.
1 0 . Removethe vinyl tape. ROLLER
DRIVESHAFT
'11. Inspectthe driveshaftfor damageand otherfaults.
0\
tI
Mark
CIRCLIP
Removethe circlip. Mark the spider and driveshaftto identifythe position of the spideron the shaft. 7.
Removethe spiderusinga bearingremover.
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16-23
RearDriveshafts Reassembly Notetheseitemsduring reassembly: . Cleanthe disassembledparts with solvent,and dry them thoroughlywith compressedair. Do not wash the rubber partswith solvent, o r''..@El:
Thoroughlypackthe inboardjoint and both joint bootswith the joint greaseincludedin the new driveshaft set.
Greasequantity: fnboard Joint/Outboard Joint: 80 - 90 g 12.8- 3.2 ozl
SETRING Replace.
LEFTINBOARDJOINT (withsmalldriveshaftring)
\@
CIRCLIP
BOOTBANOS Beplace.
DRIVESHAFT RINGS
DRIVESHAFT
RIGHTINBOARDJOINT (withlargedriveshaftring) Packcavity with grease.
BOOTBANOS Replace. ROLI.ER
.6{
Pack cavity with grease.
16-24
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OUTBOARDJOINT
'1. Wrap the splineswith vinyl tape to preventdamage to the boots.
6.
Reinstallthe rollersto their originalpositionson the spider by aligning the marks.After installation,make sure to hold the driveshaftpointed straight up to prevent the rollersfrom fallingoff.
ROLLER
VINYLTAPE
lnstallthe boots onto the driveshaft,and seat the smallend of the bootsinto the grooveson the driveshaft,lf the smallendsof the bootsare not seatedin t h e g r o o v e s ,t h e b o o t l e n g t h a d i u s t m e n tw i l l b e rncorrect. Removethe vinyl tapefrom the end of the driveshaft.
7.
Packthe joint and the boot with the joint grease includedwith the new boot. Greasequantity: 80 - 90 s {2.8- 3.2 o2)
Installthe spideronto the driveshaftby aligningthe mark on the spiderwith the mark on the end of the driveshaft.
lnstalla new circlip into the end g.oove on the driveshaft. Rotatethe circlip in its groove to make sure its fullv seated. (cont'd)
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16-25
RearDriveshafts (cont'd) Reassembly 8.
Installthe joint by holdjngthe driveshaftstraightup and aligningthe markson the joint with the marks on the rollers,
9.
Adjustthe positionof the jointsto the specifications shown. then adjustthe boots halfwaybetweenfull compressionand full extension.Makesurethe ends of the bootsare seatedin the groovesin the joints.
10. Set the double loop band onto the boot with the bandend towardthe front of the vehicle,
1 1 . Pull up the slackin the band by hand. Inboard ioint l€ngth: 153- 157mm {6.02- 6.18inl
12. M a k ea m a r ko n t h e b a n d 1 0 - 1 4 m m ( 0 . 4- 0 . 6 i n ) from the clip.
CLIP
Outboard ioint l6ngth: l/l:' - 147 mm {5.63- 5.37 in}
16-26
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1 3 . Threadthe free end of the band through the nose sectionof a commerciallvavailableboot band tool (KD-3191 o r e q u i v a l e n t )a, n d i n t o t h e s l o t o n t h e winding mandrel, 1 4 . Placea wrench on the winding mandrelof the boot band tool, and tighten the band until the marked spot on the band meetsthe edgeof the clip.
BOOTBANDTOOL (KD-3191 or equivalent)
16. Unwind the boot band tool, and cut off the excess free end of the band to leavea 5 - 10 mm (0.2- 0.4 in) tail protrudingfrom the clip.
5-10mm (0.2- 0.4in)
Markon band.
WINDING MANDREL
Lift up the boot band tool to bend the free end of the band 90 degreesto the clip, Center-punchthe clip,then fold overthe remainingtail onto the clip.
HAMMER
17. Bendthe band end by tapping it down with a hammer. NOTE: . Makesurethe banddoes not move. . R e m o v ea n y g r e a s er e m a i n i n go n t h e s u r r o u n d i n g surfaces.
(cont'd)
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16-27
RearDriveshafts (cont'd) Reassembly
lnstallation
18. Installthe new set ring into the driveshaftgroove.
'1. lnstall the outboardjoint into the trailingarm.
SETRING Replace.
ICI SET RINGGROOVE
Installthe rear driveshaftsinto the rear differential assembly(seesection15). Apply a small amount of engine oil to the seating surfaceof the new spindlenut.
WHEELNUT 12x 1.5mm 108N.m (11.0kgt.m,80lbtftl
SPINDLE NUT22 x 1.5mm 181 N.m (18.5kgf.m, 134lbl.ftl Replace.
Installa new spindlenut, then torquethe nut. After tightening,usea driftto stakethe spindlenut shoulder againstthe driveshaft. Cleanthe mating surfacesof the brakedisc and the wheel, then install the rear wheel, and torque the wheel nuts.
16-2A
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PropellerShaft Inspection UnivarsalJoint and Boots
PropellorShaft Runout
1.
Shiftthe transmissionto Neutral.
6.
Installa dial indicatorwith its needleon the centerof No, 1 or No.2 propellershaft.
2.
Raisethe vehicleoff the ground,and supportit with safetystandsin the properlocations(seesection1).
7.
Turn the other propellershaft slowly and checkthe runout.Repeatthis procedurefor the other propeller shaft.
3.
Checkthe cente.supportbearingfor excessiveplay or rattle.It the centersupporthas excessiveplay or raftle,replacethe propellershaftassembly.
No. 1 PropellerShaft Runout: ServiceLimit: t.5 mm (0.06in)
No.1 PROPET_LER SHAFT Checkthe universaljoint boots for damageand deterioration.lt the boots are damagedor deteriorated, replacethe propellershaftassembly.
No. 2 PropellerShaft Runout: ServiceLimit: 1.5 mm {0.06inl
Checkthe universaljoints for excessiveplay or rattle. lf the universaljoints have excessiveplay or rattle, replacethe propellershaftassembly.
lf the runout on either oroDellershaft exceedsthe servicelimit, replac€the propellershaftassembly.
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16-29
PropellerShaft RemovaUlnstallation 1,
Removethe propellershaftprotectors.
4,
Removethe centersupportbearingmountingbolts.
No. 1 PROPELLER SHAFT
SHAFT PROPELLER PROTECTOR
FLANGEBOLT I x 1.25 mm 22 N.m (2.2kg{.m. 16lbl'ft) SHAFT No. 2 PROPELLER
FLANGEBOLT 8 x 1.25mm 22 N.m 12.2kgf.m, 16lbf.ft)
SELF-LOCK|NG BOLT 10x 1.25mm 39N'm14.0kg{.rn,29lbtftl Replace.
Mark the No. I propellershaft and transferassembly acrosstheir jointsas shown. o.
PNOPELLER SHAFT PROTECTOR 2.
uErrrEnDurrr.r'rI I'EAnrNu
Mark the No. 2 propellershaft and rear differsntial acrosstheirjointsas shown.
Removethe four 12-pointbolts, and remove the No. 1 propellershaft from the transferassembly,
No. 'l PROPELLER SHAFT
Removethe four 12-pointbolts. and remove the No. 2 propellershaft from the rear differential.
No.2 PROPELLER SHAFT
12.POINTBOLT 8 x 1.25mm 32 N.m 13.3kst m, 24 lbtftl
12.POINTBOLT 8 x 1.25mm 32 N.m 13.3kgt'm, 2,1lbf.ft)
7. REARDIFFERENTIAL
16-30
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TRANSFER ASSEMBLY
Installthe propellershafts in the reverseorder of removal.Make sure to align the marks on the prop€ller shafts with the marks on the rear differential and the transferassemblv.
Steering SpecialToofs ............. 17-2 *SteeringColumn ComponentLocations Removal/lnstallation ................ .......17-2O Index................ .......17-3 lnspection .............. 17-21 Troubleshooting SteeringLock Replacement............ 17-22 GeneralTroubleshooting................ 17-4 Power Steering Hoses,Lines Noiseand Vibration......................... 17-8 FfuidLeakageInspection................. 17-23 FluidLeaks ............. 17-10 Repfacement ..........17-23 Inspection and Adiustment Power SteeringPump SteeringOperation.......................... 17-12 Repfacement ..........17-24 Power Assist Check Disassembly ...........17-25 With VehicleParked.................... 17-12 fnspection .............. 17-26 SteeringLinkageand Gearbox .......17-13 Reassembly ............ 17-28 Pump Belt 17-14 Power Steering Gearbox RackGuideAdjustment................... l7-15 Removal ................. 17-31 FluidRep|acement...................,,.,.... 17-15 Disassembly ...........17-34 PumpPressure Check.................,,... 17-16 Reassembly ............ 17-40 *SteeringWheel Ball Joint Boot Replacement..........17-50 Removal ................. 17-18 Installation ............. 17-51 Disassembly/Reassembly............... 17-18
4'%/b
.......... -r'-7--a/
SUPPLEN\EN\AL RES\RA(N\ SYSTES{\(SRS\ This model has an SRSwhich includesa driver'sairbagin the steeringwheel hub. a passenger's airbagin the dashboard abovethe glove box ('97 - 00 models),and seat belt tensionersin the seat belt retractors('98 - 00 models).Information necessaryto safelyservicethe SRSis includedin this ServiceManual.ltems markedwith an asterisk(*) on the contents pageinclude,or are locatednear,SBScomponents.Servicing.disassembling or replacingtheseitemswill requirespecial precautionsand tools,and shouldonly be done by an authorizedHondaoearer.
To avoid rendering the SRS inoperative, which could lead to peFonal iniury or death in the event of a sevore trontal collision. allSRS servicework must be performod by an authorized Honda dealer. lmproper service procedurgs, including incorrect removal and installalion of the SRS, could lead to personal iniury causedby unintontional deployment of th€ airbags {'97 - 00 models),and seat belt tensioners ('98 - 00 modelsl. Do not bump the SRS unit. Otherwise, the system may lail in case ot a collision, or the airbags may deploy when the ignition switch is ON (lll. SRS electricalwiring harnessesare identitied by yellow colof coding. Ralatedcomponents are located in the steering column, front console,dashboard,dashboard lower panel, and in the dashboardabove the glove box. Do not use electrical test equipment on these cilcuits, www.emanualpro.com
Ret. No,
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Tool Numbel 07GAF- PH70100 07HAG- SF10100 07GAG- SD40200or - SD4O2OA OTGAG 07JGG 001010A 07MAC- S100200 OTNAD_ SR3O2OA 07NAG SR30900or 07NAG, SR3OgOA 07RAK- 5040110 07RAK- 5040120 07406- 0010001or 07406- 0010004 07725- 0030000 0 7 7 4 6- 0 0 1 0 1 0 0 07749- 0010000 07916- SA50001 07974- SA50200or 07974- SA5050A 07974- SA50800
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Description
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PilotCollar PistonSealRingGuide PistonSealRingSizingTool
1 1
11-39 17-44 11-44
BeltTensionGauge B a l lJ o i n tR e m o v e r , 2 m 3m CylinderEndSealRemoverAttachment ValveSealRingSizingTool
1 1 1 1
1 7- 1 4 't]-31 17-37 't7-4'l
P/SJoint Adaptor(Pump) P/SJoint Adaptor(Hose) P/SPressureGauge
1 1 1
1 7 - ' t 61, 7 1 7 - 1 61, 7 11-16,17
UniversalHolder Attachment,32 x 35 mm Driver LocknutWrench,40 mm SleeveSealRingSizingTool
1 1 1 ,l
17-26,30 't]-42,43 't1-42, 43 11-15 't]-42
1
BallJoint BootClip Guide @ * Includedin the BeltTensionGaugeSet 07TGG- 001000,4
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17-2
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ComponentLocations lndex Notetheseitemsduringdisassembly: ' lf an intactairbagassemblyhas been removedfrom a scrappedvehicleor has beenfound defectiveor damagedduring transit,storageor service.it shouldbe deployed(seesection24), a Beforeremovingthe gearbox,removethe driver.sairbagassemblyand steeringwheel. . After installingthe gearbox,checkthe wheelalignmentand adjustif necessary. SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,and proceduresanthe SRs section(24)beforeperformingrepairsor servrce. STEERINGWHEEL Removal,page17,18 Disassembly/Reassembly, page1?,18 page17-19 Installation, DRIVER'SAIRBAGASSEMBLY Removal/lnstallation, see section24
STEERINGGEARBOX RackGuideAdjustment,page17-15 Removal,page17-31 page17-34 Disassembly, page17,40 Reassembly, page17,51 Installation, VALVEBODYUNIT Overhaul,page17-38
STEERINGCOLUMN page17-20 Removal/lnstallation. pagel7 21 Inspection, page17 22 SteeringLockReplacement, CABLEREEL Removal/lnstallation, see section24
tcNrnoNswtTcH See s€ction23 STEERINGHOSES,LINES Replacement.page l7-23
RESERVOIR page17 15 FluidR6placement. Fluid Leakagelnspection,page 17-23
END BALLJOINT BallJointBootReplacement, page17-50
PumpBeltInspection and Adjustment, pag€ t7-14 PumpPressure Check,page17-16ot 17-1j Replacemont, page17-24 Disassembly,pa96 17,25 Inspection,page 17-26 Reassembly.page17-28
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17-3
Troubleshooting g GeneralTroubleshootin Checkthe followingbeforeyou begin: . Hasthe suspensionbeenmodifiedin a way that would affectsteering? . Are tire sizes,tire varietyand air pressurecorrect? . ls the steeringwheeloriginalequipmentor equivalent? . ls the power steeringpump belt properlyadjusted? . ls steeringfluid reservoirfilledto properlevel? . ls the engineidle speedcorrectand steady?
HardSteering(Checkthe powerassist,see page17-12.lf the forceis over 29 N (3.0kgl 6.6 lbfl, proceedwith this troubleshooting.i
C h e c kt h e p u m p f l u i d p r e s s u r e (seepage17-16or 17-17). Measuresteadystate lluid pressure at idle with the pressurecontrol valve and the shut-offvalve (it so equipped) fullyopen. The fluid pressureshould be 1,500 psi)orless. kPa(15kgf/cm,,213
Abnormalthiid pressure(Iluid pressureis too high)
Checkthe teed and return circuit lines and hose betweenthe gearbox and pump for clogging and deformation.
Normallineand hose
Normal Faultyvalvebody unit
C h e c kt h e p u m p f l u i d p r e s s u r e (seepage17-16or l7-17). Measurepump reliefpressureat i d l e w i t h t h e p r e s s u r ec o n t r o l valve and the shut'off valve lil so equipped) fullyclosed. The fluid pressureshould be 6,900 7,800kPa (70- 80 kgflcm,, 1,000 - 1,140psi).
Reliefpressure too low
Checkthe flow controlvalve(seepage17 26). . Checkthe valv€lor smooth movementin the housing. . Checkthe relief valve for leaks.
Normalreliefpressure
Go to page 17 5
1 7 -4
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Abnormal
Faultypump assembly
Faultyflow control valve
Checkthe force requiredto turn the wheellseepage17 12). Startthe engineand measurethe force requiredto turn the wheel to the right and left.Difference of t h e f o r c e r e q u i r e dt o t u r n t h e wheel to the right and to the left shouldbe 2.9 N (0.3 kgf,0.7 lbt) or less,
Abnormal
Deformed
Not deformed
Faultycylinderlines
Readjust the rackguide (seepage17-15)
AdjustmentOK Normal Bent
I
Faultysteeringgearbox
Compairthe steeringto another alikevehicle.
(cont'd)
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17-5
Troubleshooting (cont'dl GeneralTroubleshooting Assist(excessively lightsteering)at high speed.
Checkthe rack guide for proper adjustment(seepage17-15).
Shockor vibrationwhen wheelis turnedto full lock.
Checkthe rack guide for proper adjustment(seepage17'15).
lf the problemis not correctedby adjustingthe rack guide, adjust t h e f r o n t w h e e l a l i g n m e n t( s e e section18).
Adjustthe rackguide. Rackguideis adiustedproperly.
C h e c kt h e b e l t f o r s l i p p a g ea n d (seepage17-14). adjustas necessary
lf the problemis not correctedby adjustingthe rack guide,replace the gearbox.
Steeringwheelwill not return smoothly.
A a n d B c y l i n d e rl i n e sa r e n o r mal, checkwheel alignment(see section18).
W h e e l a l i g n m e n ti s a b n o r m a l , adjustas needed.
Wheelalignmentis normal. Checkthe steeringwheel operation and power assistcheck(see page 17-121.
l f t h e m e a s u r e m e n tasr e o u t o f s p e c i f a c a t i o n as d , j u s tt h e r a c k guade.
lf the problemis not correctedby adjustingthe rackguide,replace the gearbox,
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Unevenor roughsteering.
Ad,usttherackguide(seepage17-15).
ll the problemis not correctedby adjustingthe rack guide,replace the gearbox.
Beltslippingon pulley.
Adjustthe belttension.Replacethe belt,if necessary(seepage17-14).
ldlespeedlow or erratic.
l f t h e e n g i n es t a l l sw h e n t h e wheel is turnedwhile the vehicle is stopped or moving at low speed,adjustthe idle speed(see section111.
Air in reservoir,or check power steeringtluid level.
Checkpower steeringlluid level.lf the level is excessivelylow check for leaks in the system.Add fluid to the specifiedlevel.
lf fluid levelis OK, checkO-rings a n d s e a l so n b o t h e n d s o f t h e p u m p i n l e t h o s e ,a n d t h e P / S p u m p h o u s i n gm a t i n gs u r l a c e s and drive shaft oil seal for suc tion leaks.Checkthe reservoirfor cracks,Replaceparts as neces-
Steeringwheel kicksback duringwide turns.
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P u m p b e l t s l i p p i n go n p u l l e y (pumpstopsmomentarily).
Adjustthe belt tension(seepage 17-14) or replace belt.
Installthe power steeringpressure gauge, Closethe pressure control valve and shut off valve (if so equipped)fully and measure the pump pressure(seepage 17-16 ot 17 17).
Checkif pump pressureis normal and the gauge needletravel is 500 k P a ( 5 k g l / c m , ,7 1 p s i ) o r l e s s . Checkthe flow controlvalve if the needletravelexceeds500 kPa (5 kgflcm',71 psi). lI the flow control valve is normal, replacethe pump as an assembly,
7-7
Troubleshooting NoiseandVibration NOTE:Pumpnoisein first 2 - 3 minutesafterstartingin cold weatheris normal.
Humming
Rattleor chattering
Humming due to pulsationof fluid is normal, particularlywhen the wheel is turnedwith the vehiclestooDed.
lf equippedwith automatictransm i s s i o n ,t h e h u m c o u l d b e t h e torqueconverteror pump noase.
Confirm by temporarily removing the pump belt.
Feedhose (high-pressure) touching the frame.
Beposition the feed hose.
Loosesteeringshaft connector, tie-rod,or balljoint.
C h e c ka n d t i g h t e n , o r r e p l a c e parts as necessary,
Columnshaftwobbling.
Roplacethe columnassembly.
Checkthe rack guide for proper adjustment(seepage17-15).
Adjust,if necessary.
Rattlingsound and feeling when turning the steeringwheel right and left with th€ engineOFFis normal.
Pump noise,though not loud,from the valvebody unit can be heardwhen turning the steeringwheelto full lockin eitherdirection.This is normal.Do not hold the steeringwheelat full locklor morethan five secondswhen inspecting.
17 -8
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Pumpnoise
Gratingnois€ trom pump
Cavitationcausedby air bubbles in the fluid.
Checkthe fluid lev€1. l t l o w , f i l l t h e r e s e r v o i rt o t h e properlevel.and checkfor leaks. Tightenor roplaceas necessary,
Checkfor a crushedinlet hoseor a loose hose clamp allowing air into the suctionside of the sys t e m . C h e c kt h e r e s e r v o i rf o r cracks.Tighten or replaceas nec-
Checkthe driveshaftoil seal.
Pumpnoise
Raftleor chattering
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Pump noise up to 2 - 3 minutes after starting in cold weather is normal,Comparepump noiseat operatrngtemperatureto another vehicle.
ll pump noiseis abnormallyloud, removeand inspectthe pump for wear and damage(see page 17251.
Tightenor replacethe pulley. l I s h a f t i s l o o s e , r e p l a c et h e pump.
17-9
Troubleshooting FluidLeaks Checkthe gearboxassemblyfor oil leakscarefully.Oil can leakout ot variouspoints,dependingon locationof the faulty oil seals/seal rings.Checkthe followingbeforeremovingthe gearboxfrom the frame.
SteeringGearbox
Leakingfrom the oil seal on the top of the valvehousing.
Replace the valve oil seal from the valve housing.
Leakingfrom cylinder end into left tie rod boot.
Replace the valve oil seal from the pinion shaft.
Replacethe cylinderend seal on the valvebody unit side.
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17 -1 0
Leakingfrom cylinder end into right tie-rod boot.
Replacethe cylinderend seal on the cylinderend side.
Leakinglrom the shaftupperend sectionor pin engagementsection of the pinionshaft.
R e p l a c et h e v a l v e b o d y u n i t .
Leakingfrom cylinderlineA or B (attlarenut). connections
Tightenthe connector.It it's still leaking,replacethe line,cylinder or valvehousing.
L e a k i n gc a u s e db y a d a m a g e d cylinderlineA or B.
Replace cylinderlineA or B.
Leakingfrom pump outlet hose and returnlinejoint fittingon the valvebody unit {attlarenut}.
Tightenthe connector.ll it's still leaking,replacethe line,joint fitting or valvehousing,
B e p l a c et h e h o u s i n g O - r i n g s . if the housing still leaks, replace the pump.
is overfilled. Reservoir P u l l o f f t h e h o s e a n d d r a i nt h e reservoirto the properlevel.
Air leakin suctionsideof the system (reservoir,pump inlet hose, front pump seal).
PumpoLrtlethose (high-pressure)
Pumpinlet hose (low pressure)
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L e a k i n ga t t h e t h r e a d e d f i f t i n g .
Tightenthe fifting. lf it's still leaking, replacethe O-ringor pump outlethose,
Leakingat the swagedjoint.
Replace the pump outlethose.
Leakingbecauseof damage,dete' rioration, or improperassembly,
Replace or repairas necessary.
17-1
Inspectionand Adjustment Steering Operation
PowerAssistCheckwith VehicleParked
Placethe front wheels in the straight ahead position. and measurethe distancethe steering wheel can be turnedwithout movingthe front wheels.
1.
Checkthe power steeringfluid level (see page 1715)and pump belttension(seepage 17-14).
ROTATIONALPLAY:0 - 10 mm (0 - 0.39 inl
2.
lf the play exceedsthe limit, perform rack guide adjustment (seepage17-15). lf the play is still excessiveafter rackguide adjustment, inspectthe steeringlinkageand gearbox as described on the nextpage.
Startthe engine,allow it to idle, and turn the steering wheel from lock-toiockseveraltimes to warm u p t h ef l u i d .
3.
Aftacha springscaleto the steeringwheel,With the engine idling and the vehicleon a clean.dry floor, pull the scaleas shown and read it as soon as the tires beginto turn.
ROTANONALPLAY
+i r
f::1-t
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SPRING SCALE (Commercially available)
The scaleshould read no more than 29 N (3.0 kgf, 6 . 6 l b f l . l f i t r e a d sm o r e , c h e c kt h e g e a r b o xa n d oumo.
17-12
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SteeringLinkageand Gearbox
PINIONSHAFTGROMMET Inspoctfor damageand deterioration.
STEERINGJOINTS Checkfor loosejoint bolts.
NE-RODLOCKNUT CheckIor loose locknut. BALLJONT AOOT Inspoctlor damageand deterioration. S€e page 17-50for replacemont.
Inspectfor loose mounting bolts. GEARBOXMOUNTINGCUSHIONS lnsp6ctfor dgterioration.
BOOT lnspectfor damag€andd€terioration. END AAtL JOINT Inspectfor faulty movement ano oamag€.
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17-13
Inspectionand Adjustment PumpBelt When using a new belt.first adjustthe deflectionor tension to the values for the new belt, then readjustthe deflectionor tensionto the valuesfor the used belt after runningenginefor five minutes.
Measurementwithout Belt Tension Gauge: Apply a force ot 98 N (10 kgf,22 lbt) and measurethe deflectionbetweenthe power steering pump and the crankshaftoullevs.
Inspection
Deflection: UsedBelt:11.0- 1i1.5mm {0.'(l - 0.57in) New Belt: 7.5 - 10.0mm {0.30- 0.39 in)
Notetheseitemsduring inspection: a lf there are cracksor any damageevidenton the belt, replaceit with a new one. . Followthe manufacturer's instructionslor the tension gauge. '1. Remove the P/Sreservoirfrom the bracket,and set it aside. 2.
Measurehere.
Attach the belt tension gauge to the belt with the gaugefacetowardthe engine,and measurethe tension of the belt. Removethe belt tension gauge carefullyto avoid hittingthe gaugeresetlever. PULLEY CRANKSHAFT
Tension: Used Belt: New Belt:
390 - 540 N {40 - 55 kgf, 88 - 121 lbf) 7,[0- 840 N (75 - 90 kgf, 165- 198 lbf)
Adiustment '1.
L o o s e nt h e p o w e r s t e e r i n gp u m p m o u n t i n g b o l t and pump lockbolt. PUMPMOUNNNG BOLT 24 N'm(2.4kgf'm,17lbfftl
PUMPLOCKBOLT 24N.m12.4kgf.m,17lbf.ftl
PULLEY CRANKSHAFT
Adjust the belt tensionby moving the power steering pump with a 1/2" drive breakerbar to obtainthe p r o p e rb e l t t e n s i o n ,t h e n r e t i g h t e nt h e m o u n t i n g bolt and lockbolt. Start the engine and turn the steeringwheel from lock-to-lock severaltimes,then stop the engineand recheckthe deflectionof the belt.
17 -1 4
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RackGuide Adjustment
Fluid Replacement
1 . Setthe wheelsin the straightaheadposition.
Checkthe reseryoirat regularintervals,and add the recommendedfluid as necessary. CAUTION: Always use Gsnuine Honda Power Steering Fluid-V or S. Using any other type of power steering tluid or automatic transmissionfluid can causeincreassd wear and poor steering in cold w3athel. SYSTEMCAPACITY: 0.85 liter {0.90US. qt. 0.75 lmp.qtl at disasssmbly CAPACITY: RESERVOIR 0.,1liter (0.42US. gt, 0.35 lmp.qi)
Loosenthe rack guide screw locknutwith the specialtool,then loosenthe rackguidescrew. For'98 - 00 models,removethe rack guide screw. R e m o v et h e o l d s e a l a n tf r o m r a c k g u i d e s c r e w threadedsection,and apply new sealantto the first three threads.Looselyinstallthe rack guide screw on the steeringgearbox.
RACKGUIDESCREW UPPENLEVELLINE
LOWERLEVELLINE
1 . Raisethe reservoir.then disconnectthe returnhose to drainthe reservoir.Takecare not to spill the fluid on the body and parts.Wipe off any spilledfluid at once.
LOCKNUT 25 N.m 12.5kgt m, 18lbtftl
5.
4.
Tightenthe rack guide screwto 25 N.m (2.5 kgf'm, 18 lbf.ft),then loosenit. R e t i g h t e nt 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 lbf.ft),then back it off to specifiedangle. 2, SpecifiedReturn Anglo: 10 r 5" 37 model: '98 - 00 modeb: 20' Max
3.
T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e screw. 6.
Checkfor tight or loose steeringthrough the completeturningtravel.
7.
Performfollowinginspections: . Steeringoperation(seepage17-12). . Powerassistwith vehicleparked
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4. 5. 6.
7.
Connecta hose of suitablediameterto the disconnectedreturn hose,and put the hose end in a suitablecontainer. Stan the 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 go u t o f t h e h o s e ,s h u t o f f t h e engine.Discardthe fluid. Beinstallthereturnhoseon the reservoar. Fillthe reservoirto the upperlevelline, Startthe engineand run it at fast idle.then turn the severaltimes to bleedair steeringfrom lock-to-lock from the system. Recheckthe fluid leveland add some if necessary. Do not fill the reservoirbeyondthe upperlevelline.
lnspectionand Adjustment PumpPressureGheckWith T/N 07406- 0010001 Checkthe fluid pressureas follows to determinewhether the troubleis in the pump orgearbox. 1.
Checkthe powsr steeringfluid level (see page 1715),and pump belttension(seepage17-14).
2.
Disconnectthe pump outlet hose from the pump outlet with care so as not to spill the pow€r steering iluid on the frame and other pans. thon installthe P/Sjoint adapter(pumplon the pump outlet.
5. Fully open the shut-off valve. PRESSURE CONTROLVALVE
6 x 1.0mm BOLT {Partoftool) FEEDHOSEFITTING
PUMPOUTLETHOSE
11 N.m ll.1 kgl.m, E lbf.ftl P/S PRESSURE GAUGE 07('6 - 0010001 6 x t.0 mm BOLT {Partoftool) 11 N.m (1.1kgt m, 8 lbf.tr)
6. Fullyopenthe pressurecontrolvatve. 7. Startthe engineand let it idle. 8. Turn the steeringwheel from lock-to-lockseveral times to warm the fluid to operating temperature. 9, Measuresteady-statefluid pressurewhile the engine is idling. lf the pump is in good condition,the gauge should read lessthan 1,500kPa(15 kgf/cmr,213 psi). lf it reads high, checkthe outlet hose or valve bodv unit (seeGeneralTroubleshooting). 10. Close the pressure control valve, then close the shut-off valve gradually until the pressuregauge nsedle is stable.Readthe pressure. CAUTION: Do not k€ap tha prca3un control valvo clorod mo.c thon 5 srconds or thc pump cluld bo damEgodby ovor-hoating.
Connectthe P/Sjoint adapter (hose)to the p/S pressure gauge,then connectthe pump outlet hose to the P/Sioint adspter(hose). I n s t a l l t h e P / S p r e s s u r eg a u g e t o t h e p / S j o i n t adapter(pump),
11. lmmodiatelyopenthe pressurecontrolvalvefullv. lf the pump is in good condition,the gaugeshould read at least 6,900- 7,800 kpa (70 - 80 kgflcmr, '1,000- 1.140psi). A low readingmeanspump output is too low for full assist.Repairor replacethe DUMD.
17-1 6
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PumpPressureCheckWith T/N 07406- 001000A Checkthe fluid pressureas follows to determinewhether the troubleis in the pump or gearbox. 1.
Checkthe power steeringtluid level (see page 17151,and pump belttension(seepage 17-14).
2.
Disconnectthe pump outlet hose from the pump outletwith careso as not to spill the power steering fluid on the frame and other parts,then installthe P/Sjoint adapter(pump)on the pump outlet.
5. Open the pressure controlvalve fully.
PRESSURE CONTROLVALVE
6 x 1.0mm BOLT (Partoftool)
FEEDHOSEHfNNG
PUMPOUTLETHOSE
1'l N.m 11.1kgf.m,8lbfft) GAUGE P/S PRESSURE 07406- 001000A 6 x 1.0 mm BOLT (Partol tool) 11 N.m (1.r kg{.m,8lbf'ft|
Startthe engineand let it idle. 7 . Turn the steering wheel from lock-to-lockseveral timesto warm the tluid to operatingtemperature. Measuresteady-statefluid pressurewhile the engine is idling.It the pump is in good condition,the gauge shouldread1,500kPa(15koflcm' ,213psi).lf it reads high. checkthe outlet hose or valve body unit {see GeneralTroubleshooting), Closethe-pressurecontrolvalve graduallyand read the oressure. CAUTION: Do not keep the pressurs control valve closed more then 5 seconds or the pump could bo damaged by overheating.
1 0 . lmmediatelyopenthe pressurecontrolvalvefully. Connectthe P/Sjoint adapter (hose)to the P/S pressure gauge,then connectthe outlet hoseto the P/S joint adapter(hose).
lf the pump is in good condition,the gauge should read at least 6,900 - 7;800 kPa (70 - 80 kgflcm' , 1,000- 1.140psi), A low readingmeanspump outDut is too low for {ull assist.Repairor replacethe oumo.
I n s t a l l t h e P / S p r e s s u r eg a u g e t o t h e P / S j o i n t adapter(pumpl.
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17-17
SteeringWheel Removal SRS componentsare located in this area. Reviewthe SRScomponentlocations,precautions,and procedures in the SRSsection(24)beforeperformingrepairsor service. 1.
Align the front wheelsstraightahead.then remove the driver's airbag assembly(seesection24) from the steeringwheel.
2.
Disconnectthe horn connectorand cruise control switch connectors.
3.
Loosenthe steeringwheel bolt, then install a steering wheelpulleron the steeringwheeland removeit. Notetheseitemswhen removingthe steeringwheel: . Do not tap on the steeringwheel or the steering columnshaftwhen removingthe steeringwheel. . lf you threadthe puller bolts into the wheel hub morethan five threads,the boltswill hit the cable reel and damageit. To preventthis, installa pair of jam nutsfive threadsup on eachpullerbolt. STEERINGWHEELBOLT 39 N.m 14.0kgt.m,29 lbtftl
CONTROL SWITCHESCONNECTOR
STEERINGWHEELEOLT
Disassembly/Reassembly STEERINGWHEEL
EOSSCOVERPLATE
WHEELBODYCOVER
_^M @,
h
"\
BODY COVERCAP ACCESSPANEL
17- 1 8
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lnstallation 1.
Beforeinstallingthe steeringwheel, make sure the front wheelsare alignedstraightahead,then center the cablereel.Do this by first rotatingthe cablereel clockwise until it stops. Then rotate it counterclockwise approximatelytwo turns. The arrow mark on the cablereel labelshouldpoint straightup.
2.
Installthe steeringwheel on to the steeringcolumn shaft,makingsurethe steeringwheel shaftengages the cable reel and cancelingsleeve.Do not tap on the steeringwheel or steeringcolumn shatt when instailingthe steeringwheel
CABLEREEL ARROWMARK
HOLE Installthe steeringwheel bolt, and tighten it to 39 N.m (4.0 kgf.m, 29 lbf.ft). Connectthe horn connectorand the cruisecontrol switchconnectors, Installthe driver's airbag assembly,and confirm propersystemoperation(seesection24).
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17-19
SteeringColumn Removal/lnstallation SRS componentsare located in this area. Review the SRScomponentlocations,precautions,and procedures in the SRSsection(24)beforeperformingrepairsor service.
1.
Remove the driver's side dashboard lower cover and kneebolster(seesection20),
Notetheseitemswhen removingthe steeringcolumn: . Before removing the steering column, remove the driver'sairbag assemblyand cable reel (seesection 24). . Beforeremovingor installing,set the columnshaft in the neutralpositionby pullingup the steeringcolumn to uppermostposition,then lower it 8 mm (5/16in). Tightentilt lever.
Removethe columncovers. With A"/T,move the shift lever to the E position, and removethe shift cable from the column. and set it aside(seesection14). Remove the combinationswitchassemblyfrom the steeringcolumn shaft by disconnecting the connectors, and removing the two screws.
FULLSTROKE: 23 mm 10.9in) MAXIMUMUPPER POSTTTON
Disconnectthe steeringjoint from the enginecompanment.
8 mm (5/16)
7.
MAXIMUM LOWER POSTTTON
Removethe steeringwheel (seepage 17-18).
R e m o v et 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 t h e attachingnuts and bolts.
TILT LEVER SHAFTCENTER
1 1 1m m
1 0 0m m
JOINT COVER
5mm
UPPER COLUMNCOVER
COMAINANONSWITCHASSEMBLY BOOTBAND
9,8 N.m l r .0 kgf.m,7 lbf.fO JOINT DUSTSEAL 22 N.m (2.2kgl.m, 16lbtftl
JOINT COLUMNBMCKET LOWERATTACHINGBOLTS 39 N.m lir,o kgf.m, 29 lbf.ft) UPPERATTACHINGNUTS 16 N.m lr.6 kgf.m, 12 lbf.ftl
17-20
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LOWERCOLUMNCOVER
22 N.m (2.2 kgf.m, 16lbt.ftl
8.
is the reverseofthe removalprocedure. Installation Notetheseitemsduring installation: . Be sure the wires are not caught or pinchedby any partswhen installingthe column. a Make sure the wire harnessis routed and fastened properly. . Make sure the connectorsare properlyconnected. . Make sure the steeringjoint is connectedas follows: a. lnsertthe uDperend of the steeringjoint onto the steeringshaft (line up the bolt hole with the flat ot the shaft). b. Slip the lower end of the steeringioint onto the Dinionshaft (lins up the bolt holewith the groovearoundthe shaft).and installthelower ioint bolt. Be sure that the lower joint bolt is securelyin the groovein the pinionshaft' c. Pullon the steeringjoint to makesurethat the steeringjoint is JullYseated. Then installthe upperjoint bolt and tightenit.
SIEERING JOIMT
UPPERJOINT BOLT Bolt must IineuP with fl6t on shaft. Flatponion. JOINT STECRING
LOWER JOINTBOLT Boltmustlineupwith groovearoundon shaft,
Inspection Checkthe steeringcolumn ball bearingand the steering joint bearingsfor play and proper movement.lf there is noisyor if there is excessiveplay,replacethe steeringcolumn as an assemblY Checkthe retainingcollar for damage.lf it is damaged,replacethe retainingcollar. PLASl'tC INJECTIONS
.
Checkthe absorbingplates,absorbingplate guides and slidingcapsulesJordistortionand breakage. ReDlacethe column as an assemblyif they are distorted or broken. SLIDINGCAPSUII This part is attached to the column bracket with the plastic injections.
ABSOBBING PLATE
FETAININGCOLLAR
SHIFT I.EVER Seesection 14.
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ABSORBING PLATEGUIDE |GNMON SWTTCH See section23.
(cont'd)
17-21
SteeringColumn Inspection(cont'dl
SteeringLockReplacement
1 . Move the tilt lever from the loose position to the l o c k p o s i t i o n3 t o 5 t i m e s ; t h e n m e a s u r et h e t i l t lever preload10 mm (0.4in) from the end of the tilt rever. Preload:70 - 90 N (7 - 9 kgf, 15 - 20 lbf) 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 tollowingprocedures. a. Loosenthe tilt lever,and set the steeringcolumn in the neutralposition.
1 . Bemovethe steering column (see page 17-20). Centerpunchthe shearbolt, and drill bolt head off with a 5 mm (3/16in) drill bit. Removethe shear bolt from the switch body. Be carefulnot to damagethe switchbody when removing the shearbolt. Insertthe ignitionkey and turn it to "1". Push the lock pin down, and pull out the steering lockbody from the steeringcolumn.
b , R e m o v et h e 6 m m l o c k b o l t . a n d r e m o v e t h e stop. Be carefulnot to loosenthe tilt leverwhen installingthe stop or tighteningthe 6 mm lock bolt. NLT LOCKBOLT Tighten the lock bolt with the tilt leverraised.
SPRINGSCALE
SHEARBOLT Replace.
L-_
6 mm LOCKBOLT 7 N.m(0,7kgf.m,S tbtftl Adjustthe preloadby turningthe tilt lockbolt left or ri9ht.
I n s e r t t h e i g n i t i o n k e y t o t h e n e w s t e e r i n gl o c k body,and turn it to "1". 7 . Push the lock pin down, and insen the steering lock body into the steeringcolumn until it clicksinto place. 8 . Looselyinstallthenew shearbolt.
d . Pull up the tilt lever to the uppermostposition.
and installthe stop. Checkthe preloadagain. lf t h e m e a s u r e m e n its s t i l l o u t o f s p e c i f i c a t i o n , r e p e a tt h e a b o v e p r o c e d u r e sa . t h r o u g h c . t o adjust.
Checktor proper operation of the steeringwheel lock,and that the ignitionkeyturns freely. 1 0 . Tightenthe shearbolt untilthe hex headtwistsoff. TWIST.OFF PORNON
SHEARBOLT
1 7- 2 2
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PowerSteeringHoses,Lines Fluid LeakageInspection HOSESand LINES . lnspecthosesfor damage.leaks.interferenceand twisting . Inspectfluid linesfor damage,rustingand leakage. . Checkfor leaksat hoseand line joints and connections. FEEDHOSE 37N.m13.8kgf.m,27lbtft)
RETURNLINEJOINT 28 N.m (2.9kgf.m.21 lbf.ftl
CYLINDERLINES 17 N.m (1.7kgf.m. 12 lbf.ftl FOWERSTEERINGPRESSURE SWITCH 12 N.m (1.2kgf.m,8.7 lbtft)
GEARBOX.nd VALVEBODYUNll Checkfor leaksat the mating surface and flare nut connections.
CYLINDER 26 N.m (2.7 kgf.m, 20 lbf.ft)
FEEDHOSE 11 N.m ('1.1kgt.m, 8 lbf.ftl
SUCTIONHOSE PUMPASSEMBLY Checkfor leaksatthe pump seal.inletand outletfittings.
Replacement Notetheseitemsduring installation: . Connecteachhoseto the correspondingline securely until it contactsthe stop on the line. Installthe clamp or adjustableclampat the specifieddistancefrom the hoseend as shown. . Checkall clamDsfor deteriorationor deformation; replacewith the clampsnew onesif necessary. . Add the recommendedpower steering fluid to the specifiedlevelon the reservoirand checkfor leaks. ADJUSTABLEHOSECLAMP:la) . 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 s a t t h e p o i n t s indicatedby (a) in the drawingabove. . Slidethe hoseoverthe line until it contactsthe stop.
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10.01- 0.22 in)
2.0 - 4.0 mm - 0.16inl 10.08
HOSECLAMP:lbl . Positionthe hose clamps at the points indicatsdby (b) in the drawingabove. . Slidethe hoseoverthe line until it contactsthe stop,
2.5- 5.5mm {0.01- 0.22 in}
17 -23
PowerSteeringPump Replacement 1.
Placea suitablecontainerunderthe vehicle.
7 . Connectthe pump inlet hoseand pump outlethose. Tightenthe pump fittingssecurely.
Drainthe powersteeringfluid from the reservoir.
Looselyinstallthe pump in the pump bracketwith the mountingbolt and lockbolt.
Removethe belt by looseningthe pump mounting bolt and pump lock bolt.
Installthe pump belt. PUMPOU'I.TT HOSE
PUMPMOUNNNG BOI.T 24 N.m12.4kgtm, 17lbl.ftl
11 N.m (1.1 kgf.m, E rbf.ti)
Notetheseitemsdu.ing belt instsllation: . Make sure that the power steering belt is properly positionedon the pulleys. . Do not get power steering fluid or greaseon the power steering belt or pulley faces,Cleanoff any fluid or greasebeforeinstallation
FOWERSTEER G EELT PUTrlY
1 0 . Adiustthe pump belt (seepage17-141. 'l
l. Fill the reservoirto the upper level line (see page
't7-151..
PUMPLOCKBOLT 24 N.m(2.4kg{.m,1, tbfttl Cover the IVC compressorwith several shop towels to protectit from spilledpowersteeringfluid. Disconnectthe pump inlet hose and pump outlet hose from the pump, and plug them. Takecare not to spill the lluid on the body or parts.Wipe off any spilledfluid at once. R e m o v et h e p u m p m o u n t i n gb o l t a n d p u m p l o c k bolt, then removethe pump. Do not turn the steering wheelwith the pump removed. Coverthe openingof the pump with a pieceof tape to preventforeignmaterialfromenteringthe pump.
17-24
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Disassembly Notetheseitemsduringdisassembly: . The powersteeringcomponentsare madeof aluminum,Avoid damagingthe componentsduringassembly. partswith a solvent,and dry them with compressedair. Do not dip the rubber parts in a sol. Cleanthe disassembled vent. . Always replacethe O-ringsand rubbersealswith new ones beforeassembly. . Apply recommendedpower steeringfluid to the partsindicatedin the assemblyprocedures. . Do not allow dust,dirt, or otherforeignmaterialsto enterthe power steeringsystem. . Replacethe pump as an assemblyifthe partsindicatedwith asterisk(*)areworn ordamaged. FLANGEBOLTS 20 N.m 12.0kgt'm, 1a tbf,ft)
.PUMP COVER
ROLLER PUMPCOVERSEAL
*OUTERSIDEPLATE .PUMP CAM RING
*PUMPHOUSING 5l x 2.4 mm O-RING Repiace.
13x 1.9mm O-RING Replace. PUMPSEALSPACER INLETJOINT PUMPDRIVESHAFT FLANGEBOLTS 11 N.m 11.1kgt m, 8 tbf.ft)
PULI.-EY NUT fl N.m (6.5kgf.m, /r7 lbf.ftl
(cont'd)
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17 -25
PowerSteeringPump Disassembly(cont'dl 1 . Drainthe fluid from the pump.
Hold the steering pump in a vise with soft jaws. hold the pulley with the specialtool, and remove the pulleynut and pulley.Be carefulnot to damage the pump housingwith the jaws of the vise.
Inspection Flow Control Valve 1.
Checkthe flow control valve for wear, burrs, and other damageto the edges of the grooves in the valve. '97 model: FLOW CONTROLVALVE
UNIVERSAL HOLDER 07725- 0030000
Checkfor damageto edges.
'98 - 0Omod€ls: FLOWCONTBOL VALVE
Checkfor damage to edges.
Insp€d the bore of the flow controlvalvetor scratches or wear. Slip the valve back in the pump, and checkthat it moves in and out smoothly.lf OK, go to step 4; if not, replacethe pump as an assembly.The flow controlvalveis not availableseparately.
L o o s e nt h e f l o w c o n t r o l v a l v e c a p w i t h a h e x wrench,and removeit.
CONTROLVALVE
Removethe O,ring,flow controlvalveand spring. Removethe inletjoint and O-ring. Removethe pump coverand pump coverseal. 7 . Removethe outer side plate,pump cam ring, pump rotor,pump vanes,side plateand O-rings. 4. Removethe snap ring, then removethe sub-valve from the pump housing.
Attacha hoseto the end of the valveas shown. FLOWCONTROL VALVE
9 . Removethe circlip, then remove the pump drive shaft by tappingthe shaft end with the ptastichammer. 1 0 . Removethe pump sealspacerand pump seal.
17-26
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HOSE
5.
Submergethe valve in a containerof power steering fluid or solvent,and blow in the hose.lf air bubbles leakthroughthe valve at lessthan 98 kPa (1.0kgflcm' ,14.2psi),repairit as follows('97model). For'98 - 00 models,the flow control valve cannot replacethe pump as an assembly be disassembled;
Ball Bearing: '1. Inspectthe ball bearingby rotatingthe outer race slowly. lf any play or roughnessis felt, replacethe b a l lb e a r i n g .
AIR PRESSURE BALLEEARING
POWERSTEENING FLUIDor SOLVENT
6.
For'97 model only, hold the bottom end of the valvewith a open end wrench.Unscrewthe seatin the top end of the valve,and removeany shims,the relielcheckball,reliefvalveand reliefvalvespring.
2.
Replacethe ball bearingusinga press.
RELIEF ALVE RELIEFCHECKBALL
{w@r
Remove
lnstall Press
I Press
SEAT 9 N.m (0.9kgf.m, 6.5 lbfft)
I
RELIEFVALVE SPRING Hold this end with a open eno wrencn.
7.
FLOWCONTBOLVALVE
C l e a na l l t h e p a r t s i n s o l v e n t ,d r y t h e m o t f , t h e n reassembleand retestthe valve. T h e r e l i e f p r e s s u r ei s a d j u s t e da t t h e f a c t o r y b y addingshims underthe checkball seat lf you found shims in your valve,be sure you reinstallas many as you took out.
8,
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lnstallwith the r e d s h a e l d e ds i d e facing down.
NOTErSuPPortthe innerrace with the tool securelY-
lf the flow control valve tests OK, reinstallit in the pump. It the flow controlvalvestill leaksair, replace the pump as an assembly.The flow controlvalve is not availableseparately.
17-27
PowerSteeringPump Reassembly '1.
Align the pin of the sub-valvewith the oil passage in pump housing,and push down the sub-valve. Installthe snsp ring properly.
5.
Coatthe pump coversealwith power steeringfluid, and installit into the groovein the pump cover.
OIL PASSAG€ Alignthe pin of
ROLLERSET HOLES
the oil passage.
OUTERSIDEPLATE
#q ;1..*
5 mrh ROLLER
\
PUMPHOUSING
SNAP RING
Installthe new pump seal(with its groovedside facing in) into the pump housingby hand,then install the pump sealspacer.
PUMPCOVER
Positionthe pump drive shaft in the pump housing, then drive it in usinga 29 mm socketas shown,
H go
29 mm SOCKET
lnstallthe oute. side plateoverthe two rollers. PUMPCAMRING
,O mm CIRCLIP
un.t SHAFT BALLBEARfNG /=\ PUMPDRIVE grlu,e
/
1 /\
t\v4
t/\ Y ry^\i- d #
ROLLERSET HOLES
/ffi\
I
PUMP SEALSPAC,ER
F
@.--#$i":*' ROLLERS
PUMPHOUSING
4,
Installthe 40 mm circlipwith its radiusedside facIng out.
17 -2A
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7.
Set the pump cam ring over the two rollerswith the "' " markon the cam ring upward.
12. Coatthe O-ringwith power steeringfluid, and position it into the pump housing.
8. Asssmble pump rotor to the pump cover, 9. Set the 10 vanes in the groovesin the rotor, Make surethat the round ends of the vanesare in contact with the slidingsurfaceof the cam ring.
FLANGEBOI-TS 20 N.m (2.0kgt m, 14 tbf.ft)
PUMPROTOR
51 x 2.4 mm O-RING Replace.
1 3 . lnstallthe pump cover assemblyin the pump housing.
1 0 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d installit into the groovesin the side plate.
1 4 . Coat the tlow control valve with power steering fluid. FLOWCONTROL VALVE 137modol)
Eg
SPRING
I
SII'E PLATE
15.2x 2.4 mm O.RING ('97 modell 16.7x'1.8mm O-RING
15.2 x 2-1 ftm GRING Replace. ROL1IR SET HOI,E
Gfooves.
SETHOTT
FLOW CONTBOL VALVE l'98 - 0Omodeltl FLOW CONTROL VALVE CAP 49 N.m (5.0kgl.m, 36 tbf.ft)
BOLI-ERS
'15. Installthe flow controlvalveand springin the pump housing. 1 6 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d installit on the flow controlvalvecap.
1 1 . Installthe side plateon the cam ring by aligningthe
rollerset holesin the side Dlatewith the rollers.
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1 7 . Installthe flow controlvalvecap on the pump hous(cont'd) ing,and tightenit.
17-29
PowerSteeringPump Reassembly(cont'dl '18. C o a t t h e O - r i n g w j t h p o w e r s t e e r i n gf l u i d , a n d installit into the groovesin the inletjoint.
FLANGEBOLTS 11 N.m 11.1kgf.m, 8 rbf.ft)
'13x '1.9 Replace. r
E
1 9 . Installthe inletjoint on the pump housing. 20. I n s t a l lt h e p u l l e y a s s h o w n b e l o w . t h e n l o o s e l y installthe pulley nut. Hold the steeringpump in a vise with soft jaws. Be careful not to damagethe pump housingwith the jaws of the vise.
17-30
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21. Holdthe pulleywith the speciattoot, and tightenthe p u l l e yn u t .
Checkthat the pump turns smoothlyby turning the pulleyby hand.
PowerSteeringGearbox Removal Notetheseitemsduring removal: . Using solventand a brush,wash any oil and dirt off the valve body unit its lines,and the end if the gearbox. Blow dry with compressedair. . Be sure to removethe steeringwheel beforedisconnectingthe steeringjoint. Damageto the cable reel can occur. . With 4WD.tilt the enginewith a jack to expandthe clearancebetween the transfer assembly and rear beam when removingthe steeringgearboxfrom the rearoeam. Do not removethe steeringgearboxby removingthe transferassemblyfrom the transmission. 1.
7. Removethe cotterpin from the nut, and removethe castle nut {'97 - 98 models) or hex nut ('99 - 00 models).
Drainthe power steeringfluid as describedon page '17-15. Raisethe vehicle,and suppon it on safetystandsin the properlocations(seesection1). Removethe front wheels, Removethe drive/s airbagassembly{seesection24). Removethe steeringwheel{seepage 17-18). Removethe steeringjoint bolts, then disconnectthe steeringjoint by moving the joint toward the column.
COTTER PIN Replace. Installthe 10 mm hex nut on the ball joint. Be sure that the 10 mm hex nut is flush with the ball joint pin end, or the threadedsectionof the ball joint pin might be damagedby the specialtool. Referto section 18 for ball joint removerusageinstruction,Be carefulnot to damagingthe ball joint boot.
UPPERJOINT BOLT
Separatethe tie-rodball joint and knuckleusingthe specialtool.
1 0 . Removethe right and left tie-rodends,then extend the rackall the way to the right. 1 1 . Removethe TWC(seesection9). Disconnectthe shift linkagefrom the transmission (M/T:see section 13,A/T: see section 14).
1 3 . With 4WD. separatethe propeller shaft and transfer assembly(seesection161.
LOWERJOINT BOLT
(cont'd)
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17-31
PowerSteeringGearbox Removal(cont'dl 1 4 . L o o s e nt h e 1 4 m m f l a r e nut, and disconnectthe pump outlethose. AN'USTABLEHOSECLAMP
4WD:Stepr 18-22 18. Removetherighttront mount,then applyvinyl tape to the sideframe to protectit from the transmission coverand stop bolt. 12 x 1.25 fiiA Replace.
x 1,25mm
RIGHTFRONTMOUNT
NUT 14mm FLARE 15. Loosenthe adjustablehose clamp and disconnect the returnhose,
SIDEFRAME
Vinyltapeor equivalgntmaterial.
'19. Remove the left front mount, then apply vinyl tape to the side frame to protect it from the stop bolt.
16. Loosenthe 16 mm flare nut, and removethe return hosejoint. 17. After disconnecting the hosesand lines,plug or seal them with a pieceof tape or equivalentto prevent foreign maisrialsfrom enteringthe valve body unit. NOTE: . Do not loosenthe cylinderline A and B between the valvebody unit and cylinder. . With 2WD, continue to step 23.
10x 1.25mm
Vinyltap€or equival€ntm6terial. STOPBOLT
17 -32
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20. Removethe rearmount bracketand rear mount. REARMOUNT 12x 1.25mm Replace.
22. Jack up the engineand tilt the enginebackuntil the transferassemblyis loweredapproximately40 mm (1.57 in). Notetheseitemswhen tiltingthe engine: . Checkthat the wire harnesses,hosesand pipes are not caughtby any surroundingparts. . Do not tilt the enginemore than necessary.
approximately .Lower '40 mm (1.57in)
REARMOUNT BRACKET
12 x 1.25mm Replace.
14x 1.5mm Replaco.
ASSEMBLY
2 1 . P l a c ea j a c k u n d e r t h e e n g i n e b l o c k i n t h e a r e a shown,
Removethe stiffenerolate. NOTE:Somestiffenerplatemountingbolts a.e also used as gearboxmounting bolts.The gearboxwill tilt to the sidewhen theseboltsare removed.
STIFFENER PLATE
?* JACK.UPPOINT
(cont'd)
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17-33
PowerSteeringGearbox Removal(cont'dl
Disassembly
24. Removethe mountingbrackets.
Steering RackDisassembly Notetheseitemswhen disassembling: . Beforedisassemblingthe gearbox,wash it off with solventand a brush. . Do not dip sealsand O-ringsin solvent. 1.
Removethe steeringgearbox(seepage 17-31).
2.
Removeairtube and clips.
MOUNTINGBRACKETS AIR TUBE
25. lvlovethe steeringgearboxto the right so the left rack end clearsthe rear beam, then placethe left rackend belowthe rearbeam. 3.
Removethe boot bandsand tie-clips.
4.
Pullthe bootsawayfrom the endsof the gearbox.
STEEBINGGEARBOX
Move the steeringgearboxto the left, and tilt the left sidedown to removeit. With 4WD. remove the steering gearbox through the clearancebetweenthe transfer assemblyand propellershaft.
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17 -3 4
5.
Hold the steeringrackwith a wrench {'98- 00 models: left end onlv), and unscrewthe rack end with anotherwrench,Be carefulnot to damagethe rack surfacewith the wrench,
8. RemovecylinderlinesA and B from the gearbox,
LOCKWASHER
LINEA CYLINDER 9 . Drain the fluid from the cylinderfittings by slowly movingthe steeringrackbackand {orth.
6.
L o o s e nt h e l o c k n u t ,t h e n r e m o v et h e r a c k g u i d e screwand O-ring('97model).
Removethe two tlangebolts,then removethe valve body unit from the gearbox. (See page 17-38for valvebody unit disassembly.) DUSTCOVER VINYLTAPE
RACKGUIDE FLANGEBOLT
LOCKNUT
1 1 . Apply vinyl tape to stepped portion of the pinion
1.
Removethe spring and the rack guide from the gearDOX.
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shaft,and removethe dust cover. (cont'd)
17-35
PowerSteeringGearbox Disassembly{cont'd} 12. Drill a 3 mm (0.12in) diameterhole approximately 2.5 - 3.0 mm (0.10- 0.12in) in depth in the staked point on the cylinder.Do not allow metal shavings to enter the cylinder housing.After removing the cylinderend, removeany burrsat the stakedpoint.
- 0.12inl D.oth: 2.5- 3.0mm 10.10
CYUNOER
'12 14, Assemblea 12 x 1.25mm flangenut onto a x 175 mm grade 10 flangebolt as shown,Wrap the flange portion of the bolt with vinyl tape to protect the cvlinder,
12mmFLANGENUT VINYLTAP€ tp/N90177- SLO- OOOI 1 5 . Installthe flange bolt into the end of the steering r a c k u n t i l i t b o t t o m s i n t h e h o l e .t h e n b a c kt h e flange bolt out 1/4 turn. Hold the flange bolt, and tightenthe flangenut againstthe rackby hand. Installthe bearingseparatoron the gearbox housing as snown.
BEARINGSEPARATOR 0- 1112' (Commercially available)
13. Hold the gearboxusing using a C-clampas shown, Loosenand removethe cvlinderend.
STEERINGRACK CYLINDER€ND
1 7 . Set the gearbox in a press so the lelt side points upward,then pressthe cylinderend seal and steering rack out of the gearbox.Hold the steeringrack to keep it from fallingwhen pressedclear.Be caref u l n o t d a m a g et o i n n e r s u r f a c eo f t h e c y l i n d e r housingwith the flangebolt.
17-36
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18. Removethe 12 mm bolt and nut trom the stsering rack, 19. Remove the cylinder end seal from the steering racK.
22. Carelully pry the piston sesl ring and O-ring off the piston rack.Be carefulnot to damagethe insideof seal ring groove and piston edgeswhen removing the sealring.
Replace.
I
II
CI 20. lnsert a 24" long,3/8" drive extension and the special tool into the cvlinderfrom the left side. Make sure that the specialtool is securelypositionedon the backup ring edges. Be careful not damage to innersurfaceof the cylinderwith the specialtool.
Replaco.
Prass 24 'LONG 3/8' DRIVEEXTENSION (Commerciallv available)
BACKUPRING CYLINDEREND SEAL
CYLINDERENDSEAL REMOVERATTACHMENT 07NAD- SR3020A
2 1 . Set the gearboxin a press,then pressout the cylinder end sealand backupring from the gearbox. Note these items when pressingthe cylinder end seat: . K e e pt h e t o o l s t r a i g h tt o a v o i d d a m a g i n gt h e cylinderwall.Checkthe tool angle,and correctit if necessary, when removingthe cylinderend seal. . Use a pressto removethe cylinderend seal.Do not try to removethe seal by strikingthe tool. lt will breakthe backupring, and the cylinderend sealwill remainin the gearbox.
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(cont'dl
17-37
PowerSteeringGearbox Disassembly(cont'd) Valve Body Unit Dbassembly 23. Beforeremovingthe valvehousing,applyvinyltape to solinesof the Dinionshaft. VALVEHOUSING
2 6 . C h e c kf o r w e a r , b u r r s a n d o t h e r d a m a g et o t h e edgesof the groovesin the sleeve. NOTE:The pinion shaft and sleeveare a precision m a t c h e ds e t . l f e i t h e r t h e o i n i o n s h a f t o r s l e e v e must be replaced,replaceboth partsas a set. SLEEVESEALRINGS Checkfor Deeloff or
Separatethe valve housingfrom the pinion shafv valveusinga press. Checkthe innerwall of the valve housingwhere the seal ring slideswith your finger.lf there is a step in t h e w a l l , t h e v a l v e h o u s i n gi s w o r n . R e p l a c et h e valve housing. Notetheseitemsduringinspection: o There may be the sliding marks from the seal ring on the wall of the valve housing. Replace the valvehousingonly if the wall is stepped. . When the valve housingis replaced,installnew shim{s)on the bearingsurfaceof the housingto adiustthe thickness. C h e c kt h e i n s i d e o f v a l v e h o u s i n g for a step in the wall.
17-38
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27. Removethe circlipand sleevefrom the pinionshaft.
28. Usinga cutte. or an equivalenttool, cut and remove the four seal ringsfrom the sleeve.Be carefulnot to damagethe edgesot the sleevegroovesand outer surfacewhen removingthe sealrings.
SLEEVE
3 0 . R e m o v et h e v a l v e o i l s e a l a n d b a c k u pr i n g ( ' 9 7 model)or wave washer ('98 - 00 models)from the pinionshaft. Notetheseitemsduringdisassembly: . Inspectthe ball bearingby rotatingthe outer race slowly. lf there is any excessiveplay, replacethe pinionshaftand sleeveas an assembly. . The pinion shaft and sleeveare a precisefit; do n o t i n t e r m i xo l d a n d n e w D i n i o ns h a f t sa n d sreeves, BALLBEARING WAVE WASHER l'98 - 0Omodelsl
29. Using a cutter or an equivalenttool. cut the valve s e a l r i n g a n d O - r i n ga t t h e g r o o v e i n t h e p i n i o n shaft. Removethe valve seal ring and O-ring. Be carefulnot to damagethe edgesof the pinion shaft grooveand outer surfacewhen removingthe valve sealrjng and O-ring.
PINION SHAFT
BACKUPRING {'97 modell
VALVEOIL SEAL
Replace. 3 1 . Pressthe valveoil sealand roller bearingout of the valve housing using a hydraulicpress and special tool shown below.
Cuftingslot position. PILOTCOLLAR
ROLLERSEARING
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PowerSteeringGearbox Reassembly Notetheseitemsduring reassembly . Cleanthe disassembled partswith a solvent,and dry them with compressedair. Do not dip the rubberparts in a solvent. . Always replacethe O-ringsand rubbersealswith new ones beforeassembly. . Apply the recommendedpowersteeringfluid to the partsindicatedin the assemblyprocedures. . Do not allow dust.dirt, or othertoreignmaterialsto enterthe power steeringsystem. . Usethe appropriatespecialtoolswhere necessary. FLANGE BOLTS 20N.m(2.0kgl.m,14lbtftl CYLINDERLINE A
FLARENUTS 17 N.m 11.7
12 rbl.ftl
VALVEHOUSING
VALVEOIL SEAL Beplace. ROLLERBEARING CYLINDEREND SEAL Replace.
CIRCLIP Replace.
BA.KUP RING
\
BACKUPRING Replace. 97 model:
WAVEWASHER HOUSING
VALVESEALRING Replace.
\/^"
O.RING Replace. 32 mm SHIMS '97 mod6l only: RACKGUIDESCREW
@---r-ocxr'rur '97 model: O-RING Replace. '9? model only:
END CYLINDER 69 N.m (7.0 kgf.m, 51 lbf.ft)
'98 - (x) models:
PISTONSEALRING Replace.
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17-40
STEERINGRACK
'98 model: '99 - 0Omod6ls:
Valve Body Unh Roa$embly 1.
Apply vinyl tape to the steppedportion of the pinion shaft,and coat the surfaceof the vinyl tape with the power steeringfluid. VALVEOIL SEAL Vinyl tape (Stopp6d portion)
Replace. Makesurethe springis seatedin the oil seal.
8. Apply power steering fluid to the surface of the v a l v e s e a l r i n g t h a t w a s i n s t a l l e do n t h e p i n i o n shaft. Apply power steeringfluid to the insideof the special tool. Set the largerdiameterend of the special tool overthe valvesealring. VALVESEALRING SIZNG TOOL 07NAG - SR309q' ot 07NAG - SR3oltoA
Serling
E PINIONSHAFT BACKUPRING 137 modell
\ /
WAVEWASHER {'98- 00modelsl Installthe backupring {'97 model)or wave washer ('98- 00 models). Coat the inside surface of the new valve oil seal with powersteeringfluid. Installthe valveoil sealwith its groovedside facing oppositethe bearing,then slide the valve oil seal over the pinion shaft, being carefulnot to damage t h e s e a l i n gl i p . Apply vinyl tape to the splinesand steppedponion of the shaft, and coat the surfaceof the vinyl tape with the power steeringfluid. PINIONSHAFT
l
r
r
.
r
j
1
tffifrE-r r.] r\-''] 7
Usgth6 larg€r diameter end of the special toollirst to make th€ valve seal ring tit in the pinion shaft.
Mak€ the valve seal ring fit snuglyin the pinion shatt using th6 other end {smallerdiameterend)ot the specialtool.
Vinyl trp€
1 0 . Move the specialtool up and down severaltimes to makethe valvesealring fit in the pinionshaft, 1 1 . Removethe soecialtool.
12. Turn the specialtool over,and set the smallerdiameter end of the specisltool over the valveseal ring. Move the specialtool up and down severaltimes to m a k et h e v a l v e s e a l r i n g f i t s n u g l yi n t h e p i n i o n shaft. O.RING Replace. Do not twist.
R€placeDo not over-expand.
Fit the new O-ringin the grooveof the pinion shaft. Then slide the new valve seal ring over the shaft and in the grooveon the pinionshaft, 7 . Removethe vinyl tape from the pinionshaft.
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(cont'd)
17-41
PowerSteeringGearbox (cont'd) Reassembly 1 3 . Apply power steeringfluid to the surfaceof the specialtool. Set the new sealrings overthe specialtool f r o m t h e s m a l l e r d i a m e t e re n d o f t h e t o o l . a n d e x p a n dt h e s e a l r i n g s .I n s t a l lt w o r i n g s a t a t i m e Jromeachend ofthe sleeve.
18. Apply power steeringfluid to the surfaceof the pinion shaft.Assemblethe sleeveover the Dinionshaft b y a l i g n i n gt h e l o c a t i n gp i n o n t h e i n s i d eo f t h e sleevewith the cutout in the shaft.Then installthe new circlipsecurelyin the pinionshaftgroove.
Notetheseitemswhen installingthe sealring: . Do not over-expand the sealring. Installthe resin seal rings with care so as not to damagethem. A f t e r i n s t a l l a t i o nb, e s u r e t o c o n t r a c t h e s e a l ringsusingthe specialtool{sizingtool). . There are two types of sleeveseal rings: black and brown. Do not mix the different types of sleevesealringsas they are not compatible.
Notetheseitemsduring reassembly: . B e c a r e t u l n o t t o d a m a g et h e v a l v e s e a l r i n g when insertingthe sleeve. . Installthe circlipwith its radiusedsidefacingout. CIRCLIP
1 4 . Align the specialtool with each groove in the sleeve, and slide a sleeveseal ring into each groove.After installation,compressthe seal rings with your fingerstemporarily. BALLJOINT BOOTCLIPGUIDE 07974- SA508q) SLEEVE
1 9 . Apply power steeringfluid to the seal ring lip of the valveoil seal.then installthe seal in the valvehousing using a hydraulicpressand specialtools. Install the valve oil sealwith its groovedside facingthe tool.
1 5 . Apply power steeringfluid to the seal rings on the sleeve,and to the ehtireinsidesurfaceof the special tool.
ATTACHMENT, 32x35mm 077i16- (x)10100
SLEEVESEALRING SIZINGTOOL 07974- SA502O0or 07974- SA5020A
1 6 . Insertthe sleeveinto the specialtool slowly.
't1. Move the sleeve each direction several times to makethe seal rings snuglyfit in the sleeve.Be sure that the seal ringsare not turned up,
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VALVEOIL SEAL Replace. Makesurethe springis in the oilseal.
20. Pressthe new bearinginto the valve housingwith the stampedletterfacingup usinga hydraulicpress and soecialtool.
2 4 . P r e s st h e p i n i o n s h a f t / s l e e v eu s i n g a h y d r a u l i c p r e s s . C h e c kt h a t t h e p i n i o n s h a f t / s l e e v et u r n s smoothlyby turningthe pinionshaft,
DRIVER ATTACHMENT, 32x35mm 07746- 0010100
-
ROLLERBEARING Letterstampedface
21. Apply vinyl tape to the pinion shaft, then coat the vinyltape with powersteeringfluid.
Sealinglip tace.
VALVEOIL SEAL
VALVEHOUSING
PINIONSHAFT
E SLEEVESEAL 8e surethat the sealringsare not turnedup,then install.
22, Insertthe pinion shaft into the valve housing. Be carefulnot to damagethe valvesealrings. 23. Removethe vinyl tape from the pinion shaft,then removeany residuefrom the tape adhesive. (cont'd)
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17-43
PowerSteeringGearbox (cont'dl Reassembly Stecring RackR8assembly 25. Coatthe pistonseal ring guide with power steering fluid,then slideit onto the rack,big end first.
31. Wrap vinyl tape aroundthe rackteeth and rack end edges,then coat the surface of the tape with the power steeringfluid. Make sure that the vinyl tape is wrappedcarefullyso that there is no steppedportion.
26. Positionthe new O-ringand new pistonseal ring on the sDecialtool, then slide them down toward the big end of the tool. Notetheseitemsduring reassembly: a Do not over expandthe resin seal rings. Install the resin seal rings with care so as not to damage them. After installation,be sure to contract the sealring usingthe specialtool (sizingtool). a Replacethe piston'sO-ringand sealring as a set. 27. Pull rhe O-ringoff into the pistongroove,then pull the pistonsealring off into the pistongrooveon top of the O-ring.
Coatthe insidesurfaceof the new cvlinderend with powersteeringfluid.
PISTON
Installthe cylinderend seal onto the steeringrack w i t h i t s g r o o v e d s i d e t o w a r d t h e p i s t o n .W h e n installingthe cylinderend seal,be carefulnot damagethe sealinglip faceof the sealwith the edgesor teethof the steeringrack. CYLINDER ENDSEAL
24. Coatthe pistonseal ring and the insideof the specialtool with power steeringfluid.
PISTON Replace
E 07GAG- SO4O200 or - SD'()2OA OTGAG Carefullyslide the tool onto the rack and over the pistonsealring. 30. Move the specialtool backand fonh severaltimes to makethe pistonseal ring fit snugly in the piston.
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17-44
Make sure the spring is in lhe cylinder eno seal
Removethe vinyl tape from the steeringrack,then removeany residuefrom the tape adhesive.
35. Install the new backup ring on the steering rack, then placethe cylinderend sealagainstthe piston. BACKUPRING Replace.
37. Installthe flange bolt into the end of the steering f a c k u n t i l i t b o t t o m s i n t h e h o l e ,t h e n b a c kt h e f l a n g eb o l t o u t 1 / 4 t u r n . H o l d t h e f l a n g eb o l t a n d tightenthe flangenut againstthe rackby hand. Prers
12 x'175 mm FLANGEBOLT lP/N 90177- SLo- 0001 12 mm FLANGENUT
to.
Greasethe steeringrackteeth,then insertthe steering rack into the gearboxhousing,Be carefulnot to damageto inner surfaceof the cylinder wall with the rackedges.
GEARBOXHOUSING
CYLINDERENDSEAL Replace.
38. Installthe cylinderend seal into the bottom of the cylinderby pressingon the bolt with a press,Do not p u s h o n t h e b o l t w i t h e x c e s s i v ef o r c e a s i t m a y damagethe cylinderend seal. ia
R e m o v et h e f l a n g e b o l t , a n d c e n t e rt h e s t e e r i n g rack.
40. W r a p v i n y l t a p e a r o u n dt h e r a c k e n d e d g e s ,a n d coatthe surfaceof the tape with the power steering fluid. Makesurethat the vinyl tape is wrappedcarefully so that there is no steppedportion.
(cont'dl
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17-45
PowerSteeringGearbox (cont'dl Reassembly 4l. Coatthe insidesurfaceof the new cvlinderend seal with powersteeringfluid. CYLINDEBENOSEAL Replace. Makesurethe spring is in the cylinderend seal.
46. Greasethe insidesurtaceof the cylinderend, then installthe cylinderend by screwingit into the cylinder. 41. Removethe C-clampfrom the gearbox. 48. After tighteningthe cylinderend, stakethe point of the cylindershown below.Stakethe cylinderin the position oppositefrom where the stakewas removed duringdisassembly, NOTE:For '98- 00 models,go to step54. Stake point, Depth: 1,0 mm (0.04inl
Staked
posrtron. 4.0mm {0.16in) Groovedside.
42. Installthe cylinderend seal onto the steeringrack with its groovedsidetowardthe piston.
43. P u s h i n t h e c y l i n d e r e n d s e a l w i t h y o u r f i n g e r . When installingthe cylinderend seal,be carefulnot damagethe sealingfaceof the sealwith the threads a n d b u r r s a t t h e s t a k e dp o s i t i o n o f t h e c y l i n d e r housing. 44. Removethe vinyl tape from the steeringrack,then removeany residuefrom the tape adhesive. 45. Holdthe gearboxusinga C-clampas shown.
C.CLAMP
GEARBOX
BUSHING CYLINDEREND 69 N.m (7.0kgf.m,51 lbtft)
-tG 8e carefulnot to damage the bushingwhen inserting the cylinderend.
49. Selectthe 32 mm shim(s)('97 modelonlv). N O T E :O n l y r e i n s t a l tl h e o r i g i n a l3 2 m m s h i m ( s ) when the steeringgearboxis reassembledwithout replacingthe pinionshaft.valve housing,and gearbox housingwith new ones. l f t h e p i n i o n s h a f t , v a l v e h o u s i n g ,a n d g e a r b o x housingare replaced,selectthe new shim{s)as follows. Shim selection: Set the four 32 mm shims on the bearingsurfaceof the g e a r b o x h o u s i n g .T o t a l t h i c k n e s so f t h e f o u r s h i m s shouldequalno more than 0.70mm. Shim set: four 32 mm shims (Thickness: 0.10 mm, 0.15 mm, 0.20mm, 0.25mm respectively) N O T E :T h e f o u r 3 2 m m s h i m s d o n o t h a v et h i c k n e s s identification marks.Measurethe thicknessof eachshim usinga micrometer,and markthe shim for identification.
17-46
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5 0 . I n s t a l lt h e v a l v e b o d y u n i t o n t h e g e a r b o x .a n d tightenthe flangeboltsto the specifiedtorque. VALVEBODY
FLANGE BOLT 20 N.m12.0kgt.m,14lbtft)
Example: Measurementis 0.28mm (0.011in); 0 . 7 0 - 0 . 2 8 = 0 . 4 2m m ( 0 . 0 2 8 - 0 . 0 1=1 0 . 0 1 7i n ) T h e s e l e c t e ds h i m s s h o u l db e 0 , 2 5m m ( 0 . 0 1 0i n l a n d 0.15mm (0.006in) in thickness. lf the required shim thicknessis 0.10 mm or less, no shrmsare necessary. 53. Set the selected32 mm shims on the bearingsurfaceof the gearboxhousing.
SHIM SET (fourshims)
VALVEBODYUNIT
FLANGEBOLT 20 N.m (2.0 kgf.m, la lbl.frl
/
a)
E?
E
ct.
O.RING Replace.
-6{
Measurethe clearancebetween the gearbox and valve body unit using a feelergauge.Measurethe c l e a r a n c ea t t h e p o i n l m i d w a y b e t w e e nt h e t w o mountingbolts.
GAUGE NEEDLEBEARING
-6lr 54. Coatthe new O-ringwith grease,and carefullyfit it on the valvehousing. Apply greaseto the needlebearingin the gearbox housing. D e t e r m i n et h e r e q u i r e dt h i c k n e s so f t h e 3 2 m m shims by subtractingthe clearanceobtainedin the step "c" from the total thicknessof the four shims. ( T o t a lt h i c k n e s so f t h e 4 s h i m s ) - ( C l e a r a n c e=) Reouiredthicknessof the shims
56. Installthe valve body unit on the gearboxhousing by engaging the gears. Note the valve body unit installationposition(directionof line connection). 5 7 . Tightenthe flangeboltsto the specifiedtorque.
Selectthe shims so that the total thicknessis close to, but lessthan,the requiredthickness.
(cont'd)
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17-47
PowerSteeringGearbox (cont'dl Reassembly
(
58. InstallthecylinderlinesA and B Notetheseitemsduring reassembly: . C l e a nt h e j o i n t s o f t h e c y l i n d e rl i n e sA a n d B thoroughly.The joints must be free of foreign material, . lnstall the cylinder lines A and B by tightening the flare nuts by handfirst,then tightenthe flare nutsto the soecifiedtorque.
6 3 . I n s t a l lt h e n e w l o c k w a s h e ri n t h e g r o o v e i n t h e steering rack. LOCKWASHER Replace.
STEERINGRACKENO 54 N.m (5.5kgf.m,40 lbtftl
17 N.m 11.7kgd.m,12lbf.ttl
26 N.m {2.7 kgl.m, 20
STEERING
64. Screwthe rackends into the rack.
CYLINDEF LINEA Greasethe sliding surface of the rack guide, and installit onto the gear housing.
60. For'97 model,applya thin coatof greaseto the new O-ring,and installit on the rackguidescrew. For'98 - 00 models.removethe old sealantfrom the threadsof the rackguide screw.then apply new sealantto the first threethreads. RACKGUIOE
Hold the steering rack with a wrench ('98 - 00 models: left end only), and tighten the rack ends. Be careful not to damage the rack surface with the wrench. After tighteningthe rack ends, stakethe four sections of lockwasherwitha drift and a mallet. .
. .
Placethe wood blockon the presstable,then set the lock washer section of the rack end on the wood block securely. Be sure the tool is aligned with the flat sections of the steering rack end before pressing. Stake the lock washer in the center of the flat section of the steering rack end, ROLLPIN PUNCH lCommorcially.Y.il.blel Snap-OnNo. PPR8or oquival.nt.
-6r
O-RING
nlcr cutDE R"Pl""u' SCREW LOCKNUT 37 model: 38 model:
NOTE: This drift has a flat shoulderto prevent puncturingof metalwasher. ot.
Installthe spring, rack guide screw and locknuton the gear housing. Adjustthe rack guide screw (seepage 17,15).After adjusting,checkthat the rack moves smoothly by slidingthe rackright and left.
17-48
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STEERINGRACK
WOODENBLOCK
67. Apply greaseto the circumferenceof the rack end housing.
70. Adiust the air hose fitting positionof the boots by turning it as shown below. LEFTBOOT {Viewedfromthe leftside)
RIGHTBOOT (Viewedtrom the rightside)
+
ro
m
''rT.a'. Front
+
, tri"
\,'tAr-
{,1@}tr )Fr1
RACKENDGROOVE .={@ GREASE SILICONE
/
\
BOOT AIR HOSEFITTING FIT'I'ING
68. A p p l y a l i g h t c o a t o f s i l i c o n eg r e a s et o t h e b o o t grooveson the rackends. 69. lnstall the boots in the rack end with the tie-rod clips. NOTE:Installthe bootswith the rackin the straight ahead position (right and left tie-rodsare equal in length).
71. Installnew boot bandson the boot, and bend both setsof lockingtabs. CAUTION: Stake the band locking tabs firmly.
RACK ENO
NOTE: Wipe the greaseoff the threadsection.
Lightlytap on the doubled-overportionsto reduce their height. Slide the rack right and left to be cenain that the bootsare not deformedor twisted. (cont'd) TIE.RODCLIP
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17-49
PowerSteeringGearbox Reassembly(cont'd)
BallJoint Boot Replacement
7 4 . C o n n e c tt h e a i r t u b e b e t w e e nt h e r i g h t a n d l e f t boot,
't. Removethe boot set ring and the boot. CAUTION:Do not contaminatethe boot inslallation section with graase.
CYLINDER LINEA
Packthe interiorof the boot and lip with grease. Wipe the greaseoff the sliding surfaceof the ball pin.then packthe lower areawith freshgrease. CAUTION: . Keep greaseoff the boot installation section and the tapered section of th€ ball pin. . Do not allow dust, dirt, or other to.eign materials to enter the boot. EALLPIN TAPERED SECTION Wipe olf the grease. CYLINDERLINE
75. Installthe clips on the cylinderlines,then clampthe air tube with the clips. B(X)T IT{STALLATION
76. Apply vinyl tape to around the pinion shaft, and coat the surfaceof the tape with grease.
sEclroN Wipe off the grease.
BOOT INSTALLATION SECTION Wipe offthe grease.
Installthe boot in the grooveof the boot installation sectionsecurely.then bleedair.
DUSTCOVER Vinyl Tsp€
VALVEOIL SEAL
Adjust the specialtool with the adjustingbott until the end of the tool aligns with the groove on the boot. Slidethe set ring over the tool and into posiI|on. CAUTION: After installing the boot, chock the batl pin lapered section for grease contamination and wipe it it n€cessary.
VALVEBODYUNIT
ADJUSTINGBOLT Adiustthe depth by turningthe bolt.
77. P a c kt h e i n t e r i o r o f t h e d u s t c o v e r a n d l i o w i t h grease,then installdustcoveron the valvebodv unit. Removethe vinyl tapef.om the pinionshaft.
17-50
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SET RING
lnstallation 1.
Beforeinstallingthe gearbox,extendthe rackall the waYto right.
2.
lnstallthe mounting cushion on the steerlnggearbox.
3.
Passthe right side of the steeringgearbox above and throughthe right sideof the rearbeam.Be careful not to bend or damagethe two power steering
5.
I n s t a l lt h e s t i f f e n e rp l a t e w i t h t h e t w o g e a r b o x mounting bolts and stiffenerplate attachingbolts. Be sure the air tube is not caught or pinched by stiffener plate. Installthe bolts loosely first. then tightenthem securely. NOTE:With 2WDcontinueto step 11. PLATE STIFFENER MOUNTINGBOLTS 38 N.m
:/
STEERINGGEARBOX
I n s t a l lt h e m o u n t i n g b r a c k e to v e r t h e m o u n t i n g c u s h i o n .t h e n i n s t a l lt h e t w o g e a r b o xm o u n t i n g b o l t s .P o s i t i o nt h e s p l i t p o r t i o no f t h e m o u n t i n g cushionas shown.
With 4WD,lower the iack,and returnthe engineto the originalPosition.
MOUNTINGBBACKETS
1.
l n s t a l lt h e r e a r m o u n t a n d r e a r m o u n t b r a c k e t . Tightenthe mountingbolts in order:A, B and C. 8.12 x 1,25mm 59 N.m (6.0 kgt.m. *l lb{'ftl Replace.
10 x 1.25mm 6,aN.m 16.5kst.m, 47 lbl'ft) R€place.
) \ ^ o
(
]
GEARBOXMOUNTING BOLTS 39 N.m 14.0kgf.m, 29 lbf.ft)
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17-51
PowerSteeringGearbox Installation(cont'd) 8,
Installthe left front mount. Tighten the mounting boltsin order:A and B.
LEFTFRONTMOUNT
B-12x 1,25mm 59Nm (6.0 kgtm,,€ lbl.ftl Replaca.
11. Installthereturnhosejoint by tighteningthe 16 mm flare nut.
AD.'USTAB[THOSECLAMP (Forinstallation reterto page 17,23)
RETURNHOSEJOINT: 16 mm FLARENUT 28 N.m 12.9kg{.m.21 lbt{t)
A-10x 1.25mm 4,1N.m la.s kgt m, 33 lbf.ft)
9.
Instsllthe right front mount, Tightenthe mounting bolts in order:A and B.
B-12x 1.25mm 59 N.m 16.0ks[.m, ,|:| lbf.ftl Replace.
14 mm FLARENUT 37 N.m (3.8 ksf.m, 27 lbl'frl A-10x 1.25mm a,aN.m
't2. Connectthe return hose securely.and tighten the adjustablehoseclamp.
1 3 . Connectthe pump outlet hose, and tighten the l4 mm flare nut. NOTE: Makesure that there is no interference betweenthe fluid lines,the rear beam or any other parts.
10. Removethe vinyl type from the side frame (both sides).
17-52
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't4. Centerthe steeringrackwithin its stroke. 1 5 . Installthe steeringjoint, and reconnectthe steering shaftand pinionshaft. NOTE:Make surethe steeringjoint is connectedas follows.
17. Wipe off any greasecontaminationtrom the ball joint taperedsectionand threadsthen reconnectthe tie-rod ends to the steeringknuckles.For'97 - 98 models;torque the castle nut to the lower torque s p e c i f i c a t i o nt,h e n t i g h t e n i t o n l y f a r e n o u g h t o alignthe slot with the pin hole.Do not align the nut by loosening.Installnew cotterpins. TIE.ROOEND
a. Insenthe upperend of the steeringjoint onto the steeringshaft (line up the bolt hole with the flat on the shaft). JOINTBOLT UPPER 22 N.m 12.2kgf.m,16lbl.ft,
HEXNUT l'g!t - 00 modeb) il:l N.m
JOINT STEERING
CAST1TNUT (9t - 98 modol!) 39 - iU N'm lil.o - 4.8 kgl.m, 29 - 35 tbf.ftl
14.4ksl.m, 32 tbf.f0
'99 - lD modeb:
COLUMN SHAFT
UPPERJOINT BOLT Bolt must line up with tlat on shatt.
LOWERJOINT BOLT Bolt must lineup with groove around on shaft. PINION SHAFT
b, Slip the lower end of the steeringioint onto the pinionshaft. c. Installthe lower joint bolt (line up the bolt hole with ths groove around the shaft).Be sure that the lower joint bolt is securelyin the groove in the pinionshaft. d. Pull on the steeringjoint to make sure that the steeringjoint is fully seated. e, Installthe upperjoint bolt, 1 6 . Reinstallthe steeringwheel{seepage'17-19).
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PIN COTTER RePlace. bend on reassembly, thecotterPinasshown.
LOWERJOINTBOLT 22 N.m 12.2kgf.m,16lbtftl
1 8 . With 4WD,connectthe propellershaft and transfer assembly(seesection16). 1 9 . Connectthe shift linkageto the transmission(M/T: see section 13,A,/T;see section 14). 20. InstalltheTwc (seesection91. 2 1 . lnstallthe front wheels, 22. Fill the systemwith power steeringfluid, and bleed air from the system(seepage 17-15).
23. After installation.performthe followingchecks. .
. .
S t a r t t h e e n g i n e ,a l l o w i t t o i d l e , a n d t u r n t h e steering wheel from lock-to-lockseveraltimes to warm up the fluid. Checkthe gearboxfor leaks (seepage17-23). Adjustthe front toe (s€esection18). Checkthe steeringwheel spokeangl€.Adjust by turning the right and left tie-rodsequally,if necessary.
17-53
Suspension ............. 18-2 SpecialTools ComponentLocations ......18-3 lndex ................ WheelAlignment 18-4 Servicelnformation......................,.. .................. 18-4 Camber ......18-5 Caster............... Front Toe Inspection/ ........18-5 Adiustment RearToe Inspection/ ........18-6 Adiustment Turning Angle Inspection/ ........18-6 Adiustment Wheel/HubInspection 18-7 BearingEnd Play .......................,...... .......18-7 WheelRunout Front Suspension SuspensionArms Replacement.....18-8 18-9 Knuckle/Hub Replacement............. LowerBallJoint Replacement.......18-15 18-16 BallJoint Boot Replacement..........
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Front Damper 18-16 ................. Removal 18-17 .................. Disassembly/lnspection 18-18 ........... Reassembly 18-18 ............. lnstallation RearSuspension SuspensionArms Replacement.....18-19 Hub BearingUnit Replacement......18-20 Upper Arm Bushing .....18-23 Replacement RearDamper 18-23 ................. Removal 18-24 .................. Disassembly/1nspection 18-25 ........... Reassembly ............. 18-25 lnstallation
S p e ci a l T ools
Ref.No.
I
o
Tool Number 07GAF- SE00l00 07GAG- SD40700 07JAF- SH20200 0 7 L A D- S M 4 0 1 0 0 07MAC- S100200 07746- 0010200 07749- 0010000 07947- 6340400 07965- SA50100 07965- 5400600 07965- S800100 07965- S800200 07965- SD90100 07974- SA50700
/a @ /6 lol
o @ 6r
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Hub Dis/Assembly Tool B a l lJ o i n tB o o tC l i pG u i d e BallJoint RemoverBase DriverAttachment,60 mm B a l lJ o i n tR e m o v e r , 2 m 3m DriverAttachment,3Tx 40 mm Driver DriverAttachment,62 x 64 mm Hub Dis/Assembly Tool DriverAttachment BallJoint Remover/lnstaller BallJoint InstallerBase SupportBase BallJoint BootClip Guide
1 1 1 1 1 1 1 1 'l I 1 1 I 1
c
f1 U
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o
18-2
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r 8-'13 ' 1 81 6 18-15 1A-22 1a-1't,12 1a-21 1 8 - 1 31, 4 , 2 1 , 2 2 18-13 1a-22 1 8 -1 4 1 8 -1 5 18-15 l8-14 18-16
ComponentLocations FrontSuspension:
BAR STABILIZER
LOWERARM
Rear Suspension: REAROAMPER BAR STABILIZER ARM UPPER
LOWERARM
COMPENSATOB ARM
TRAILING ARM
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18-3
WheelAlignment Caster
Camber
F o r p r o p e ri n s p e c t i o n / a d j u s t m eonf tt h e w h e e l a l i g n ment, checkand adjustthese items beforecheckinqthe alignment:
Inspection
. Checkthat the suspensionis not modified. . Checkthe tire sizeand tire pressure. . Checkth( runoutof the wheelsand t;res, . Checkthe suspensionball joints.(Hold a wheel with your hands,and move it up and down and right and leftto checkfor wobbling.)
U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e ldo u r w h e e l alagnment equipmentto measurewheel alignment(cast, e r , c a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o wt h e e q u i p , ment manufacturer's instructions. 1 . C h e c kt h e c a m b e ra n g l e . Camberangle: Front: 0'00' 1 1" Rear:- 1' :! 1" 2.
Inspection U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e fdo u r w h e e l a l i g n m e net q u i p m e nt to m e a s u r ew h e e la l i g n m e n(tc a s t e r , c a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o wt h e e q u i p ment manufacturer's instructions. 1.
Check the caster angle. Caster angle: 2'10':t 1" l f o u t o f s p e c i f i c a t i o n c, h e c k f o r b e n t o r d a m a g e d s u s p e n s i o nc o m p o n e n t s .
18-4
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lf out of specification,checkfor bent or damaged suspensron components.
FrontToe Inspection/Adjustment
RearToe Inspection/Adjustment
U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e fdo u r w h e e l alignmentequipmentto measurewheelalignment(caster, camber,toe, and turning angle).Follow the equipment instructions, manufacturer's
U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e fdo u r w h e e l alignmentequipmentto measurewheelalignment(caster, camber.toe, and turning angle).Follow the equipment manufacturer'sinstructions.
Checkthe tire pressure.
1.
1.
Releaseparking brake to avoid an incorrectmeasurement.
Centerthe steeringwheel spokes. Checkthe toe. 3.
C h e c kt h e t o e w i t h t h e w h e e l s p o i n t e d s t r a i g h t ahead.
Ro8rtoe-in:2 :1 mm {lN l/16:t 1/16 in,
Fronttoe-in:0 i 3 mm {0 t 1/8 inl
-
lf adjustmentis required,go to step2.
-
lf adjustmentis required,go on to step 4.
-
lf no adiustmentis required.remove alignment equrpmenr.
-
lf no adjustmentis required,remove alignment equipment.
Beforeadjustment,note the locationsof adjusting boltson the right and left compensatorarms.
Loosenthe tie-rod locknuts,and turn both tie-rods i n t h e s a m e d i r e c t i o nu n t i l t h e f r o n t w h e e l s a r e pointingstraightahead.
Loosenthe adjustingbolts, and slide the compensatorarm in or out. as shown,to adiustthe toe. FLANGEBOLT '10x 1.5mm 6a N.m 16.5kgf.m, 47 lbf'ftl
sir N m (5.5kgJ.m,'O lbf.ft)
ARM COMPENSATOR
5.
Turn both tie-rodsequally until the toe readingon the wheel alignmentcomputeris correct.
-
A f t e r a d j u s t i n g t, i g h t e n t h e t i e - r o d l o c k n u t sa n d repositionthe tie-rod boots if they are twisted or displaced.
-
5.
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Example:After the reartoe inspection,the wheel is 2 mm (0.08in) out of the specification. M o v e t h e a r m s o t h e a d j u s t i n gb o l t m o v e s 2 m m {0.08in) inwardfrom the positionrecordedbeforethe adjustment. The distancethe adjustingbolt is moved should be equalto the amountout-of-specification. Tightenthe adjustingbolts.
18-5
WheelAlignment TurningAngle Inspection U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e fdo u r w h e e l alignmentequipmentto measurewheelalignment(caster, c a m b e r t, o e , a n d t u r n i n ga n g l e ) F . o l l o wt h e e q u i p m e n t manufacturer's instructions. 1.
Turn the wheel right and left while applying the brake, and measure the turning angle of both wneets.
Turningangle: Inwardwheel:37.00' Outwardwheel lreference): 31.30'
2.
l f t h e t u r n i n ga n g l eis not within the specifications, c h e c kf o r b en t o r d a m a g e ds u s p e n s i o nc o m p o nenIs.
18-6
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Wheel/Hublnspection BearingEndPlay
WheelRunout
1 . Raisethe vehicleoff the ground,and makesure it is securelysupported.
1.
Raisethe vehicleoff the ground,and makesure it is securelysupported,
Removethe wheels,then reinstallthe wheel nuts.
Checkfor bent or deformedwheels.
Attachthe dial gaugeas shown.
Attachthe dial gaugeas shown.
Measurethe bearingend play by movingthe discor drum inwardor outward.
Measurethe wheel runoutby turningthe wheel.
Front/Rear; Standard:0 - 0.05 mm (0 - 0.002in)
Front and RearWhoel Axial Runout: Standard: Steel Wheel: 0 - 1.0 mm {0 - 0.0i[ in] AluminumWheel:0 - 0.7 mm l0 - 0.03in) ServiceLimit: 2.0 mm 10.08inl
Measureend play at the hub flange.
Front and RearWheel Radial Runout: Standard: Steel Whoal: 0 - 1.0 mm (0 - 0.04 inl Aluminum Whoel: 0 - 0.7 mm {0 - 0.03 in} 1.5mm (0.06inl Servics Limit:
Rear:
Measureend play at centerof the hub flange.
108 N.m {11.0kgf.m, q} lbf.ftl
It the bearingend play measurementis more than the standard,replacethe wheelbearing.
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lf the wheel runout is more than the servicelimit, reolacethe wheel.
18-7
FrontSuspension Suspension ArmsReplacement Notetheseitemsduring replacement: . Replacethe self-lockingnuts afterremoval. . The vehicleshouldbe on the ground beforeany boltsor nuts connectedto rubbermountsor bushingsare tightened. . Beforetighteningthe upper and lower mountingnuts on the stabilizerlink,adjusrthe locationof the link with the susp e n s i o nu n d e rv e h i c l el o a d . . After installing the suspensionarm, checkthe front wheel alignment,and adjustif necessary(seepage 18-4|.
FLANGEEOLTS 10x 1.25mm 54 N.m (5.5kgf.m, 40 tbf.ft)
STABILIZER BAR Alignthe stabilizermark with end of stabilizer bushing.
STAEILIZER
STABILIZER Checkfor bendingand damage. UPPER ARM Checkthe bushingfor deterioration and damage.
BALLJOINT BOOT . Checkfor deter'oration ano oamage, Seepage18 16for boot replacement.
FLANGEBOLT 1 { x 1 . 5m m 103N.m {10.5kgf.m, 76 tbf.ft)
LOWERARM RUBBER BUSHING Checkfor deterioration and damage.
..'.{l@3 GREASE SILICONE RUBBER BUSHINGS SELF-LOCKING NUT 10 x 1.25rr|m 29 N.m (3.0kgf.m,22 lbf.ft) Feplace. Holdthe ballioint pin usinga hex wrenct
BOOT Checkfor deterioration ano oamage,
18-8
o\
SELF.LOCKING NUT 1 4x 1 . 5m m Replace. 83 N.m (8.5 kgt.m,61 lbt.ftl FLANGEBOLT 1 4x 1 . 5m m 89 N.m (9.'l kgl.m, 66 tbf.ft) DAMPERFOBK Checkfor damage.
AOLT 10x 1.25mm !$ N.m (4.4 kgt.m, 32 rbf.ftl
STABILIZER LINK Checkfor daftage.
29 N.m {3.0 kgl.m, 2.2 lbf.ftl Beforetighteningthe llangenut, positionthe balliointpin in the middleof its rangeof travel, with the suspensionundervehicleload. www.emanualpro.com
FLANGEBOLT 8 x 1.25mm 22 N.m {2.2kg{.m, 16 tbf.ftl
DAMPERFORK RUBBER BUSHING Checkfor deterioration and damage.
SELF.LOCKING NUT 12 x 1.25mm Beplace. 64 N.m (6.5kgt.m, 47 lbf.ft)
Knuckle/HubReplacement Notetheseitemsduring replacement: . Replacethe selt-lockingnuts afterremoval. . The vehicleshouldbe on the ground beforeany boltsor nutsconnectedto rubbermountsor bushingsare tightened. . Torquethe castlenuts to the lowertorquespecifications, then tightenthem only far enoughto alignthe slotswith each pin hole.Do not alignthe nuts by loosening. o Use only genuineHondawheel weightsfor aluminumwheels.Non'genuinewheel weights may corrodeand damage t h e a l u m i n u mw h e e l s . . Onthealuminumwheels,removethe centercap from the insideof the wheelafter removingthe wheel. . Beforeinstallingthe brakedisc,cleanthe matingsurfacesof the front hub and brakedisc. . Beforeinstallingthe wheel.cleanthe matingsurfacesofthe brakediscand wheel. . Wipe off the greasebeforetighteningthe nuts at the balljoints.
CALIPERMOUNTINGBOLT 1 2x 1 . 2 5m m 108N.m (11.0kgtm.80 lbt.ftl
CASTLENUT 1 0x 1 . 2 5m m 39 - 47 N.m (i1.0- 4.8 kgf.m,29 - 35 lbf.ftl COTTERPIN Replace.
WHEELBEARING Beplace. page18-13 Replacement, CIRCLIP
SPLASHGUARD SCREW 5x0.8mm 4.9N.m {0.5kgf.m,3.6lbf.ft)
LOWERBALLJOINT Inspectfor faulty movementand wear, page'1815 Replacement,
F R O N TH U B C h e c kf o r d a m a g e a n d
SETRING
Replacement, page 18 10
BALLJOINTBOOT Checkfor deterioration ano oamage.
COTTERPIN Replace.
CASTLENUT 12x 1.25fim 49 - 59 N.m 15.0- 6.0 kgt.m.36 - € lbf.ft)
BRAKEDISC Checkfor wear and rust. R e p l a c e m e n t ,p a g e 1 8 - 1 0 I n s p e c t i o n ,s e c t i o n 1 9 .
SPINOLENUT 24 x 1.5mm 245 N.m {25.0kgI.m, 181 lbtft} Replace. . Beforeinstallingthe spindlenut,apply engineoil to the seatingsurfaceof the nut. . Aftertightening,usea driftto stakethe spindlenut shoulderagainstthe spindle.
WHEELNUT 1 2x 1 . 5m m 108N.m {11.0kgt m, 80 tbf.ftl
6 mm BRAKEDISCRETAININGSCREW 9.8 N.m (1.0kgtm, 7.2 lbtftl
(cont'd)
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18-9
FrontSuspension (cont'dl Replacement Knuckle/Hub 1 . Loosenthe wheel nuts slightly.
7. Removethe 6 mm brakedisc retainingscrews,
Raisethe front of the vehicle,and make sure it is secu.elysupported. Removethe wheel nuts and wheel. 6 mm BRAKEDISC RETAININGSCREWS 9.8 N.m (1.0 kgl.m,7.2 lbf.ftl
8 x 1.25mm BOLTS 8. Screwtwo 8 x 1.25mm bolts into the discto push it awav from the hub. Turn each bolt two turns at a time to prevent cockingthe disc excessively, NUT SPINDLE 24x 1,5mm 245N.m(25.0kgf.m,181lbtft) Replace. Raisethe lockingtab on the spindle nut, then remove the nut.
Removethe brakediscfrom the knuckle. Checkthe front hub for damageand cracks. 1 1 . R e m o v et h e w h e e l s e n s o rf r o m t h e k n u c k l e( f o r vehicleswith ABS). Do not disconnectthe wheel sensor connector.
Removethe brakehosemountingbolts. BRAKEHOSEMOUNTINGBOLT 8 x 1.25mm 22 N.m {2.2kgt m, 16 lbtft)
9.8 N.m (1.0 kgf.m, 7.2 tbttrl
CALIPER MOUNTING BOLTS 12x 1.25mm 108N.m(11.0kgl.m,80 lbl.ft)
Removethe caliper mounting bolts, and hang the caliperassemblyto ona side.To preventdamaggto t h e c a l i p e ra s s e m b l yo r b r a k e h o s e , u s e a s h o r t pieceof wire to hangthe caliperfrom the undercarriage. www.emanualpro.com
18-10
MOUNTING BOLTS 9.8 N.m lr.0 kgf.m, ?.2lbf.ftl
12. Cleanany dirt or greaseoff the ball joint. 1 3 . Removethe cotter pin from the steeringarm, and removethe nut.
17. Oncethe specialtool is in place,turn the adjusting bolt as necessaryto make the jaws parallel.Then h a n d - t i g h t e nt h e p r e s s u r eb o l t , a n d r e c h e c kt h e jaws to makesurethey are still parallel.
14. Apply greaseto the specialtool on the areasshown.
This will ease installationof the tool and prevent damageto the pressurebolt threads. PRESSURE BOLT
ADJUSTINGBOLT
tc.
lnstalla 10 mm hex nut on the ball joint. Makesure the hex nut is flush with the ball joint pin end to prevent damage to the threaded end of the ball joint. 28 mm BALLJOINTREMOVER, 07MAC- SL(x)2(x) HEXNUT
HEX NUT 10x 1.25mm ('99 modcll 43 N.m lit.a kgl.m. 32 tbtft) 6:)
After makingthe adjustmentto the adjustingbolt, make sure the head of the adjustingbolt is in this positionto allow the jaw to pivot. 1 8 . With a wrench, tighten the pressurebolt until the ball joint shaft pops loosefrom the steeringarm. wear eye protection. The balt ioint @ can break loose suddenly and scatter dirt or other dsbris in your ey€s. 1(|
Removethe tool, then removethe nut from the end of the ball joint, and pull the ball joint out of the steering/suspensionarm. Inspectthe ball joint boot. and replaceit if damaged.
CASTLENUT 10x '1.25mm l'97 - 98 modcls) 39 - 47 N.m {4.0- 4.8
29- 3s rbtftt
COTTER Replace.
37 -98 models:
'99 -00 modol:
Onre6ss€mbly, bendthe cofterpin 16. Install the special tool as shown. Insert the jaws carefully,makingsure you do not damagethe ball joint boot. Adiust the jaw spacing by turning the pressurebolt. lf necessary,apply penetratingtype lubricantto loosenthe ball ioint.
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(cont'dl
1 8 - 11
FrontSuspension Knuckle/HubReplacement(cont'd) 20. Removethe cotterpin from the lower arm ball joint castlenut, and removethe nut.
23. Removethe cotterpin from the upper ball joint castle nut, and removethe nut. COTTERPIN Replace. On reassembly,bend the cotterpin as shown.
COTTERPIN Replace. On ra6ssembly, bend the cofter pin
CASTI.ENUT 12 x 1.25mm ilg - 59 N.m (5.0 - 6.0 kgf.m, 36 - a3 lbf.ftl
CASTLENUT 10 x 1.25mm 39 - 47 N.m 14.0- ,4.8kgt m, 29 - 35 tbt.ftl
10 mm
nEMOVER, 28 mm 07MAC_ SLtD2(xl 24. Installthe 10 mm hex nut on the ball joint. Makesurethe hex nut is flush with the ball joint pin end, or the threaded section of the ball joint pin might be damagedby the balljoint remover. 25. Usethe specialtool as shown on page 18-11to separatethe ball joint and knuckle.lf necessary,apply penetratingtype lubricantto loosenthe ball joint.
CASTLENUT 12 x 1.25mm COITER PIN Replace.
BALLJOINTREMOVER, 28 mm 07MAC- Sl(xr2(x,
26. Pull the knuckleoutward, and remove the driveshaft outboardjoint from the knuckleby tapping the driv+ shaft end with a pl8stichammer,then removethe knuckle. KNUCKI.E Checklor damage.
Installa 12 mm hex nut on the ball joint. Make sure the hex nut is flush with the balljoint pin end,or the threadedsectionof the ball joint pin might be damaged by the balljoint remover. Usethe specialtool as shown on page 18-11to sepa r a t et h e b a l l j o i n t a n d l o w e r a r m . l f n e c e s s a r y , apply penetratingtype lubricantto loosenthe ball joint.
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18-12
27. Separatethe hub from the knuckleusingthe special tool and a hydraulicpress.Takecare not to distort the splashguard.Hold on to the hub to keepit from fallingwhen pressedclear.
29. Pressthe wheel bea.ingoutofthe knuckleusingthe soecialtoolsand a Dress.
DRIVER 077,19- 0010000
HUBDIS/ASSEMELY TOOL 07GAF- 5800100
ORIVER ATTACHMENT, 62x64mm 07947- 6340400
FRONTHUB
SETTING POINT
28. Removethe circlip and the splashguard from the knuckle. 30. Pressthe wheel bearing inner race from the hub using the specialtool, a bearing separator,and a press. Checkfor bendingand damage.
HU8OIS/ASSEMBLY TOOL 07GAF- SE00100 EEARING SEPARATOR O-1112in. (Commercially available)
{cont'd}
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18-13
Front Suspension Knuckle/HubReplacement(cont'dl 3 1 . Wash the knuckleand hub thoroughlyin high flash point solvent before reassembly, Pressa new wheel bearinginto the knuckleusing t h e o l d b 6 a r i n g ,a p l a t e .t h e s p e c i a lt o o l , a n d a press.Placethe wheel bearingon the knucklewith the pack seal side facing (metal color) toward the inside.Be careful not to damagethe sleeveof the Dackseal.
35. lnstallthe hub on the knuckleusingthe specialtools shown and a hydraulicpress.Be carefulnot to distort the splashguard.
ORIVER 077irg- 0010000
DOUBLELIPSEAL IBLACKCOLORI
SPLASHGUARO
BASE SUPPORT 0?965- SD90t00
33. Installthe circlip securelyin the knucklegroove.
scREws
5 N.m 10.5kgl m, 4 lbl'tt)
CIRCLIP
34. Installthe splashguard and tight€nthe screws.
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18-14
lnstall the knuckle in the reverse order of removal, and pay particular attention to the following items: Be careful not to damage the ball joint boots when installing the knuckle. r Torque a\\ mount\ng hardv{are to ths speci{ied torquevalues, o Torque the castle nuts to the lower torque speci fications, then tighten them only iat enough to align the slots with each pin hole. Do not align the castlenut by loosening. a lnstall new cotter pins on the castle nuts or hex nut aftertorquing. . Avoid twisting the sensorwires when installing the wheel sensor. . Before installing the brake disc, clean the mating surfacesof the front hub and the inside of the brakedisc. . Beforeinstallingthe spindle nut, apply a small amount of engine oil to the seatingsurfaceoJthe nut. After tightening, use a drift to stakethe spindle nut shoulderagainstthe driveshaft. . Beforeinstallingthe wheel.cleanthe matingsurfaceof the brakediscand the insideof the wheel. . Checkthe front wheel alignment,and adjust it if necessary {seepage 18-4).
.
Lower BallJoint Replacement '1.
Removethe knuckle(seepage 18-10).
8.
Installthe ball joint boot and set ring usingthe specialtool {seepage18-16}.
o
Installthe knucklein the reverseorder of removal. and pay particularattentionto the followingitems:
Removethe boot by prying the set ring off. Checkthe boot for deteriorationand damage.and replaceit if necessary. lnstallthe specialtools on the ball joint, and tighten the castlenut. 8AI.I JOINT REMOVEN/INSTALLER
BAII JOINTBEMOVER BASE 07JAF- SH2oe00 P o s i t i o nt h e s p e c i a lt o o l s o v e r t h e b a l l j o i n t a s shown. then set the assemblyin a vise. Pressthe ball joint out of the knuckle. Placethe ball joint in positionby hand. 7.
Installthe specialtools over the ball joint as shown, then pressthe balljoint in. BAII JOINT INSTAL1IR BASE
BALLJOINT HOUSINGSURFACE
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Be careful not to damage the ball joint boots when installingthe knuckle. . Torque all mounting hardwareto the specified torouevalues. a Torquethe castlenuts to the lower torque specifications,then tighten them only far enough to align the slot with the pin hole. Do not align the castlenut by loosening. . Install new cotter pins on the castle nuts after IOrqurng. Avoid twisting the sensorwires when installing the wheelsensor. Beforeinstallingthe brakedisc,cleanthe mating surfacesof the front hub and the inside of the brakedisc. Beforeinstallingthe wheel.cleanthe matingsurfaceof the brakediscand the insideof the wheel. Checkthe front wheel alignment,and adjust it if necessary(seepage18-4). .
18-15
Front Damper
FrontSuspension BallJoint Boot Replacement
Removal
1 . Removethe set ring and the boot.
1,
Removethe front wheels(seepage 18-10).
2.
Removethe damper pinch bolt from the top of the damperfork.
Packthe interiorof the boot and lip with grease.Do not contaminatethe boot installationsectionwith grease.
DAMPERFORK
BALL PIT{TAPEFEOS€CTION
DAMPER PINCH BOLT '10x 1.25
B{rcYHSI
SECTIO
wip6 off tho gr6aso.
BOOT|NST
SECTION
Wipo otf th6 grors€.
Wipe the greaseoff the sliding surfaceof the ball pin, and pack it with fresh greass. Keep grease off the boot installation section and the taoered section of the ball pin. Do not allow dust, dirt, or other foreign materialsto enter the boot. Installthe boot in the grooveof the boot installation sectionsecurelv,then bleedair. Installthe upper and lower ball joint boot set rings usingthe specialtools as follows: Lower ball joint: Adjust the special tool with the adjustingbolt until the end of the tool alignswith the groove on the boot. Slidethe set ring over the tool and into oosition. Upper ball joint: Hold the tool over the ball joint, then slidethe set ring overthe tool and into position. EAII JOINT B(X)TCUP GUttrE
AD'USN G BOLT Adjustth6 depthby turningthe bolt.
UPPERBAI.I
Jott'trBoor:
07GAG - SO407q) LOWEF BATI JOIIYI EOOTI 0t97il - SA507lXl
After installing the boot, check the ball pin tapered section for greasecontamination,and wipe it if necgssary.
18-16
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SELF.LOCKING NUT 12x 1.25fifi Replace. Removethe damper fork bolt and self-lockingnut from the bottom of the damper fork, then remove the damperfork. Removethe damperby removingthe two nuts.
DAMPER
Disassembly/ Inspection Disass.mbly 1 . C o m p r e s st h e d a m p e rs p r i n gw i t h a s p r i n g c o m pressor accordingto the manufacturer'sinstructions,then removethe self-lockingnut. Do not compressthe spring more than necessary to removethe nur.
SELF-LOCKING NUT 10 x 1.25mm 29 N.m (3.0kgl.m,22lbtftl Replace.
DAMPERMOUNTINGWASHER DAMPERMOUNTING
RUBBER Check for 10 mm SELFLOCKING Replace.
ano oamage.
DAMPERMOUAMNGCOLLAR DAMPERMOUNTING BASE
STRUT
DAMPERMOUNTING RUBBER Checkfor det€rioration ano oamage.
COMPRESSOR: lComm6rciallyavailablo) BRANICK@T/N MST-580A or Mod6l 7200 or equivalent
Releasethe pressurefrom the spring compressor, then disassemblethe damperas shown in the next cotumn. Inspection 1.
Reassemble all parts,exceptfor the spring.
2.
Pushon the damperassemblyas shown.
SPRINGMOUNTING
BUMPSTOPPLATE
..rg
BUMPSTOP g
DUST
weaknessand
C h e c k for bendingand damage. damage,
Checkfor smooth operationthrough a full stroke, b o t h c o m p r e s s i o na n d e x t e n s i o n .T h e d a m p e r should move smoothly.lf it does not (no compress i o n o r n o e x t e n s i o n )t ,h e g a s i s l e a k i n g a , nd the dampershouldbe replaced. Checkfor oil leaks,abnormalnoises,or bindingduring these tests.
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Front Damper lnstallation
Reassembly 1.
Installthe damperunit on a springcompressor. STRUTSPflNG COMPBESSOR: lcomm.rcillly .vrilrble) BRANICKCT/N MST.sEOA or Mod.l 7200 or oquivtla
1 . Loosely install the damper on the frame with the a l i g n i n gt a b f a c i n ginside,then loosely install tne two flangenuts. NUT FLANGE
.46 -
10 x 1.25mm 59 N.m {5.0 kgt m, 43 tbf.ftl
-__---a-"-
g*-
| -,./
./
--... -4
ADAMPER ASSEMBLY
SPRINGLOWERSEAT
Assemblethe damper in reverseorder of removal exceptthe damper mountingwasherand self locking nut. Align the bottom of the damperspring and the springlower seatas shown.
ALIGNING TAB
Positionthe damper mountingbaseon the damper unit as shown. 2, Installthe damperfork over the driveshaftand onto t h e l o w e r a r m . I n s t a l lt h e f r o n t d a m p e r i n t h e damperfork so the aligningtab is alignedwith the slot in the damDerfork,
10x 1.25mm il3 l+m {4.4kgf'm,
Compressthe damperspring, Installthe dampermountingrubber,dampermounting washer,and a new 10 mm self-lockingnut. NUT SELF-LOCKING 10x 1.25mm Zt N.m 13.0kgf.m, 22 lbf.ft) Replace.
DAMPER MOUNfING WASHER
Hold the dampershaft,and tightenthe 10 mm selflockingnut.
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18-18
Replace.
3. Looselyinstallthe damper pinch bolt on the top of the damperfork. 4. Looselvinstallthe damperfork bolt and a new selflockingnut on the bottom of the damperfork. 5. Raisethe knucklewith a floor iack until the vehiclejust lifts off the safetvstand. The lloor iack must b€ socurely positioned or personal iniury may result. 6. Tightenthe damperpinch bolt. 7. Tightenthe damperfork bolt and self-lockingnut. 8. Tightenthe flangenuts on top of the damper. 9. Installthe brakehose mounts with the brake hose mountingbolts. 10. Installthefront wheel.
RearSuspension Suspension ArmsReplacement when the suspensionarms are to be removed, plsce additional weight in lhe trunk beto.o hoisting. when @ substantial weight is removed from the rear of the vehicle, the center ot grsvity m8y chango causing the vehicle to tip forward. Notetheseitemsduring replacement: . Replacethe self-locking nuts afterremoval. . Any boltsor nuts connectedto rubbermountsor bushingsshouldbe tightenedwith the vehicleon the ground. . Makesurethe toe adjustingboltson the compensatorarm are installedin the samedirection, . After installingthe suspensionarm, checkthe rearwheelalignment,and adjustif necessa ry (seepage 18-4),
FLANGEEOLT 10 x 1.25mm 64 N.m 16.5kgf.m,47 lbf.ft)
FLANGEBOLT 10 x 1.25mm 54 N.m (5.5kgt.m, 40 lbf.ftt.
\
--1/
\A1(\
t \
BAR STABILIZER Checkfor bending or oamage.
STABILIZER 8AR
\a'v..:r UPPERARM BUSHING Checkfor deterioration and damage.
il ,
FLANGEBOLT 'l0 r 1.25mm 54 N.m (5.5 kgf.m,
8 mm EOLTS 22 N.m {2.2 kgf.m, 16 bl.ftl
40rbtft)
stLtcoNE
TRAILINGARM Checkfor bending 'anooamage.
UPPERARM BUSHING
-6l FLANGEBOLTS 10 x 1.25mm 39 N.m 14.0kgf.m, 29 lbf.ft)
stLtcoNE .@i COMPENSATOR ARMBUSHING
UPPERARM Checklor bendingor damage.
// ^/
COMPENSATOR ARM BUSHING
FLANGENUT 10 x 1.25mm 29 N.m {3.0kg{.fl,22 lbf.ft} Beforetighteningthe flangenut, positionthe balljoint pin in the middleof its rangeof travel,with the suspension under vehicleload. FLANGEBOLT 10 x 1.25mm 54 N.m {5.5 kgf.m, 40 lbf.ft}
64 N.m 16.5kgf.m, 47 lbtftl SELF.LOCKING NUT 10 x 1.25mm 29 N.m (3.0kgl.m, 22 tbf.ft) Replace. Holdthe ballioint pin usinga hexwrenct,, and tightenthe self-locking nut. STABILIZER LINK . Checkfor bendingand damage. . Checkthe bushingtor deterioration and damage.
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,/ FLANGEBOLT 10 x 1.25mm s4 N.m 15.5kst'm, 40 lbf ftl
Checktor damage. LOWERARM BUSHING Checkfor deterioration and damage. LOWENARM BUSHING
-6il
stLrcoNE
RearSuspension HubBearingUnit Replacement Notetheseitemsduring replacement: . Use only genuineHondawheel weightsfor aluminumwheels.Non-genuinewheel weights may corrodeand damage t h e a l u m i n u mw h e e l s . . Beforeinstallingthe brakedrum, cleanthe matingsurfacesof the rearhub and the brakedrum. . Beforeinstallingthe wheel,cleanthe matingsurfacesof the brakedrum and wheel.
FLANGEBOLI 12x 1,25mm 103N.m 110.5kgf.m, 76 tbtfr) BACKINGPLATE SPINDI-ENUT 2 2 x ' 1 . 5m m 181 N.m {18.5kgf.m, 134 lbf.ftl Replace. NOTE:Altertightening,usea drift punchto lockthe spindlenut shoulder intothe spindle.
BRAKESHOE TRAILINGARM Check{or cracking ano oamage.
FLANGEBOLT 10x 1.25mm 64 N'm 16.5kgf.m, 4? lbt.ft)
Checkfor cracking ano oamage. BRAKEDRUM Checkfor wear ano oamage,
WHEELNUT 1 2x 1 . 5m m 108N.m {11.0kgt m,80lbtftl
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1A-20
't. Raisethe rear of the vehicle,and make sure it is
7 . Disconnect the brakeline from the wheelcylinder.
securelysupponed. 6.
Removethe rearwheel. Removethe brakedrum from the hub by threading 8 x,r.25 mm bolts into the drum to push it away from the hub bearingunit. Turn each bolt two turns at a time to preventcockingthe drum excessively.
a
Removethe wheel sensorfrom the backing plate ( f o r v e h i c l e sw i t h A B S ) . D o n o t d i s c o n n e c t h e wheelsensorconnector. Removethe 12 mm flangebolts.
8 x 1.25mm BOLTS
i+/3 ',1
/
"@,1 /
-->-
\ . ' - - 7J
SPINDLENUT r81 N.m t18.5kgt m, 134lbt'ftl Replace.
WHEELNUT 12 x 1.5 mm 108N m 111.0kgf'm, 80 lbf ftl
4.
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.
5.
Removethe brakeshoes.
6.
Removethe parking brakecable from the backing plateusinga 12 mm offsetwrenchas shown.
PULLER available) lCommercially
1 0 . 4WD; Removethe backing plate/hubbearing unit from the rearaxlewith a pullerif necessary.
BACKINGPLATE
1 1 . Separatethe rear hub from the hub bearing unit
usingthe specialtoolsand a press. Notethe followingitemsduring disassembly: . Takecare not to distort the backing plate. . Hold on to the hub to keep it from falling when
DRIVERATTACHMENT, 37 x ilo mm 07746- 0010200
PARKINGARAKECABLE
(cont'd)
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1a-21
RearSuspension Hub BearingUnit Replacement(cont'd) 12, Pressthe wheel bearing inner race from the hub usingthe tools,a bearingseparator,and a press. HUB DIS/ASSEMBLYTOOL 07965- SA50100 BEARING SEPARATOR mml 0 -,t 1/2 in {0 - 11i1.3 qvailable) (Commercially
't7. Installthe hub bearingunit onto the rear hub using the specialtools and a press. DRIVER ATTACHMENT, 60 mm 07LAO- SM40100
Prcss
+
DRIVER 07749- 0010000
BEARING
13. Removethe 12 mm flangebolts.
HUB BEARINGUN]T
REARHUB
O.RING
1 8 . I n s t a l l t h e b a c k i n g p l a t e / h u b b e a r i n gu n i t o n t h e trailing arm. FLANGEBOLTS 12 x 1.25mm 103N.m 110.5kgf'm,75lbfft)
1 4 . R e m o v et h e h u b b e a r i n g u n i t f r o m t h e b a c k i n g plate. 15. Installa new O-ringon the hub bearingunit. FLANGEBOLTS 10x 1.25mm 64 N.m (6.5kgf.m, 47 lbf.ftl
16. Installthe hub bearingunit on the backingplate.
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18-22
19. Installthe hub bearingunit in the reverseorder of removal,and pay particularattentionto the following items: . Before installingthe spindle nut, apply a small amountof engineoil to the seatingsurfaceof the nut, After tightening, use a drift to stakethe spindle nut shoulderagainstthe driveshaft. . Avoid twisting the sensorwires when installing the wheelsensor, . Fill the brakereservoirand bleed the brakesystem {seesection19). . Adjustthe parkingbrake(seesection191. . Checkthe rear wheel alignment,and adjust it if necessary(seepage 18-4).
RearDamper UpperArm BushingReplacement 1.
R e m o v et h e u p p e r a r m b u s h i n g a n d u p p e r a r m innerbushingas shown. UPPER ARM INNERBUSHING
Removal 't. Removethe rearwheels(seepage '18-21), Removethe damper accesspanel and the damper cap.
UPPER ARM AUSHIT{G 5.
Removethe two flange nuts. ACCESSPANEL
OAMPERCAP
REARUPPERARM Mark a scribeline on the upper arm inner bushing so it is in linewith the bolt mountingsurface.
4.
Removethe flangebolts.
BOLT MOUNTII{G SURFACE
Makea mark on the upperarm at two pointsso the marks are in line and at a right angle with the arm as shown in the drawing. Drive in the upper arm inner bushingwith the marks aligned until the leadingedge is flush with the uoDerarm. L o w e r t h e r e a r s u s p e n s i o n ,a n d r e m o v e t h e damper.
Drive the upper arm bushing into the upper arm untilthe leadingedge is flush with the upperarm.
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1a-23
RearDamper Disassembly/lnspection Disassembly L
Compressthe damper spring with the spring comp r e s s o ra c c o r d i n gt o t h e m a n u f a c t u r e r 'isn s t r u c tions,then removethe self-lockingnut. Do not compressthe spring more than necessary to removethe self-locking nut. SELF-LOCKING NUT 10 x 1.25mm Replace.
OAMPER MOUNTING WASHER
SELF-LOCKING NUT 10x 1.25mm 29 N.m {3.0kgf.m,22 lbf.ft) Beplace.
OAMPERMOUNTING
RUBBER C h e c kf o r deterioration ano oamage.
DAMPERMOUNTING COLLAR DAMPER MOUNTINGBASE DAMPERMOUNTING RUBBER Checkfor deterioration ano oamage.
STRUTSPRING COMPRESSOR: lCommercirlly avaihblo) BRANICKO I/N MSI-580A or Mod6l/7200or equivalent
2.
Releasethe pressurefrom the spring compressor, then disassemble the damperas shown on page 1825.
Inspection 1. 2.
DAMPER Checkfor weakness, compressron
'"dd"^.s"' //F,
DUSTCOVERPLATE
SPRINGMOUNTING RUBBER CheckIor deterioration and damage. BUMP STOP Checkfor weakness ano oamage. BUMP STOPPLATE
Reassemble all parts,exceptthe spring. Pushon the damperas shown. DUSTCOVER Checkfor bending and damage. DUSTCOVENBOOT Checkfor deterioralion ano oamage. WOODENELOCK
DAMPER
3.
4.
Checkfor smooth operationthrough a full stroke, b o t h c o m p r e s s i o na n d e x t e n s i o nT. h e d a m p e r should move smoothly.lf it does not (no compress i o n o r n o e x t e n s i o n )t ,h e g a s i s l e a k i n g a, n d t h e dampershouldbe replaced. Checkfor oil leaks,abnormalnoises,or bindingdurino thesetests.
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lnstallation
Reassembly 1.
I n s t a ltlh e d a m p e ru n i to n a s p r i n gc o m p r e s s o r ,
1.
L o w e r t h e r e a r s u s p e n s t o n a, n d p o s i t i o n t h e d a m p e r .T h e s p r i n g s t o p o n t h e r i g h t d a m p e r should face rearward,and the s p r a n gs t o p o n t h e left dampershouldfaceforward.
2.
Loosely install the two flange nuts.
2 . Assemblethe reardamperin reverseorderof disassembly except the damper mounting washer and self-lockingnut. Align the bottom of the damper springand the springlower seatas shown.
DAMPERMOUNNNG
STRUTSPBINGCOMPRESSOR: (Commorcislly!v.ilablel BRANICKCT/N MST.s8OA
SPRINGSTOP
FLANGENUTS 10x 1.25mm . .: {9 N.m 15.0kgf.m,36 lbtft}-----.-* :',,rigf't"n if'"""_nrr. in qla^ 7 Step7.
3. 3.
Looselyinstallthe flangebolt.
Positionthe dampermountingbase on the damper u n i ta s s h o w n .
FLANGEEOLT 10 x 1.25mm 54 N.m 15.5kgt.m, 40 tbI.ft)
Compressthe damper spring with the spring compressor. I n s t a l lt h e d a m p e rm o u n t i n gw a s h e r ,a n d l o o s e l y nut. installa new self-locking
Raisethe rear suspensionwith a floor jack until the vehiclejust lifts off the safetystand.
NUT SELF.LOCKING 10x 1.25mm 29 N.m (3.0 Replace.
The floor iack must be securely posi@ iioned or personal iniury may result. Tightenthe flangebolt.
Holdthe dampershaftwith a hex wrench,and tightnut. en the self-locking
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6.
Tighten the two flange nuts on the top of the damperto the specifiedtorque.
7.
Installthe dampercap and accesspanel.
8.
Checkthe rearwheelalignment.and adjustif necessary (seepage 18-4).
18-25
Brakes . . . . . . . . .1. .9 - 1 Anti-lockBrakeSystem (ABS) ............. 19-25
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Brakes 19-2 ............. SpecialTools ComponentLocations ......19-3 lndex ................ Inspectionand Adlustment BrakeSystem RubberParts 19-4 and BrakeBooster..........,,,.......... ............ 19-5 BrakePedal ........19-6 ParkingBrake 19'7 ................. Bleeding 19-8 BrakeSystemIndicator................... Front BrakePads Inspectionand Replacement..........19-9 Front BrakeDisc 19-11 DiscRunoutInspection................... DiscThicknessand 19-11 Parallelism Inspection........,........ Front BrakeCaliper ............... 19-12 Disassembly/Reassembly
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MasterCylinder/BrakeBooster 19-13 ....................... Removal/lnstallation Master Cylinder .............. 19-14 Inspection/Disassembly PushrodClearanceAdiustment ......19-14 19-15 BrakeBoosterInspection...,.,,,,....... RearDrum Brakes 19-15 .............. Inspection BrakeShoes .....19-r8 Replacement Wheel CylinderReplacement.........19-20 BrakeHoses/Lines Specifications... 19-21 Inspection/Torque ..,,,19-22 ....,...,............. HoseReplacement ParkingBrakeCable Inspectionand Replacement..........19-23
SpecialTools
Ref. No. (,
19-2
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Tool Number |
07JAG. SD40100
Description |
PushrodAdiustmentcauge
psge Reference
ety I
r
I
tg_rt
Gomponent Locations lndex
ERAKESYSTEMINOICATOR CircuitDiagram,page't9-8 PARKINGBRAKE Adjustment,page19-6 '19-8 ParkingBrakeSwitchTest, page PARKINGBRAKECABI..E and Replacement, Inspection page19-23 BRAKEBOOSTER page19-15 BrakeBoosterInspection, page19 13 Removal/lnstallation,
)i't
' -"''
/'"''t,'.., ,
1...,.
\,,,. 'a., i ,.' I .)
t
^fl)
..)
REARDRUM BRAKE pago19-16 Inspection, BrakeShoesReplacement, page19-18 WheelCylinder page19-20 Replacement, MASTERCYLINDER page19-13 Removal/lnstallation, lnspection/Disassembly. p a g e1 9 - 1 4 PushrodClearance Adjustment, p a g e1 9 l d BrakeFluidLevelSwitchTest, page19-8
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Inspection/TorqueSpecification,pag€'19-21 Hose Replacement,Page19-22 FrontBrakePads,page19-9 FrontBrakeDisc.page19-11 FrontBrakeCaliper,page19-12
19-3
Inspectionand Adjustment BrakeSystemRubberPartsand BrakeBooster @-BrakeBooster Checkbrakeoperationby applyingthe brakes. lf the brakesdo not work properly,checkthe brake booster.Replacethe brakeboosteras an assemblyif it does not work properlyor if thereare signsof leakage. @-Piston Cup and PressureCup Inspection . Checkbrakeoperationby applyingthe brakes. Visuallycheckfor damageor signs of tluid leakage. R e p l a c et h e m a s t e rc y l i n d e ra s a n a s s e m b l yi f t h e pedaldoes not work properlyor if there is damageor signsof fluid leakage. .
Checkfor a differencein brakepedalstrokebetween q u i c ka n d s l o w b r a k ea p p l i c a t i o n R s .e p l a c e the mas-. ter cylinderif there is a differencein pedalstroke.
19-4
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(9-BrakeHoses Visuallycheckfor damageor signsof fluid leakage. Replacethe brake hose with a new one if it is dama g e do r l e a k i n g . O-Caliper Piston S€al and Piston Boots Checkbrakeoperationby applyingthe brakes. Visuallycheckfor damageor signsof fluid leakage.lf the pedaldoes not operateproperly,the brakesdrag, or there is damageor signs of fluid leakage,disass e m b l ea n d i n s p e c t h e b r a k ec a l i p e r .R e p l a c et h e boots and sealswith new ones wheneverthe brake caliperis disassembled. @-WheelCylinder Piston Cup and Dust Cover Checkbrakeoperationby applyingthe brakes. Visuallycheckfor damageor signsof fluid leakage.lf the pedaldoes not operateproperly,the brakesdrag, or there is damageor signs of fluid leakage,replace the wheelcvlinder.
Brake Pedal Pedal Hoight 1. Disconnectthe brakeswitch connector,loosenthe brake switch locknut, and back off the brake switch until it is no longertouchingthe brakepedal. 2.
4.
Screw in the brakeswitch until its plunger is fully p r e s s e d( t h r e a d e de n d t o u c h i n g t h e p a d o n t h e pedal arm), Then back otf the switch 1/4 turn to make 0.3 mm (0.01 in) of clearancebetween the threadedend and pad. Tighten the locknutfirmly. Connectthe brake switch connecto.. Make sure that the brakelights90 off when the pedalis released
5.
Checkthebrakepedalfreeplay as describedbelow
Lift up the carpet,At the insulatorcutout,measure the pedalheightfrom the middleof the right side of the oedalpad. BRAKESWITCH
ERAKESWITCH
Pedal FreePlay 1. With the engine off. inspect the free play on the pedalpad by pushingthe pedalby handStandard Pedal Height (with floor m8i removed): A/T: 161mm (5 5/16 in) M/T: 155 mm {6 U8 in}
FreePlay:1 - 5 mm (1/16- 3/16 in) 2.
Loosenthe pushrodlocknut,and screwthe pushrod in or out with pliersuntil the standardpedal height from the floor is reached.Do not adjustthe pedal heightwith the pushrodpressed.After adiustment, tightenthe locknutfirmly.
adiust lf the pedalfree play is out of specification, the brake switch. lf the pedal free play is insufficient,it may resultin brakedrag.
swtTcH
PEOALPAD
PUSHRODLOCKNUT 15 N.m 11.5kgj m, 11 lbf ftl
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PEDALFREEPLAY
19-5
Inspectionand Adjustment ParkingBrake Inspeqtion 1.
3.
Releasethe parkingbrakelever.
Pull the parkingbrake lever with 196 N (20 kqf, 44 lbfl forceto fully applythe parkingbrake. The parkingbrakelevershould be lockedwithin the specifiednumberof clicks. L.var LockodClicks:2 - 6
Adjust the parking brake by turning the adjusting nut. Checkthat the parkingbrakesdo not drag when the rearwheelsare turned.Readjustif necessary.
2.
Adjustthe parkingbrakeif the leverclicksare out of specification.
Adiustment 1.
Raisethe rear wheels off the ground. and support the vehicle on safety stands.
@@
Bbck tho front who€ts betore iacking
up the rear ot tho vohicle.
2.
Removethe parkingbrakecover PARKINGBRAKECOVER
19-6
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Makesurethe parkingbrakesare fully appliedwhen the parkingbrakeleveris pulledup fully. 7.
Installtheparkingbrakecover.
Bleeding CAUNON: . Do not spill brake tluid on the vehicle. it may damage the paint; if brake fluid does contaqt th€ paint, wash it otf immodiately with water. . Maks sure no dirt oy other forsign matter is allowsd to contaminate the brake fluid.
FRONT:
NOTE: . Do not reusethe drainedfluid. . Always use GenuineHondaDOT3 BrakeFluid.Using a n o n - H o n d ab r a k ef l u i d c a n c a u s ec o r r o s i o na n d decreasethe life of the svstem. . The reservoiron the mastercylindermust be at the MAX (upper)level mark at the start of bleedingprocedureand checkedafter bleedingeach brakecaliper and wheelcylinder.Add fluid as required. 1,
Makesure the brakefluid levelin the reservoiris at levelline. the MAX (uDDer)
MAX {UPPER)LEVEL LINE RESERVOIR MASTERCYLINDER
2. 3.
4.
Havesomeoneslowly pump the brakepedalseveral times,then applysteadypressu.e. Loosenthe brakebleedscrewto allow air to escape f r o m t h e s y s t e m .T h e n t i g h t e n t h e b l e e d s c r e w securely. Repeatthe procedurefor eachwheelin the sequence shown below until air bubblesno longer appearin the tluid. Refill the reservoir on the master cvlinder to the MAX (upper)levelline.
BLEEO SCREW 7 N.m(0.?kgf.m,5 lbf.ftl
ALEEDINGSEOUENCE: O Front Right
Gt RearRight
O Front Lefl
O Rear Left
NOTE:Bleedthe front calipersfirst in the bleeding procedure.
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19-7
Inspectionand Adjustment BrakeSystemIndicator Circuit Diagram
lNuLR.HorJD
UNDEB.DASH FUSE]NEtAY BOI
GNrT0ll St!ITCH
r l l A N l ]4 2 4 ! A
GBNiBEO
I
o\ t uEU0 r E V E9r! 1I ( N lt j I ERAK
P A FN KCB R A ( E S\I'ICH
| BIK
o P t ^ r ' f ., r' 1
I
-o:
G401
Parking BrakeSwitch Test
Brake Fluid Level Switch Test
1.
Removethe parkingbrakecover,
1.
2.
Disconnectthe connectorfrom the parking brake switch.
R e m o v et h e r e s e r v o i rc a p . C h e c kt h a t t h e f l o a t movesup and down freely;if it doesn't,replacethe reservoircap assembly.
2. 3.
Checkfor continuitybetweenthe terminaland body ground in eachpositionaccordingto the table.
Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the table.
Terminal
\
LeverPosition \
Positive Terminal
\ Body Ground
--o
LeverUp
r9''r
Position FLOATUP FLOATDOWN
Lever Down
1
o
RESERVOIR CAP
GROUND
NOTE(Canada):lf the parking brakeswitch is OK, but the brake system indicatordoes not function, perform the input test for the daytimerunninglightscontrol unit (seesection23).
19-8
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Switch contacts open at proper fluid level.
2
Front BrakePads Inspectionand Replacement 4. Nsvgr u9e an air hose or dry brush to clean brake assemblies. Use an OSHA approved vacuum cleaner to avoid broathing brake dust. 1.
U s i n g v e r n i e rc a l i p e r s ,m e a s u r et h e t h i c k n e s so f each brake pad lining.The measurementdoes not includethe pad backingplatethickness. Brake PadThickness: - 0.45in) Standard: 10.5- 11.5mm {0.,11 Servics Limit: 1.6 mm (0.06in)
Loosenthe front wheel nuts slightly,then raisethe v e h i c l e ,a n d m a k e s u r e i t i s s e c u r e l ys u p p o r t e d . Removethe front wheels. Removethe caliper bolt, and pivot the caliper up out of the way. Checkthe hosesand pin boots for damageand deterioration.
i)n. CALIPER BOLT 3.
EACKINGPLATE
lf the brake pad thicknessis less than the service limit. replacethe front padsand shimstogetheras a set.
CALIPERBODY
Remove the pads, pad shims, and pad retainers.
Cleanthe caliperthoroughly;removeany rust, and checkfor groovesand cracks.
INNEBPADSHIMS Checkfor weakness.
7.
Checkthe brakediscfor damageand cracks.
L
Installthe pad retainers.
'.'..i
# I
OUTERPADSHIM Checkfor weakness.
PAD RETAINERS
(cont'd)
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19-9
Front BrakePads (cont'dl Inspection and Replacement 9 . A p p l y M o l y k o t e M 7 7 g r e a s e o r D a i k a l u b5 2 8 D greaseto both sidesof the pad shims and the back of the pads.Wipe excessgreaseoff the shims.
ApplyMolykote M77
'11. Pushin the piston so that the caliperwillfit over the pads. Make sure the piston boot is in position to p r e v e n td a m a g i n g i t w h e n p i v o t i n g t h e c a l i p e r down. CALIPER BOLT 49 N.m(5.0kgf.m,36 lbf.ftl
to both sides of shims.
INOICATOR Apply MolykoteM77 or 0aikalub528D to both sidesof shim.
INNERPAD
OUTERPAD
Pivot the caliperdown into position,being careful not to damagethe pin boot. Installthe caliperbolt and tightenit, 1 3 . Pressthe brake pedal severaltimes to make sure the brakeswork, then test-drive.
1 0 . l n s t a l lt h e b r a k e p a d s a n d p a d s h i m s c o r r e c t l y . Installthe pad with the wear indicatoron the inside.
.
When reusing the pads, always reinstall the brakepads in their originalpositionsto prevent loss of braking efficiency. . Contaminatedbrake discs or pads reducestopping ability.Keepgreaseoff the discsand pads.
19-10
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N O T E : E n g a g e m e n ot f t h e b r a k e m a y r e q u i r e a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 1 4 . After installation, check for leaks at hose and line joints and connections,and retighten if necessary.
Front BrakeDisc DiscRunoutInspection l.
Loosenthe front wheel nuts slightly,then raisethe v e h i c l e ,a n d m a k e s u r e i t i s s e c u r e l ys u p p o r t e d . Removethe front wheels. Removethe brakepads{seepage 19-9). I n s p e c t h e d i s c s u r f a c ef o r d a m a g ea n d c r a c k s . Cleanthe discthoroughly,and removeall .ust. Use wheel nuts and suitableplain washersto hold the disc securelyagainstthe hub, then mount a dial i n d i c a t o ra s s h o w n , a n d m a a s u r et h e r u n o u t a t 10 mm (0.4in) from the outer edgeof the disc.
DiscThicknessand Parallelism Inspection 1.
Loosenthe front wheel nuts slightly,then raisethe vehicle, and make sure it is securely supported. Removethe front wheels. Removethe brakepads(seepage 19-9). Usinga micromater,measurediscthicknessat eight points,approximately45'apan and 10 mm (0.4 in) in from the outeredgeof the disc.Replacethe brake disc if the smallest measurementis less than the max. refinishinglimit.
BrakeDi3c Runout: ServiceLimit: 0.10 mm {0.00,0in)
NUTAND WHEEL PLAINWASHER 108N.m{11kg{m, 80 lbf.ft) lf the disc is beyond the servicelimit, refinishthe brake disc with an on-car brake lathe. The KwikLathe produced by Kwik-way ManufacturingCo. and the "Front Brake Disc Lathe" offered by Snapon ToolsCo. are approvedfor this operation. M8x. RofinishLimit: 21.0 mm l0.8il in) NOTE:A new disc shouldbs refinishedif its runout is greaterthan 0.10mm (0.004in).
Brake DiscThickness: Standard: '97 - 98 modsls: 22.9 -23.1mm {0.90- 0.91 inl '99 - 00 mod€ls: 23.6- 23.8 mm {0.93- 0.94 in} Max. RefinishingLimit:21.0 mm (o.txlin) Brake Disc Parallelism:0.015mm {0.0006in} max. NOTE:This is the maximum allowabledifference betweenthe thicknessmeasurements, lf the disc is beyondthe servicelimit for parallelism, refinishthe brake disc with an on-car brake lathe. The Kwik-Latheproduced by Kwik-WayManufacturing Co. and the "Front BrakeDiscLathe" offered by Snap-on Tools Co. are approved for this operatron. NOTE:Seesection18for brakedisc replacement.
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1 9 - 11
Front BrakeCaliper Disassembly/Reassembly . Never use an air hose or dry brush to clean brake assemblies. . Usean OSHAapprovedvacuumcleanerto avoidbreathingbrakedust. . Contaminatedbrake discs or pads reducestopping ability. . When reusingthe pads,alwaysreinstallthebrakepadsin their originalpositionsto preventlossol brakingefficiency. CAUTION: . Do not spill brakefluid on the vehicle;it may damagethe paint; if brakefluid does contactthe paint,wash it off immediatelYwith water. NOTEI . To preventspills,coverthe hosejointswith ragsor shoptowels. . C l e a na l l p a n si n b r a k ef l u i da n d a i r d r y ;b l o wo u t a l l p a s s a g ews i t h c o m p r e s s eadi r . . Beforereassembling, checkthat all partsare free of dust and otherforeignparticles. . Replacepartswith new oneswheneverspecifiedto do so. . Makesure no dirt or otherforeignmatteris allowedto contaminatethe brakefluid. . D o n o t r e u s et h e d r a i n e df l u i d . . A l w a y su s e G e n u i n eH o n d aD O T3 B r a k eF l u i d .U s i n ga n o n - H o n d ba r a k ef l u i d c a n c a u s ec o r r o s i o na n d d e c r e a s teh e life of the system. . C o a t h e p i s t o np, i s t o ns e a l ,a n dc a l i p e b r o r ew i t h c l e a nb r a k ef l u i d . . ReDlace all rubberoartswith new oneswheneverdisassembled. . After installingthe front brakecaliperdo the following. - Checkfor leaksat hoseand linejointsand connections, and retightenif necessary. - Checkthe brakehosesfor interference and twistinq. t".:jil ,,.'.1!!!!9!il: Rubber grease (Use recommended
grease in the caliper set)
Siliconegrease(use recommendedsealgreaseand p,n greasein the caliperset)
--6,
I N N E RS H I M
I N N E RS H I M B
12 mm FLANGEBOLTS 113N.m (11.5kgtm,83lbf.ftl
WEABINDICATOR
.@ irf"i:;;T::fl,-J'I",0 \ i ft i l 1 # PIN B
#
I
OUTERPAOSHIM
EANJO BOLT 34 N.m {3.5kgf m,25 lblftl SEALING WASHERS Replace.
PIN BOOT
-Cr
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ERAKEPADS
'f,-rre
PADSPRING
> 6-
PIN A
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AFACKET CALIPER BOOY
I N m 10.9kStm, 6.5lbnft) \ CALIPEREOLTS 49 N.m {5.0kgl.m, 36lbf.ftl
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19-1 2
{
PISTONSEAL Replace.
PADRETAINERS PISTONAOOT Replace. "..-a=a-. PISTON ..,--"sEqri
Master Cylinder/BrakeBooster Removal/lnstallation 1, 2. 3. 4.
5. 6.
Disconnect the brakefluid levelswitchconnectors. Removethe reservoircap from the mastercylinder. R e m o v et h e b r a k ef l u i d f r o m t h e m a s t e rc v l i n d e r reservoirwith a syringe. Disconnect the brakelinesfrom the mastercylinder. To preventspills,cover the line joints with rags or shop towels. R e m o v et h e m a s t e rc y l i n d e rm o u n t i n g n u t s a n d wasners. Removethe mastercylinderfrom the brakebooster.
9. Removethe four boostermountingnuts. ' 1 0 .P u l l t h e b r a k eb o o s t e rf o r w a r d u n t i l t h e c l e v i si s clearof the bulkhead. 1 1 . R e m o v et h e b r a k eb o o s t e rf r o m t h e e n q i n ec o m panment. 12. Installthe brakeboosterand mastercylinderin the reverseorderof removal,and notetheseitems: . When connectingthe brakelines,makesure that there is no interferencebetweenthe brake lines and other parts. . Be carefulnot to bend or damagethe brakelines when installingthe mastercylinder. . lf replacingthe mastercylinderor brakebooster, checkand adjust the pushrod clearancebefore installingthe mastercylinder(seepage19-14).
CAUTION: Be careful not to bend or damagethe brakelineswhen removingthe mastercylinder. Do not spill brake fluid on the vehicle; it may dam. age the paint; it brake fluid does cont.ct the paint, wash it oft immediately with water. 7. 8.
Disconnect the vacuumhosefrom the brakebooster. Removethe cotterpin and clevispin from the clevis. Do not disconnectthe clevis by removing it from the operatingrod of the brakebooster.lf the clevis i s l o o s e n e d ,a d j u s t t h e p u s h r o d l e n g t h b e f o r e installingthe brakebooster(seepage 19-15).
1 3 . F i l l t h e m a s t e rc y l i n d e rr e s e r v o i r a , n d b l e e dt h e brakesystem(seepage 19-7). 1 4 . After installation,checkthe brakepedal height and brakepedalfree play (seepage 19-5),and adjust if necessary.
vAcuuM HosE | BRAKE FLUTD LEvEL |
15N.m{1.5kgtm, r r rbf.ft) / To FrontCaliper(WithoutABS)
\
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I
I
I r o R e awr h e ect y l i n d e r s/
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To MasterCylinder (WithoutABS) To ModulatorUnit (with ABs)
swrrcHcoNNEcroRs
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COTTERPIN
neotace I
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-#q CLEVISPIN
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To FrontCaliper
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9i \.
13 N.m 11.3kg{.m, I rbf.ft) PROPORTIONING CONTROLVALVE
MASTERCYLINDER BRAXEBOOSTER
15 N.m (1.5kgf.m,11 lbl.ftl
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Master Cylinder Inspection/Disassembly
PushrodClearance Adjustment
CAUTION: Do not spill brake fluid onthe vehicle;it may damsge the paint; il brake fluid does contact th6 paint. wash it off immodiately with water.
NOTE:Mastercylinderpushrod-to-piston clearancemust be checkedand adjustments made, if necessary.before installingthe mastercylinder.
NOTE: . Beforereassembling, checkthat all parts are free of dust and otherforeignparticles. . Do not try to disassemble the mastercylinderassembly. Replacethe mastercylinderassemblywith a new pan it necessary, . Make sure no dirt or other foreign matter is allowed to contaminatethe brakefluid.
1.
Set the specialtool on the master cylinder body; push in the centershaft until the top ot it contacts the end of the secondarypiston by turning the adjustingnut. PUSHRODADJUSTMENTGAUGE 07JAG- SD{o100 SECONDARY
RESERVOIR SEAL Checkfor damaoeand deterioration,
MASTERCYLINDER ADJUSTINGNUT
Without disturbingthe center shaft's position, installthe specialtool upsidedown on the booster. RESERVOIR Checkfor damage. RODSEAL Checkfor damage and deterioration.
Installthe mastercylindernuts,and tightenthem to the sDecifiedtoroue. Connectthe boosteriniine with a vacuumgauge0 101 kPa (0 - 760 mmHg, 30 in Hg) to the booster's e n g i n e v a c u u m s u p p l y , a n d m a i n t a i na n e n g i n e speedthat will deliver66 kPa(500mmH9,20 in Hg) vacuum. With a feeler gauge, measurethe clearancebetween the gaugebody and the adiustingnut as shown.
-€-1 SILICONEGREASE MASTERCYLINOER Checkborefor wear,rustand damage.
Clearanco:0 - 0.4 mm (0 - 0.02 inl VACUUM GAUGE lCommo.cidly 6vailablcl 0 - 101 kPt l0 - 760 mm Hg, 30 in Hgl
MASTERCYLINDERNUT 15 N.m 11.5kgt m, 11 lbt.ftl
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19-14
BrakeBoosterInspection l f t h e c l e a r a n c eb e t w e e nt h e g a u g e b o d y a n d adjusting nut is 0.4 mm (0.02in), the pushrod-topistonclearanceis 0 mm. However.if the clearance betweenthe gaugebody and adjustingnut is 0 mm, the pushrod-to-piston clearanceis 0.4 mm (0.02in) o r m o r e . T h e r e f o r ei t m u s t b e a d j u s t e da n d recheck€d. 6. lf clearanceis incorrect,loosenthe star locknut,and turn the adjusterin or out to adjust. . .
FunctionalTest 1. With the enginestopped,pressthe brakepedalseve r a l t i m e s t o d e p l e t et h e v a c u u m r e s e r v o i rt.h e n pressthe pedal hard, and hold it for 15 seconds.lf t h e p e d a l s i n k s ,e i t h e r t h e m a s t e r c y l i n d e r i s bypassinginternally,or the brake system (master cylinder,lines, modulator,proportioningvalve. or caliper)is leaking. 2.
Startthe enginewith the pedalpressed.lf the pedal sinksslightly.the vacuumboosteris operatingnormally.lf the pedalheightdoes not vary,the booster or checkvalveis faultv.
3.
With the enginerunning,pressthe brakepedallightly. Apply just enough pressureto hold back automatic transmissioncreep. lf the brake pedal sinks morethan 10 mm (3/8in.) in threeminutes,the master cylinderis faulty.A slightchangein pedalheight when the Ay'Ccompressor cycles on and off is normal. (TheAy'Ccompressorloadchangesthe vacuum availableto the booster.)
Adjustthe clearancewhile the specifiedvacuum is appliedto the booster. Holdthe cleviswhile adjusting.
7 . Tightenthe star locknutsecurely. 8. Removethe specialtool. 0 - 0.4mm (0- 0.02inl STARLOCKNUT 22 N.m 12.2kgt m. 16 lbtftl
Leak Test 1 . Pressthe brakepedalwith the enginerunning,then stop the engine. lf the pedal height does not vary while pressedfor 30 seconds,the vacuum booster is OK. lf the pedal rises,the booster is faulty. With the engine stopped, press the brake pedal severaltimes using normalpressure.Whenthe pedalis first pressed.it shouldbe low, On consecutive applications,the pedalheightshouldgraduallyrise.lf the pedal position does not vary. check the booster checkvalve.
9 . Adjust the pushrodlength as shown if the booster is removed, 1 1 6 1 0 . 5m m {4.6 t 0.02 inl
Boostor ChockValve Test 1.
Disconnectthe brake boostervacuum hose at the booster.
2.
Startthe engine,and let it idle.Thereshouldbe vacuum. lf no vacuum is available,the checkvalve is not working properly. Replacethe brake booster vacuumhoseand checkvalve.and retest. ERAKEBOOSTER VACUUM HOSE (Checkvalveis built-in)
PUSHROD LOCKNUT 1.5N.m11.5kgf.m.'11lbtfl)
1 0 . Install the master cylinder (see page 19-13).
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RearDrum Brakes Inspection a a rl a
Never use an air hose or dry brush to clgan brake assemblies, Use an OSHA approved vacuum cleanerto avoid breathing brake dust. Contaminatedbrake linings or drums reduce stopping ability. Block the front wheels betore iacking up lhe rear ot the vehicle,
1.
Blockthe front wheels,loosenthe rear wheel nuts slightly,then raisethe vehicle,and make sure it is securelysupponed.Removethe rearwheels.
2.
Release the parkingbrake,and removethe rearbrakedrum.
I N.m {0.9kgl.m,5.5rbr.ft)
\ \
BACKINGPLATE Markedleftand right.
\ 196 @
PARKINGEBAKE I-EVER Markedleft and right. ADJUSTERBOLT Checkratchetteeth for wearand damage. UPPERRETURN SPRING Checkfor weakness and damage. CLEVISB
CLEVISA
\L;
'l-'-' I
t /
64 N.m 16.5kgl.m, 47 lbt.ftl
BRAKESHOE Inspection, see page19 17 lf brakeshoesareto be reused,markand reassemble in sameposition.
Inspectfor leakage. Replacement, see page19-20
SPRING C h e c kf o r w e a k n e s s ano oamage.
LOWERRETURN SPRING Checkfor weakness a n oo a m a g e . RETAINER SPRING Installsecurelyon l e n s r o np r n .
19-16
Replace.
6d/
WHEEL
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u-cllP
Checkthe wheelcylinderfor leakage. Checkthe brakeliningsfor cracking,glazing,wear, and contamination. Measurethe brake lining thickness.Measurement does not includebrakoshoethickness.
8. Measure the inside diameter of the brake drum with insideverniercalioers, Drum Insido Diamoter: 219.9- 220.0mm (8.657- 8.661in) Standard: ServiceLimit: 221.0mm {8.700inl
BrakeLining Thicknoss: Standard: 3.9-,1.5 mm {0.15- 0.18inl SorviceLimil: 2.0 mm {0.08in}
WHEELCYLINOER
BRAKEDRUM
LININGS
lf the inside diameter of the brake drum is more than the servicelimit, replacathe brakedrum.
1 0 . Check the brake drum for scoring, grooves, and cracKs. lf the brakelining thicknessis lessthan the service limit, replacethe brakeshoesas a set. 7.
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Checkthe bearingsin the hub unit for smooth operation; if the bearingrequireservicing.referto section18.
19-17
RearDrum Brakes BrakeShoesReplacement 1.
Removethe upperreturnspringwith the tool.
l@
w€ar eye protestionwhen using the
7.
Removethe wave washer,parkingbrakelever.and pivot pin from the brakeshoe by removingthe UcliD.
brske spring wrench. U.CLIP Replace.
\ \
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RETAINER SPRING
BRAKESHOE
BRAKESPRINGWBENCH available) {Commerciallv
TENSIONPIN
Removethe tension pins by pushing the retainer s p r i n ga n dt u r n i n gt h e m . Lower the brake shoe assembly,and remove the lower return spring, Make sure not to damagethe dust coveron the wheel cylinder, Disconnect the parkingbrakecablefrom the parking brakelever. 5.
Removethe brakeshoe assembly,
o.
Removethe upper returnspring,self-adjuster lever, and self-adjusterspring, and separatethe brake shoes. LEVER SELF.ADJUSTER
19-18
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UPPERRETURNSPRING
Apply brakecylindergrease(P/N:08733- 80202)or equivalentrubber greaseto the sliding surfaceof the pivot pin, 8nd insertthe pin into the brakeshoe. Installthe parkingbrakelever and wave washeron the pivot pin, and securethem with a new U-clip. . .
lnstall the wave washer with its convex side facIng our. Pinchthe U-clipsecurelyto preventthe pivot pin from comingout of the brakeshoe. U-CLIP Replace.
WAVE WASHER Replace.
1 0 . C o n n e c tt h e p a r k i n g b r a k e c a b l e t o t h e p a r k i n g brakelever, 1 1 , Cleanthe threadedportionsof clevisesA and B. Coat the threads of the cleviseswith grease.To shortenthe clevises,turn the adiusterbolt.
15. Apply greaseon each sliding surface.Keepgrease or oil off the brakelinings.Wipe any excessgrease off the parts. .
Apply brakecylindergrease(P/N:08733- 8020E) o r e q u i v a l e nrt u b b e rg r e a s et o t h e s l i d i n gs u r facesas shown.
UPPERRETURNSPRING
..4
S l r d r n sgu r f a c e
Apply rubbergrease to slidingsurface.
1 2 . Hook the self-adjusterspring to the self-adjuster leverfirst,then to the brakeshoe, Installthe clevisesand upper return spring noting the installationdirection.Be carefulnot to damage the wheelcylinderdust covers.
Apply Molykote 44MA to the brake shoe ends and oppositeedgesof the shoesas shown.
.. a Oppositeedgeof the shoe .: a) Brakeshoeends (Shoesideendsand backing platecontactsurface)
1 4 . Installthelower returnspring.
(cont'd)
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RearDrum Brakes (cont'd) BrakeShoesReplacement
WheelCylinderReplacement
16. Installthe brake shoes onto the backingplate. Be carefulnot to damagethe wheel cylinderdust covers.
CAUTION: . Do not spill brake fluid on th6 vehicle; it may damage the paint; if brako fluid doos contact tho paint, wash it off immedialely whh water. . To pr6v6ni 3pills, cov6r th6 hose ioinls with rags ol shop lowels, . Use only a genuine Honda whoel cylinder spocial bolt.
17. Installthe tensionpins and the retainersprings.
1 . Removethe brakeshoes{seepage '19-18). UPPERRETURNSPRING
Disconnect the brakeline,
SEALANT BACKINGPLATE
15 N,m 11.5kgt m, 11 tbf.ftl
WHEELCYLINDER TENSIONPINS
9 N.m 10,9kgf'm. 6.5 rbtft)
18. Hookthe upperreturnspringwith the tool. wsar eye proieclion whon using tho @ brtko spring wronch. 1 9 . lnstallthebrakedrum.
Removethe bolt and the wheel cylinder from the backingplate.
20. lf the wheel cylinder has been removed,bleed the brakesystem (see page 19-7).
Apply sealant betweenthe wheel cylinder and backing plate,and installthe wheelcylinder.
21. Pressthe brake pedal several times to set the self-
Install the removed parts in the reverseorder of removal.
adjustingbrake. Adjustthe parkingbrako(seepage 19-6).
Fill the brakereservoirup. and bleedthe brakesystem {seepage 19-7). 7.
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19-20
After installation.checkfor a leak at the line joint. and retighten if necessary.
BrakeHoses/Lines Specifications Inspection/Torque and twisting leaks,interference, 1. Inspectthe brakehosesfor damage,deterioration, 2. Checkthe brakeIinesfor damage,rusting,and leakage.Also checkfor bent brakelines. and retightenif necessary. 3. Checkfor leaksat hoseand line jointsand connections, 4. Checkthemastercylinder,proportioningcontrolvalve.and ABS modulatorunit for damageand leakage. NOTE:Replacethe brakehoseclip wheneverthe brakehoseis serviced. LINE MASTERCYLINOER.Io.BRAKE 15 N.m 11.5kgt m, 11 lbnftl PROPORTIONING CONTROLVALVE. Io-BRAKELINE 15 N.m (1.5 kgf.m. 11 lbl.ftl HOSE BRAKELINE-Io-BRAKE 15 N.m 11.5kgd.m,11 lbf'ft)
BRAKEHOSE-to-CALIPER {8ANJO BOLTI 34 N.m (3.5kgf.m,25 lbf.ftl BLEEDSCREW 9 N.m 10.9kgf.m, 6.5 lbf.ftl
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CYLINDER 15 N.m 11.5kgf.m, 11 lbf.ft) BLEEDSCREW 7 N.m 10.7kgf.m, 5 lbt.ftt
with ABS:
19-21
BrakeHoses/Lines HoseReplacement CAUTION: Do not spill brak€ fluid on the vehicl€;it m8y damage th€ paint; if brak€ lluid doos contact tho paint, wash it off immediately with water. NOTE: . Beforereassembling, checkthat all pans are free of dust and otherforeignparticles. . Replaceparts with new ones wheneverspecifiedto qo so, '1.
6. Installthe brakehose on the knucklefirst, then connectthe brakehoseto the caliperwith the banjobolt and new sealingwashers.
6 mm HOSEBRACKET EOLTS 9.8Nm (1.0kgf.m,7 lbf.ftl
BRAKEHOSE
Replacethe brakehose ifthe hose is twisted,cracked. or if it leaks. Disconnect the brakehosefrom the brakeline using a 10 mm flarenut wrench. FLARENUT WRENCH (Commercially available)
BANJO BOLT 34 N.m 13.5kgf.m, 25 lbl.ftl
WASHERS SEALING Heplace. BRAKEHOSE
Removeand discardthe brake hose cliD from the brakehose.
7. Installthe brakehose on the upper brakehose bracket with a new b.akehoseclip. Replace.
1 tbtftl
F ) / BRAKE HOSEARACKET 8. Connectthe brakelineto the brakehose. 9 . After installingthe brakehose,bleedthe brakesys'19-7). tem (seepage
Removethe banjo bolt, and disconnectthe brake hosefrom the calioer. 5.
Removethe brakehosefrom the knuckle.
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19-22
Performthe followingchecks; . Checkthe brakehoseand line joint for leaks,and tighten if necessary. . Checkthe brake hoses for interferenceand twistIng
ParkingBrakeCable Inspectionand Replacement Inspection The parkingbrakecablesmust not be bent or distorted,This will leadto stiff operationand prematurecablefailure. Replacoment l.
Disconnect the parkingbrakeswitchconnector.
2.
Releasethe parkingbrakelever.and disconnectthe parkingbrakecable.
3,
Bemovethe parkingbrakeleverassembly.
4.
Removethe parkingbrakeshoes{seepage
5.
Removethe parkingbrake cable from the backing plateusinga '12mm offsetwrenchas shown.
6.
Installthecablein the reverseorderof removal.
'19-18).
PARKINGBRAKECABI-E
BRACKET PABKINGARAKECABLE or corroston, Checktor PARKINGBRAKELEVER Checkfor smooth operation,
d
,"u/n*UM -6l
(Slidingsurface)
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19-23
Anti-lockBrakeSystem (ABSI,'97- 00 Models SpecialTools ............. 19-26 ComponentLocations......................... 19-27 Anti-lockBrakeSystem (ABS) Features/Construction............. ......,19-2A CircuitDiagram ......... 19-32 ABS Control Unit Terminal Arrangement ......... 19-34 TroubleshootingPrecautions............. 19-36 DiagnosticTroubleGode(DTC) DiagnosticTroubleCode (DTC) Indication(SCSModel ................ 19-38 DTGErasure(MESMode) ............... 19-39 Troubleshooting lndex .................... 19-40 Troubleshooting ABS IndicatorLight DoesNot ComeOn ............ 19-41 ABS IndicatorLight DoesNot Go Off (No DTC)........................... 19-43
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DTC1r - 18: Wheel Sensor .... 19-45 DTC31 38: Solenoid ............. 19-47 DTC51 53: ABS PumpMotor ......................... 19-49 DTC 54: Main Relay ......... 19-52 DTC61: lgnitionVoltage ........................... 19-54 DTC81: CentralProcessingUnit (CPU).... 19-55 Modulator Unit Removal/lnstallation ....................... 19-56 ABS Control Unit Replacement ..,......19-57 Pulsers/WheelSensors Inspection .............. 19-57 Wheel SensorReplacement............ 19-58
S p e ci a l Tools
Rel. No.
o
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19-26
I
Tool Number 07PAZ- 0010100
Description SCSServiceConnector
Oty 1
PageRelerence 19-38
ComponentLocations
NOTE:The illustrations show the '97 - 98 models.The '99 - 00 modelsare similar. SERVICECHECKCONNECTOR {2PI ABS CONTROLUNIT
RIGHT-REAR WHEELSENSOR
UNDER.HOOD ABS FUSE/RELAYBOX
RIGHT.FRONT WHEEL SENSORCONNECTOR
RIGHT-FRONT WHEELSENSOR
WHEEL RIGHT-REAB SENSORCONNECTOR
MODULATORUNIT WHEEL LEFT.FRONT SENSOECONNECTOR GAUGEASSEMBLY
8OX UNDER.DASHFUSE,/RELAY
LEFT.FRONT WHEELSENSOB
FUSE/RELAYAOX UNDER.HOOO
IGl I(, AI FUSE
D!
trtrtr [r D!
ABS INDICATOR UNDER-DASH FUSE/NELAYBOX METER{7.5AI FUSE
HOBN/STOPI15 AI FUSE UNDER.HOODABS FUSE/RELAYBOX ABS +B 120Al FUSE
PUMPMOTOR('II AI FUSE
MOTORRELAY www.emanualpro.com
ABS {7.5AI FUSE
MTR CHECK17.5AI FUSE
19-27
Anti-lock Brake System (ABS) Features/Construction When the brakepedalis pressedduring driving,the wheelscan lock beforethe vehiclecomesto a stop. In suchan event, of the vehicleis reducedif the front wheelsare locked,and the stabilityof the vehicleis reducedif the the maneuverability rearwheelsare locked,creatingan extremelyunstablecondition.The ABS preciselycontrolsthe slip rate of the wheelsto and stabilityof the vehicle. ensuremaximumgrip forcefrom the tires,and it therebyensuresmaneuverbility The ABS calculates the slip rate of the wheelsbasedon the vehiclespeedand the wheel speed,then it controlsthe brake fluid pressureto attainthe targetslip rate.
Grip Force of Tire and Road Surlace COEFFICIENT OF FRICTION
TARGETSLIPRATE
RADIAL OIRECTION OF THE ROTATIONAL DIRECTION SLIPRATE
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19-24
ABS Control The ABS control unit detectsthe wheel speedbasedon the wheel sensorsignalit received,then it calculatesthe vehicle speed basedon the detectedwheel speed.The control unit detectsthe vehiclespeed during decelerationbasedon the rateof deceleration. The ABS control unit calculatesthe slip rate of each wheel, and it transmitsthe control signal to the modulator unit solenoidvalvewhen the slip rateis high The pressurereductioncontrolhasthree modes:pressurereducing,pressureretaining,and pressureintensi{yingmodes. ABS CONTROLI-INIT
Self-diagnosisFunction The ABS controlunit is equippedwith a main cPU and a sub cPU, that checkeachotherfor problems. The CPUscheckthe circuitof the system. "systemdown mode" or the "controlinhibitionmode". Whenthe CPUSdetectfailure,they shiftto the SOLENOID VALVE
LIGHT ABSINDICATOR
MAIN RELAY
SYSTEM DOWN
ON
No operatron
Drive inhibition
CONTROL INHIBITION
ON
No operaton
Drive inhibition
MODE
Restancondition
DTC
lgnition - oN (ll) Memory Operation*r switch OFF Operation
Automatic
lVemory
*1: ExceptCPUfailure can be classitiedinto thesefour categories: The self-diagnosis O : I n i t i adl i a g n o s i s O: ExceptABS control O; DuringABS control @ : D u r i n gw a r n i n g On-boardDiagnosisFunction The ABS systemcan be diagnosedwith the HondaPGMTester. The ALB Checkercannot be used with this system.For air bleeding.and checkingwheel sensorsignals,use the Honda PGIMTester.Seethe HondaPGMTesteruser'smanualsfor specificoperatinginstructions.
(cont'd)
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19-29
Anti-lockBrakeSystem(ABS) (cont'd) Features/Gonstruction ABS Modulator The ABS modulatorconsistsof the inlet solenoidvalve, outlet solenoidvalve, reservoir,pump, pump motor and the d a m p j n gc h a m b e r . The modulatorreducesthe caliperfluid pressuredirectly.lt is a circulating-type modulatorbecausethe brakefluid circulates throughthe caliper,reservoirandthe mastercylinder. The hydrauliccontrolhasthree modes:pressurereduction,pressureretainingand pressureintensifyingmodes. The hydrauliccircuitis the independent four channel-type, one channelfor eachwheel. SOLENOIDVALVE
PUMP MOTOR
t-
Pressureintensifyingmode:Inletvalveopen,outletvalveclosed, Mastercylinderfluid is pumpedout to the caliper. Pressureretainingmode: Inletvalveclosed,outletvalveclosed. Caliperfluid is retainedby the inletvalveand outletvalve. Pressurereductionmode: Inletvalveclosed,outletvalveooen Caliperfluid flows throughthe outletvalveto the reservoir. Motor operationmode: Whenstartingthe pressurereductionmode.the pump motor is ON. WhenstoppingABS operation,the pump motor is OFF. The reservoirfluid is pumpedout by the pump,throughthe dampingchamber,to the master cylinder.
19-30
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Wheel Sensor The wheel sensorsare the magneticcontactlesstype. As the gear pulserteeth rotatepast the wheel sensor'smagnetic with the wheel speed.The ABS controlunit detects The AC frequencychangesin accordance coil,AC currentis generated. the wheel speed the wheelsensorsignalfrequencyand therebydetects
GEARPULSER at LOW SPEED F
wheel Sp€od and Modulatot Control
VEHICLS EPEED VEHICLESPEED
WHEELSPEED
PRESSU
OUTLET VALVE ON OFF INLET VALVE ON OFF MOTOR ON OFF When the wheel speeddrops sharplybelow the vehiclespeed,the outlet valve opens momentarilyto reducethe caliper fluid pressure.The pump motor startsat this time. As the wheel speedis restored.the inlet valve opens momentarilyto increasethe caliDerfluid oressure.
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19-31
CircuitDiagram
UNDFS I]OODFISAFELAY 8OX Cbsod:&rrc ped. deprelled
-tjF wHT/GrN
GFrlrr'vril
GNITION
*oJG\'*" \€F*,-
UNDER-HOOD A8S FUSE/FELAY BOX (O number) 3P CONNECTOR t_--t l-| l l ' " 1
UNDER.HOOO A8S FUSE/RELAY BOX 2P CONNECTOF(! numbor)
UNDER,DASH FUSFJRELAY BOX 20PCONNECTOR(O number)
3 5 6 1 0 1 1 12 1 3 ,/ 115 ,/
J
8 9 19
s a'l fLr--'--.----1
3 4 5 6 '12 1 3 | i 4 9 10 /
PUMP MOTORCONNECTOR number)
(tr
19-32
7 18
ASSEMBLY5P CONNECTOR
----.4-
l1)/l3l/l5l Wiresideol femalelerminals
www.emanualpro.com
ll3 2ir I
{tT6TsF} !]q:]j_1,
UNDER-DASH FUSE/RELAY BOX (E number) 18PCONNECTOR 1 2
EFIAKESWITCHCONNECTOR l€-4 | 1t x l 2 |
M-OD ULATORUNIT CONNECTOR
ATi) Terminal sideoJlemaleterminals
Gil I.]NII {NBK) ABSCONTROL STOP
[m;]t
ra
-[rf$-n*'"
SEFVCE CHEC(
V
-
l'? g,l
,ln
,BFN+BsN-,| .
G2
t
8
Y WIT/BLIJ ,r-,,..J
|;
Br( --o-
: G101cr02
A ^ l 0 l T AL M
'r6P) i trr cor'hrEcroF 8LK
4
c1013,402 tG2,
rlr*r"t_._*h -----r;c, r"-!cc
Lffi_--
-
PMR,
-.^
t!94 PCOM,
.,._
Pf: -tL
t=
#
9
J*
,,-:g
GRN/8I(
t-
LT
GFNmL---l
-r
l,'2
-14
=l------5o ril| , /
, i7
19
- ) 1. 2 2 1
INK QAIA.L coNNE croR (16P)
mtTl # |
|
T?'--"r""""./ 6 ,/ 8\
F{ c7
,z
Wiresideof lemaleterminals
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, f
I'
ABScoNTRoL -- uNrr22pcoNNEcroR i-;;i,;;)
t,*---;Tr I
5
)ECHECK 9E-FY!! coNNF :CTOR(2P)
lr z :ltl,/ a ,18 e tol/ 12li3l p91 |ffi| 4 15 16)17 V I1sV l2'VIIU)4
Ilcrom.
IRE^R
-l BLr( eli -.1 BtK-L
5
,-ry
e
pliirn :C,
4iq!A
ABscoNTRoL -- uNrr26pcoNNEcroR (o;fib;;;
x
t
HEELSENSOR CONNECTOR '98-99models '97 model FRONT/ REAR FRONTIRIG-HT-REAR
iTtl\
/Jr lz !\
Termnal sideol mateterminals
Terminalsideol maleterminals LEFT.REAR
/nf'\ 1./ 1F r .4-;1
V L:J Terminalsideol lemaleterminals
19-33
ABSControlUnit TerminalArrangement ABS CONTROLUNIT26PCONNECTOR
Wire sideof femaleterminals
Teiminal numbel
Wiie color
Terminal3ign Teiminalnamgl
Voltrge Description
Condhions (lgnition Switch ON llll)
tdminals
PCOM GRNn/VHT (Primary common)
1
Power sourcefor the solenoid valve and pump motor.
1-GND
2
RRO BLUA/EL (Rear-right
4
0)
8
GRY
RLO (Rear-left 0)
GRN
FRO (Fronr-right0)
STOP {Stop)
Detocts right-rear wheel sensorsrgnat.
OFF
AC:3-6V
OFF theSCSseNice] lConnect connector \ I
A p p r o x . 3V
53mVor aboveon
Detectsleft-rearwheelsensor srgnat.
6-19
Detects right-front wheel sensorsignal.
8-21
(AC digitaltester Whenthe wheelis range) {Beference) turnedat 1 turn/second. 150mvtrp or above on oscilloscope
Stops Brakepedalpressed.
Detects bfakeswitchsignal. (Prevents unnecessary ABSoperation) 9-GND
FLO BRN^/VHT(Front-left 0)
OV
6
BatteryVoltage
BrakeDedalreleased.
Detectsleft-frontwheelsensor srgnal. 10
ON
ON
SCOM Power sourcefor the solenoid BLI(WHT (Secondary 2-GND common) Detectsignitionswitch2 BLVBLU (lgnition 2) signal.(Systemactivate signal) 3-GND
When the wheel is turned at 1 turn/ second.
10-23
Stops YEL
13 14
16 't7 19
23
RL-oUT Drivesleft-rearoutletsolenoid 12.GND (Rearleft outlet)
RR.IN RED^/vHT (Rear-right inlet) B1 WHT/GRN (Baftery 1) 82 (Battery2) GND2 BLK (Ground2) RR1 GRN/YEL(Rear-right 1) R L 1 LT BLU (Rearieft 1) FR1 GRN/BLK(Front-right 1) FL1 GBN/ORN {Front-left1}
Drivesright-rear inletsolenoid 13.GND
Powersourcefor the solenoid valveandpumpmotor.
14.GND
Power sourcefor the solenoid valve and pump motor.
15-GND
Groundfor the ABScontrol unit. Detectsright-rearwheel sensorsignal. Detectsleft-rearwheelsensor signal. Detects right-front wheel sensorsrgnat.
Detectsleft-frontwheelsensor sagnal.
ON
26
19-34
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BLK
GND3 (Gtound 3)
AC:3-6V
When the wheel is turned at l turn/second,
53 mV or above on digitaltester (AC range) (Reference)150 mVp-p or above on oscilloscope
Stops
Approx.2.5V
21-8
=
26-GND
Approx.3 V
BatteryVoltage
't7-4
25,GND
Groundtor the ABScontrol untI.
OFF
Below0.3V
ON RLIN (Rear-left inlet)
OV
16-GND
23-10
53mVorabove on digitaltester lAC (Reference) range) 150mvpporabove onoscilloscope ADprox. 2.5 V
Everytime
19-6
Approx.2.5 V BatteryVoltage OV
ON
OFF the lConnect SCSservice\ connector I \
Drives left-rearinlet solenoid
RED
Output voltago
ON
-9
OFF the /Connect SCSservice] conneclor \ I
OV AC:3-6V Approx.3 V Below0.3V
ABS CONTROLUNIT 22PCONNECIOR
Wire side ol lemale terminals Voltage Terminal numDer
Wire color
Terminal 3i9n Terminal name
Description
Conditions (lgnition Switch ON (ll)l
tominals Drivesright-frontinlet solenoidvalve.
ON
FR-IN 1
1-GND
RED/BLU (Front-right
BRN
7
10
l'l
Detects service check signal (Diagnostictrouble code (Servicecheck indication) signal)
BLU/RED (Warning ramp) YEUBLK
FL-OUT (Frontieft outlet)
FL-IN RED/BLK (Front-left inlet)
DrivesABS indicator{The indicator goes off when ABS control unit outputs battery voltage). Drives left-front outlet solenoidvalve.
17
LT BLU
(Datalink connectod
ot
4.GND
Communicateswith Honda PGM Tester.
PMR YEURED (Pumpmotor reray,
BLK
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GND2 (Ground2)
AC:3-6V
SCSserviceconnector connected. SCS service connector disconnected.
A p p r o x . 3V OV Approx.S V Approx.2 V
lndicatorON
7.GND BatteryVoltage
lndicatorOFF
=
1O-GND
ON
ON
OV
OFF
AC:3-6V
I
OFF theSCSservicq lconnect connector l \
12-GND
Pump 1 7 - G N D motor
relay
19.GND
outlet Drivesright-rear solenoidvalve.
Ground for the ABS control unit.
cl)
22.GND
'a)
ON
Battery Vollage
OFF
OV
6 I
ON
OV
OFF
AC:3-6V
OFF ponnecl theSCSservice] connector I \ ON
21.GND
A p p r o x . 3V
Approx.5 V
14-GND
ON
RR-OUT (Rear-right outlet)
OFF
11-GND
DetectsPumPmotor drive MCK BRN/YEL(Motorcheck) signal.
BLU
OV
OFF servicel theSCS lconnect connedor l \
Drivespump motor relay. 19
ON
Drivesleft-frontinlet solenoid
Drivesright-frontoutlet FR-OUT YEUBLU (Front-right solenoidvalve. outlet) 14
.9 ur
inlet)
I
Output voltage
Pump ON moror rcray OFF
OFF lconnecttheSCSservice] connector l \
A p p r o x . 3V OV AC:3 6V A p p r o x . 3V Below0.3V
19-35
TroubleshootingPrecautions
ABS lndicalor 1 lf the systemis oK, the ABS indicatorgoes off two secondsafter turning the ignitionswitch oN 1l) wathoutstaning the engine,and then comes on again and goes off after two seconds.This occursbecausethe ABS control unit is turnedon by the lG2 powersource. 2. The ABS indicatorcomeson when the ABS control unit detectsa problemin the system.However,even thouoh the systemis operatingproperly,the ABs indicatorwill come on too, underthe followingconditions: . Signaldisturbance . W h e e ls p i n . Only drivewheelsrotate . Batteryvoltagefluctuates To determinethe actualcauseof the problem,questionthe customeraboutthe problem,takingtheseconditions into consideration: 3 When a problem is detectedand the ABS indicatorcomes on, the indicatorcan stay on until the ignition switch is turnedOFF,or it can automatically go off, dependingon the mode. . Indicatorstayson untilthe ignitionswitchis turnedoff: Whenthe systemis in the systemdown mode. . Indicatorautomatically goesoff: Whenthe systemis in the controlinhibitionmode. 4 The ABS indicatorstayson when the systemis reactivatedwithout erasingthe DTC,but it goes off after starting the vehicle. When the wheel sensorsystem is faulty and the ABS indicatorcomeson. the algorithmof the systemautomatically turns off the ABS indicatorafterthe wheelspeedsignalreturnsto the normalspeed.Also,when the DTc is erased,the cpu is resetandthe ABS indicatorgoesoff whenthe systemcheckedout normalby the initialdiagnosis. Therefore,test-drivethe vehicleafterservicingthe wheel sensorsystem.and be surethat the ABS indicator does not c o m eo n . 5 When the ABS controlunit outputsbatteryvoltageto the gaugeassembly,the ABS indicatorooesoff. DiagnosticTrouble Code (DTCI 1. The diagnostictroublecode (DTc)is memorizedwhen a problemis detectedand the ABS indicator does not go off, or when the ABS indicatorcomeson. The DTc is not memorizedwhen the ABS indicatorcomeson unressthe cpu is activated, 2 The memorycan hold any numberof DTCs.However,when the same DTc is detectedtwice or more, the taterone is writtenover the old one. Therefore,when the same problemis detectedrepeatedly, it is recordedas one DTC. 3. The DTCsare indicatedin the orderof ascendingnumber,not in the orderthey occur. 4. The DTCSare memorizedin the EEPROM(non-volatile memorv). Therefore,the memorizedDTcscannotbe canceledby disconnecting the battery.performthe specifiedproceduresto erasethe DTCS. Self-diagnosis 1. Self-diagnosis can be classifiedinto thesefour categories: ' Initialdiagnosis: Performedright afterthe engine startsand untirtheABS indicatorgoes off. . ExceptABS control:Performedwhen the ABS is not functioning. . DuringABS control:Performedwhen the ABS is functioning. . Duringwarning: Performedwhen the ABS indicatoris ON. 2. The systemperformsthe fo|owing controrswhen a probremis detectedby the serf-diagnosis: . ABS indicatorON . Memorvof DTC . Mode changetothe "systemdown mode,,or the ,,controlinhibitionmode,,. MODE
ABS INDICATOR
MAIN RELAY
SOLENOID VALVE
CPU
SYSTEM DOWN
ON
No operation
Drive inhibition
Operation*r
CONTROL INHIBITION
ON
No operal|on
Drive inhibition
Operation
Restartcondition lgnition switch
DTC
oFF- ON l) Memory
Automatic
lMemory
*1: ExceptCPUfailure
19-36
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Kickback '1. The motor operateswhen the ABS is functioning.and the fluid in the reservoiris forcedout to the mastercylinder, causingkickbackat the brakepedal. 2.
The ABS controlunit operatesthe solenoidvalvewhen the brakepedalis releasedafterthe initialdiagnosisYou may hearthe solenoidvalveoperateat this time, but it is normal
PumoMotol 1. The pump motor operateswhen the ABS is functioning 2.
You may hearthe motor operateat this The ABS control unit checksthe pump motor operationduring acceleration. time, but it is normal.
Bleeding BrakeFluidReplacement/Ail and air bleedingproceduresare the sameas for vehicleswithout ABS To easebleeding,start L Brakefluid replacement with the front wheels. Troubleshooting flowchartproceduresassumethat the causeof the problemis still presentand the ABS indicator 1. The troubleshooting is still on. Followingthe flowchartwhen the ABS indicatordoes not come on can resultin incorrectdiagnosis. 2.
Ouestionthe customerabout the conditionswhen the problemoccurred,and try to reproducethe same conditions for troubleshooting. is made at varioustimes such as the initialdiagnosis,exceptABS control,during ABS control,during Self-diagnosis during the specifiedvehiclespeed,etc. Therefore,the symptom canngt be checkedunlessthe check acceleration, conditionsmatchwith the problemconditjons
3.
When the ABS jndicatordoes not come on duringthe test-drive.but troubleshootingis performedbasedon the DTC, checklor looseconnectors,poor contactof the terminals,etc.,beforeyou starttroubleshooting.
4.
erasethe DTCand test-drivethe vehicle.Be surethe ABS indicatordoes not come on. Aftertroubleshooting,
5.
The connectorillustratjonsshow the femaleterminalswith a singleoutlineand the maleterminalswith a doubleoutl ne.
ABS Function Test To simulateABS operationand activatethe solenoidvalvesand pump, usethe HondaPGMTester. Connectthe PGMTesterto the 16PDataLinkConnector(DLC).Whenthe SystemSelectmenu is displayed,selectthe ABS TestMode menu,and follow the tester'sprompts.
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19-37
DiagnosticTroubleCode(DTC) DiagnosticTroubleGodeIDTCIIndication NOTE:This operationcan also be donewith the HondapGM Tester. 1.
Connectthe SCS service connector to the service check connector (2P) located on the passenger'sside of the center consote.
2.
Turn the ignitionswitchON (ll). NOTE; Do not pressthe brakepedalwhenturningthe ignitionswitch.
3
Recordthe blinkingfrequencyof the ABS indicator.The brinkingfrequencyindicatesthe DTc.
4.
Turn the ignition switch OFF.and remove the SCSserviceconnector. NOTE:The MalfunctionIndicatorLamp (MlL) will stay on after the engine is startsdif the SCSseryicaconnecrorrs connected.
5.
Erasethe DTC.
Conditions for DTCindication . The vehicleis stopped. . The SCSserviceconnector is connectedbefore the ignition switch is turned ON flt). . The brakepedalis released. . The SCSserviceconnectorremainsconnectedduringthis procedure. The DTC indication stops and the ABS control unit axecutostha softwaro lunction if at least one of tho following conditions i3 satisfiod: . The vehicleis not stoooed. . The ABS controlunit receivesthe normalsignal(whichis for the ABS controlunit)from a HondapGM Tesrer. . The SCSserviceconnectoris disconnectod duringthis procedure. NQTE:The illustrationof gaugeassemblyshowsthe '97 - 98 models.The '99 - oo modelsare similar. SEFVICECHECK CONNESTORI2P}
u.s.A. GAUGEASSEMBLY
@ CANADA
@
A8S II{DEATOR
19-38
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DTCErasure NOTE:This operationcan also be done with the HondaPGMTester. 1.
Connectthe SCSserviceconnectorto the servicecheckconnector(2P)locatedon the passenger'sside of the center console.
2.
Pressthe brakeoedal.
3.
Turnthe ignitionswitchON (ll)while keepingthe brakepedalpressed.The ABS indicatorgoes off aftertwo seconds.
4.
Afterthe indicatorgoes off, releasethe brakepedal.The indicatorcomeson afterfour seconds.
5.
After the indicatorcomeson, pressthe brakepedalagain.The indicatorgoes off againafterfour seconds (the brake oedalis still Dressed.)
6.
Afterthe indicatorgoesoff, releasethe brakepedalagain.
7.
Afterfour seconds.the indicatorblinkstwice for 0.3secondand the DTCis erased.
8.
Confirmthe DTCindication,and checkthat the DTCwas erased.
NOTE:Always maintainthese steps.lf you disconnectthe SCSserviceconnectorand/orfail to operatethe brakepedal accordingto the indicatorindication,the DTCwill not be erased. Conditions for DTCerasure . The vehicleis stopped. . The SCSserviceconnectoris connectedbeforethe ignitionswitchis turnedON (ll) . The brakepedalis pressedbeforethe ignitionswitchis turnedON (ll). . The SCSserviceconnectorremainsconnectedduringthis procedure. The DTCerasurestops and the ABS control unit executesthe software funqtion it at least one of the following conditions b satisfied: . The vehicleis not stopped. . The SCSserviceconnectoris disconnected duringthis service. . TheABScontrolunit receivesthe normalsignal(whichis for the ABS controlunit)from a HondaPGMTester. . The brakepedalis not operatedaccordingto the indicatorindication . The DTCerasureis finished.
0.3sec. ON ABSINDICATOR OFF within3s€c. I
within3 s€c.
within3 sec.
0.3sec.
DEPRESSED BRAKEPEDAL
RELEASED lonitionswitch
dN (r)
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19-39
DiagnosticTroubleCode(DTC) TroubleshootingIndex This operationcan also be done with the HondapGM Teste.. DETECTION TIMING
DTC
3 R < Y
DIAGNOSIS/SYMPTOM
ct
z
I
o
8 < i
< = E E2E 2 = 3 eB28 ET 6 3
E X zd 9 gl
REFER TO PAGE
(J
ABS indicatordoes not come on.
19,4'l
ON
ABS indicatordoes not go off. (No DTC)
19-43
oN*
Wheelsensor{open/shortto body ground/shortto power)
't1 't5
PROBLEM LOCATION
OFF
No DTC
13
4,, to < J
FR
o o o o
17
FL RR
19-45
RL
12 't4
FR
oN*
(chippedpulsergearlelectrical Wheelsensor/Pulser notse,
o o o
FL RR
18
RL
31
FR-IN
32
FR-OUT
19-45
FL.IN 34
ON
Solenoid(open/short to body ground/shortto power/stuck)
o o o
FL-OUT RB-IN
36
RR-OUT
37
RL-IN
38
19-47
RL.OUT ON
Motor lock
ON
Motor stuckOFF
53
ON
Motor stuckON
54
ON
Main relaystuckOFF
6l
ON
lgnitionvoltage(low voltage/highvoltage)
81
ON
o o o o o o o o o o o o o o o o
19-49 19-49 19-49 ia_at
'19-54
19-55 *: lf DTcs 11-18 {wheelsensorcodes)were detectedthe last time the vehiclewas driven,the ABs indicatorwi stav on untilthe ignitionswitchis turnedON (ll),and the controlunit confirmsthat the wheelsensorsare OK,
19-4 0
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Troubleshooting ABS lndicator Does Not Come On The ABS indicator does not come on when ignition switch is turnodON lll).
checkthe METER{7.5A} fuse in t h e u n d e r C a s hf u s e / r e l a yb o x , and reinstaltthefuse if it is OK.
Reolacethe tuse and recheck.
Checkfor an open in the lcl chcuil: 1. Disconnect the gaugeassembly 5P connector. 2. Turnthe ignitionswitchON (ll). 3. Measurethe voltagebetween the gauge assembly5P conn e c t o rt e r m i n a lN o . 5 a n d body ground.
ls there battery voltage?
GAUGEASSEMBLY5P CONNECTOR
. Repairopen in the wire between lhe METER{7.5 A) luse and tho gaugeassembly. . Reolecethe under-dashfuse/ relay box. (Oponcircuit inside the box.)
Wire sideof femaleterminals
Checkthe ABS indicatorbulb in the gaugeassembly.
Replacethe ABS indicator bulb.
Checkfor a short to power in the WALPcircuit: Measurethe voltagebetweenthe g a u g e a s s e m b l y5 P c o n n e c t o r terminalNo. 1 and bodyground.
ls there batteryvoltageT
Sepair short to power in the wite b€tweenthe gaug€assembly and the ABS control unil.
(To page 19 42)
(cont'd)
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19-41
Troubleshooting ABS IndicatorDoesNot ComeOn (cont'd) (Frompage19'41)
Checkthe gruge essembly: 1. Turnthe ignitionswitchOFF. 2. Connectthe gauge assembly 5Pconnector, 3. Connectthe terminalNo. 3 to b o d y g r o u n dw i t h a j u m p e r
GAUG€ ASSEMBLY5P CONNECTOR
---g-
l1 t/l3_l/ |5| JUMPER I GNDIBLK}
wrBE
4. Turnthe ignitionswitchON (ll).
Doesthe ABSindicatorcomeon?
.Repair open in the wire between the gauge assembly and body ground. . Repair poor ground {G401, c102l-
19-42
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I
L Reolacethe ABS indicator drive circuit in the gaug€ ass€mbly.
Wiresideof femaleterminals
ABS IndicatorDoesNot Go Off (No DTGI -
With engine running, the ABS indicsior is ON. With the SCS serviceconnector conn€cted (s€€ page 19381, no DTCis indicated.
Checkthe ABS {7.5A) fuse in the undeFdashfuse/relaybox, and reinstallthe fuse if it is OK.
ReDlacelhe tuse and recheck.
Checkthe ABS +B (20 A) fuse in t h e u n d e r h o o dA B S f u s e / r e l a y box, and reinstallthe fuse if it is
oK.
Replacethe fuse and rocheck. A8S CONTROLUNIT 26PCONNECTOR
IG2IBLK/BLU) Checkfor sn open in the lG2 circuit: 1. Turnthe ignitionswitchON {ll). 2. Measurethe voltage between the ABS controlunit 26Pconn e c t o rt e r m i n a lN o . 3 a n d body ground.
Wire sideof femaleterminals
Repairopen in tho wire between the ABS {7.5A} fu3e .nd the ABS control unit, ABS CONTROLU N 26P CONf{ECTOR Check for an open in the 81 and 82 circuit: M e a s u r et h e v o l t a g e b e t w e e n bodygroundandterminalsNo. 14 and No. 15individually.
is there battery voltage?
{WHT/GRNI
Ropairopen in tho wi.e between rhe ABS +B {20 A) fuse and the ABS control unit. Wire side of female terminals
(Topage19 44)
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(cont'd)
19-43
Troubleshooting ABS IndicatorDoesNot Go Off (No DTC)(cont'dl (Frompage19,43)
ABS CONTROLUNIT 22PCONNECTOR
Check tor a short to body ground in the WALPcircuil: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ABS control unit 22Pand gaugeassembly 5P connectors. 3. Checklor continuity between the ABS controlunit 22Pconn e c t o rt e r m i n a lN o . 7 a n d body ground.
WALP{BLU/REDI
Wire side of female terminals
Repair short to body ground in the wire between the ABS cont.ol unh and the gaugeassembly.
Checkthe ABS control unit: 1. Connectthe ABS control unit 22Pconnector. 2. Turnthe ignitionswitchON (ll). 3. Measurethe voltage between the ABS controlunit 22Pconn e c t o rt e r m i n a lN o . 7 a n d body ground.
ls there batteryvoltage?
Check tor an open in the GND2 circuit: 1. Connectthe ABS controlunit 26Pconnecto.terminalNo. 16 to body groundwith a jumper 2. Measurethe voltage between the ABS controlunit 22Pconn e c t o rt e r m i n a lN o . 7 a n d body ground.
ABS CONTROLUNIT 26PCONNECTOR
JUMPCR GND2IBLKI WIRE Wiresadeof femaleterminals
. Repeir op6n in th6 wire ttetween the ABS control unit and body ground. . Rep.ir poor ground {G401, G4021.
Check tor an open in the WALP circuit: Measurethe voltagebetweenthe g a u g e a s s e m b l y5 P c o n n e c t o r terminalNo. 1 and body ground.
Check lor loose ABS control unh connectors. lf necesssry,substituie e lnown-good ABS control unit and recheck. GAUGEASSEMBLY5P CONNECTOF
WALPIBLU/FEDI
ls there batteryvoltage?
Replacothe ABS indicator drive circuit in the gauge assembly.
19-44
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Repairop6n in the wi.e botw€en the ABS control unit and th€ gau9e ass€mbly.
DTC11- 18:WheelSensor NOTE:The ABS indicatorcomeson only when the drive wheelsare turning and signaldisturbanceis detected,Therefore,testdrive the car at a speedof 12 mph (20 km/h)or more afterturning the ignition switchfrom OFFto ON l), and if the ABS indicator does not come on, the svstemis OK. -
With ths ignition switch ON llll, the ABS indicatol does not go ott. Atte. driving, the ABS indicalot comason. With the SCS serviceconnector connocted (s€€ page 19.381, DTGr 11 - 18 sre indbated.
Checkthe whcol sensorcircuit: 1. Disconnectthe ABS control unit 26Pconnector. 2, Nleasure the resistance betweenthe appropriatewheel sensorl0) and 1'l)circuitterminals{seetable).
ls the resistanceOK? /Fronr:750 r,050o (20"C,68"F\ -'1,450O (20"C,68'F, 950 \Rear:
Chocklor a short 10 power in the wheel sensoaciacuil: 1. Reconnectthe ABScontrolunit 26Pconnector. 2. Startthe engine. 3. Measurethe voltage betlveen the ABS controlunit 26Pconnector appropriatewheel sens o r ( 0 ) c i r c u i t t e r m i n a la n d body ground(seetable). ls there4 V or more?
ABS CONTNOLUNIT 26PCONNECTOR
DTC
Appropriate Terminal {0}srDE ( 1 ) S | D E
RRO IBLU/YEL}
FLO (BRN/WHTI
1 1 ,l 2 l R i g h t - f r o n t ) No.8: Fno N o . 2 1 F : R1 13, 14 (Left-front) No.10rFLo No. 23: FLl 15, 16 (Rightread No.4: RRo N o . 1 7 :R R 1
17,l8 (Lsft-rear)
No.6: RLo N o . 1 9R: L 1
. Ropairop€n in th. {01o. lll circuit wire, oa short to the (01circuit wire in the lll circuit wiro betweon the ABS control unit and th. appropriatewhasl sensot. . Roplacethe rpp.opriatc whe6l Sensor.
RRTIGRN/YELI RLl (LT BLUI
FLl IGFN/ORN} FRl IGRN/BLKI
Wire sideof femaleterminals
NOTE:Judgementvalue for short
Ropair lhort to pow.r in the l0l ot 11)circuit wiro between the ABS control unit and the appropriate whool sen6or.
NO NOTE: . Normalvoltage: Approx.2 V .0 V: Replace the ABScontrolunit. . 4 V or more indicatesa shon to power. Checkfor a short to body ground in the whoal s.n3or cilcuit: 1. Disconnectthe ABS control unit 26Pconnector. 2. Checklor cont;nuitybetween the ABS controlunit 26Pconnector appropriatewheel sens o r { 0 ) c i r c u i t t e r m i n a la n d body ground{se6table).
NO
. Ropairshort to body g.ound in th6 {01 or {1} circuit wire botweon th6 ABS cont.ol unit and tho appropriatowheol sonaot. . Roplacetho appropriate wheel sensot.
(cont'dl
(To page 19-46) www.emanualpro.com
19-45
Troubleshooting DTC11- 18:WheelSensor(cont'd)
C h e c kf o r c h i p p e d p u l s e r g e a r .
Rcplacs thc drive3haft or hub unh. (Chippedpulsor goar.l
DTC 11, 13, 15. 17: Replacothe ABS control unit. OfC 12, 11, 16, 18: Th6 ABS control unit may have dstected dgn.l disturbsnc€.
19-46
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DTC31 - 38:Solenoid -
-
With the ignition switch ON {lD, tho ABS indicator does not go off, or the ABS indic.lor comes on whil6 ABS is tunctioning. With th€ SCS service connoctor connoctcd {sce page 1$381, DTCa31 - 38 ars indicatsd.
ABS CONTROLUNIT 22PCONNECTOR FL.OUTIYEL/8LKI
DTC 31:FR'lN
32:FROUT 3 3 :F L l N
Checkfor a 3hori to power in th€ solenoidci.cuit: 1 . D i s c o n n e ctth e A B S c o n t r o l untrtlr ano zbr connectors_ 2. Startthe engine. 3. Measurethe voltage between the appropriateABS control unit connectorsolenoidcircuit terminal and body ground (see table).
ls there baReryvoltage?
34:FLOUT 35:RR-lN 36:RR-OUT
Appropraate Connector Terminal 22P No. 1 22P No. 12 22P N o .1 1 22P No.10 26P No.13 22P No.21
37: RLIN
26P
No.25
38:RL-OUT
26P
No. 12
ABS CONTROLUNIT 26PCONNECTOR
RL.OUT{YELI R € p a i rs h o r t t o p o w e r i n t h e approp.iato solenoid circuit wire betwe€n the ABS control unit and the modulator unh.
Chockfor a short to body ground in the sol€noid circuit: Checkfor continuity betweenthe appropriatesolenoidcircuit terminalandbodyground(seetable).
ls therecontinuity?
Wire sadeof femaleterminals . Ropair short to body ground in the appropriatosolenoid circuit wire betwoon the ABS control unit and the modulator unit. . Replacethe modulator unit.
DTC Checkthe ABS control unit: 1. Turnthe ignitionswitchOFF. 2. Connectthe ABS controlunit 22Pand 26Pconnectors. 3. Connectthe SCSserviceconnector. 4. Turnthe ignitionswitchON (ll). 5, Measurethe voltage between the appropriateABS control unit 26PconnectorCOMcircuit terminaland body ground (see table).
ls thereapprox.3 V7
(To page l9-48)
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Wiresideof femaleterminals
FL.OUTIYEL/BLKI
Appropriate Terminal
3 1 :F R l N
No. 2i SCOM
32:FR-OUT
No. 2: SCOM
33: FLIN
No.1:PCOM
34:FL-OUT
No. 1:PCOM
35:RRIN
No. 1: PCON4
36: RR-OUT
No. 1: PCON4
37rRL-lN
No. 2: SCOM
3a:RL-OUT
No. 2: SCOM
RL.OUT{YELI
Checktor loose ABS control unit connectors. ll nece$ary, substitut€ a known-good ABS control unit and recheck. PCOM {GRN/WHTI
19-47
Troubleshooting DTC31 - 38: Solenoid(cont'dl A8S CONTROLUNIT 22PCONNECTOR
FL.OUTIYEL/BLK} DTC 3 1 :F R I N
32:FR-OUT 33: FL-IN
Checkfor an open in the solenoid circuit: Measurethe voltage betweenthe ABS controlunit con appropriate nector solenoidcircuit terminal and bodyground{seetable).
ls thereapprox.3 V?
34:FL OUT 35:RRIN 36:RR-OUT 37:RLIN
38:RL-OUT
Connector
22P 22P 22P 22P
No. 1
26P
No.13
22P
No.21
26P
N o .2 5
No.12 No.11 No.10
No. 12
. Repair open in the appropriate COM circuit wire botween the ABS control unit and th€ modulator unit. . Repair open in the appropriate solenoid circuit wire betw€on lhe ABS control unit and the modulator unit. . Replaceih€ modulator unit.
Wire sideof femaleterminals
ABS CONTROLUNIT 26PCONNECTOR RI-.OUT{YEL)
Checkfor loos€ ABS control unil conn€ctors. lf nece$ary, substitute a known-good ABS control unit and rechock. Wire sideof femaletermanals
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19-4 8
DTC51 - 53:ABS PumpMotor -
Wilh the ignition switch ON {ll), the ABS indicator does not go ott. With the SCS seruicoconnector connoctod {sce page 19381, DTCa51 - 53 .re indicated.
-
c h e c k t h e M T R c H E c K ( 7 . 5A i luse in the under-hoodABS tuse/relaybox, and reinstallthe luse if it is OK.
ABS CONTROLUNIT 22PCONNECTOR Rsplacethe fuse and rech6ck. N O T E : S h o r t t h e P M R t e r m i n a lt o b o d y groundfor a moment,and rochockthe tuse. lf the fuse is blown,checklor a shon to body groundin the MCKcircuit. check the PUMP MOTOR(40 A) fuse in the under-hoodABS fuse/ relay box, and reinstallthe fuse if it is oK.
Wire side of female terminals
Roolacelhe tusg and rocheck. N O T E : S h o r t t h e P M R t e r m i n a lt o b o d y groundfor a moment,and recheckthe fuse, lf the tuse is blown, checktor a short to body ground in the wire betweenthe underhood ABSfuse/relay box 6nd the pump motor.
Feplacethe pump motor r6ley.
Check the pump motor powel sourc€circuit: Turn the ignitionswitchON (ll).
Doesthe pump motoroperate?
Ch6ckfo. a short to oowd in th6 pump motor power sourca circuit: Removethe pump motor relay.
Doesthe pump motor operateT
Repairrhort to power in the wire bclweon the under-hood ABS fuse/.6lay box and ihe ABS pump motor.
Ch6cktor loos6 ABS control unit connectors. lf necotsary, 3ubstitute . known-good ABS control unit and rocheck.
(cont'di (To page19 50) www.emanualpro.com
19-49
Troubleshooting DTC51 - 53:ABS PumpMotor (cont'dl UND€R-HOOO ABS FUSE/REI-AY BOX
(Frompage19 49)
JUMPERWIRE Chockthe pump motor ci.cuit: 1. Removethe pump motor relay. 2. Turn the ignitionswitchON {ll). 3. Connectthe pump motor relay connector+B and MOTORterminalswith a jumporwire for a moment,
Doesthe pump motor operate?
Check for an open in the pump motor +B circuit: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe pump motor 3. Turnthe ignitionswitchON (ll). 4. Connectthe pump motorrelay connector+B and MOTORter minalswith a iumperwire. 5. Measurethe voltage beaveen the pump motor connector terminal No. l and body ground.
ls there battery voltage?
TERMINAL
PUMPMOTORCONNECTOB MOTOR+B {WHTI Fr 12 lF-
(v) v
Doesthe pump motoroperate?
Ch6ckfor a short to body ground in the PMRcircuit: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ABS control unit 22Pconnector. 3. Checktor continuity between t e r m i n a lN o . 1 9 a n d b o d y ground.
Repairopen in the wire bstween the pump motor and body ground, or poo. ground {G3511.
Repairshort to body ground in the wir6 botweenthe underhood ABS tuse/rclay box and th€ ABS contlol unit.
{Topage19-51)
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I
Terminalsideof femaleterminals Bepair opon in the wire botween the under-hoodABS fuse/relav bor and the pump motor.
MOTOR+B IREDI Check the pump motor operation: Connectthe battery(+)terminalto the pump motor connectorterminal No. 1, and the (-) terminalto the terminalNo. 2 for a moment.
TERMINAL
MOTORGNDIBLKI Terminal sideof male terminals
Reolacethe modulator unit. lFaulty pump moto.l
ABS CONTROLUNIT 22PCONNECTOR
Wire sideof femaleterminals
(Frompage19-50)
Chcck for .n opsn in the PCOM circuit: 1. Turnthe ignitionswitchOFF. 2 . R e c o n n e ct h e A B S c o n t r o l unit 22Pconnector. 3. Connectthe SCS serviceconnector. 4. Turn the ignitionswitchON {ll). 5. Measurethe voltage between t h e p u m p m o t o r r e l a yc o n n e c t o r P C O Mt e r m i n a l a n d body ground.
ls thereapprox.3V?
tr
) l--l
r"r
Repairopon in the wire betwoen the under-hoodABS fuse/relay box and tho ABS conlrol unh. ABS CONTROLUNIT 22PCO NECTOR
Checkfor an open in tho PMRcircuh: Measurethe voltage betweenthe ABS control unit 22P connector terminalNo. 19and bodyground.
ls thereapprox.3 V?
Ropairopen in tho wir6 botwagn tho undcr-hood ABS fuse/rolay box .nd the ABS control unit.
Ch.ck tor an opon in the MCK ci.cuit: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe SCS service connector. 3. Turn the ignitionswitchON (ll). 4. Measurethe voltage between the ABS controlunit 22Pcon n e c t o rt e r m i n a l N o . 1 7 a n d body ground while connecting the pump motor relay connector+B and MOTORterminal with a jumper wire tor moment,
ls there batteryvoltage?
Chockfor loose ABS control unit connectoas,It necsssary,substitule a known-good ABS control unit and aocheck.
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Wire sideof femaleterminals
1
MCK IBRN,/YEL}
Repairopen in the wiro bdtween the under-hood ABS fus6/telay box .nd the ABS control unit.
t0 1 1
Troubleshooting DTG54:MainRelay -
With the ignition switch ON (lll, the ABS indicator does not go off. With the SCS serviceconnector connected {see page 19-381, DTC54 is indicatod.
Checkthe ABS +B 120A) fuse in the under-hoodABS luse/relay box, and reinstallthe fuse if it is
oK. FeDlacethe tu3e and recheck. AAS CONTROLUNIT 26PCONNECTON
Ch€ck tor an open in the 81, 82 circuit: M e a s u r et h e v o l t a g e b e t w e e n body groundand the ABS control unit26Pconnector terminalNo. 14 and No. 15individually. ls there batteryvoltage?
IWHT/GRNI
Repairopen in the wiro bstweon th6 ABS conirol unit and the under-hoodABS fuse/rolay box,
Checkfor a short to body ground in the PMRcircuit: L Turnthe ignitionswitchOFF. 2. Removethe pump motor relay. 3 . D i s c o n n e ctth e A B S c o n t r o l unit 22Pconnector. 4. Checklor continuitybetween t e r m i n a lN o . 1 9 a n d b o d y grouno.
ABS COf{TROLUN]T 22PCONNECTOR
Repair short to body ground in the wire betweon the underhood ABS lGe/r.lay box and the ABS control unit. Checkfor a short to body ground in the PCOM,SCOMcilcuit: 1 . D i s c o n n e ctth e A B S c o n t r o l unit 26Pconnector. 2. Checktor continuitybetween body ground and the ABS cont r o l u n i t 2 6 Pt e r m i n a l sN o - 1 and No.2 individually. ls therecontinuity?
(To page19-53)
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Wire sideof femaleterminals
Wiresideof femaleterminals
PCOM scoM IGRN/WHTI {BLK/WHTI
. R€pair short to body ground in th€ P1COM circuit wire between the ABS control unit and the und6r-hoodABS tuse/r6lay oox. . R6p.ir short to body ground in the PCOMor SCOMcircuit wire betweon th6 ABS control unit and lhe mod!lator unit. . R . D l e c et h o m o d u l r t o r u n i t . (Short circuit inside the unitl
ABS CONTROLUNIT 26PCONNECTOR PCOM (GRN/WHTI Checkfo. a short to power in tha PCOM,SCOMcircuhi 1. Startthe engine. 2. Measurethe voltage between body ground and ABS control unit 26P connectorterminals No. I and No.2 individually. ls there8 V or more?
Tu.n tho ignhion switch OFFand connect thc SCS 3orviceconnector. Then turn thc ignition switch ON (lll and measuretha voltago botween the PCOM .nd SCOM tsrminal3 and body gJound. It ther6 is 0 V, .eplecotho ABS control unit.
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'Repair short to powor in ths FCOM circuit wiro botwoon th€ ABS control unit and the underhood ABS tuse/r.lay box. . Repeir 3hort to power in tho PCOM or SCOM circuit wire betwegn tho ABS control unii and ths modulator unh, . R.placo tha modulatoi unit. (Shon to power in.ido th6 unitl NOTE:8 V or more indicatesa shortto
SCOM
Wiresideof temaleterminals
Troubleshooting DTC61:lgnitionVoltage -
Whh the .ngine running. the ABS indicator b ON, With the SCS servicc connae tor connoctod {sao prgo 1998}, DTC61 b indi)atod.
Problom vorification: 1. Erasethe DTC. 2. Start the engine.
Doesthe ABS indicatorcome on and is DTC61 indicated?
Tho ryrtom i. OK rt thb timo.
Ch.ck the lG2 circuit: Measurethe voltage betweonthe ABS control unit 26P connector terminalNo.3 and body ground. Wiresideof temaletermioals ls there18V or above?
lf the volt gc b 0 V, ch6d( to. an oD€n in lhe lG2 circuh. I thole ir 12 - 17 V, subatilui. ! known-good ABS control unit .nd r€d|eck.
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DTC81:CentralProcessingUnit (CPUI -
with the ignition 3witch ON {ll}. the ABS indicator does not go off. Whh the SCS sewice connector connectod {see page 1938), DTC81 b indicatod.
Problemvorific.tion: L Eraserne u t L. 2. Test-drive the vehicle.
Doesthe ABS indicatorcome on and is DTC81 indicated?
R€placeth. ABS control unit.
The system is OK at this time.
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19-55
ModulatorUnit Removal/lnstallation NOTE: . Do not spill brakefluid on the vehicle;it may damagethe painu if brakefluid does contactthe paint,wash it off immediatelywith water. a Takecarenot to damageor deformthe brakelinesduring removaland installation. . To preventthe brakefluidfromflowing,plug and coverthe hoseends and jointswith a shop towel or equivalentmaterial, Romoval 1.
the modulatorunit and Dumpmotor connectors. Disconnect
2.
Disconnect the brakelines,then removethe modulatorunit.
lnstallation 1.
Installthe modulatoru nit.then connectthe brakelines.Tightenthe flare nutsto 15 N.m (1.5kgf.m,11 lbf.ft).
2.
Connectthe modulatorunit and oumo motor connectors.
3.
Bleedthe brakesystem,staningwith the front wheels.
4.
Startthe engine,and checkthat the ABS indicatorgoesoff.
5.
Test-drivethe vehicle,and checkthat the ABS indicatordoes not come on, '97 - 98 models.The'99 - 00 modelsare similar. NOTE:This illustrationshowsthe
PUMPMOTOR CONNECTOR
MODULATONUNIT
\ * \
I
,@ TORXEOLT 9.8N,m(1.0kgf.m.7.2lbf ftl
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19-56
ABS ControlUnit Replacement L
Removethe passenger's side kickpanel.
Pulsers/Wheel Sensors Inspection 1 . Checkthe front and rear pulserfor chippedor damagedteeth.
Disconnect the ABS controlunit connectors.
ABS CONTROLUNIT
Measurethe air gap betweenthe wheel sensorand pulserall the way aroundwhile rotatingthe pulser. lf the gap exceeds1.0mm (0.04in),checkfor a bent susDension arm. Standard:o.il - 1.0 mm 10.02- 0.04 inl Front/Rear Removethe rear brakedrum to insDectthe rear wheol sensorair gap,
0.4- 1.0mm (0.02- 0.04 inl
CONNECTORS
Removethe ABS controlunit. Installthe ABS control unit in the reverseorder of removat.
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19-57
Sensors Pulsers/Wheel WheelSensorReplacement NOTE; . Be carefulwheninstallingthe sensorsto avoidtwistingthe wires. . The torquevalueof the boltsis 9.8 N.m ( 1.0kgf.m,7 Ibf.ft). Front
\all 6 mm BOLT 9.8 N.m {1.0kgtm. ?.2lbf'ft)
WHEELSENSOR
Rgar 1. Removethe hub bearingunit (seesection18). 2. Removethe tour backingplatebolts. to disconnectthe 3, Pullthe backingplateaway from the trailingarm, then removethe wheel sensor.lt is not necessary brakeline. '97 - 98 models,The '99 - 00 modelsare similar. NOTE:This illustrationshowsthe 6 mm BOLT 9,8 N.m 11.0kgf.m, 7.2lbf.ft)
WHEELSENSOR
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19-58
Body RearWheelwellProtectol .....20-90 Replacement .........20-72 FuelPipeProtectorReplacement...20-90 RearAir Outlet Replacement..........20-91 .........20-74 *FrameRepairChart .............................. 20-106 Front Grille lnstrument PanelRemovaland .........20-77 Repfacement .........20-47 lnstallation Glass Driver'sDashboardLower Coverand 20-29 ComponentLocationIndex ............ KneeBolsterRemovaland Hood Installation .........20-48 ......,,,20-75 Replacement Glove Box Removaland ............20-76 Adjustment lnstallation .........20-49 *lnterior Trim CenterPocketRemovaland .........20-49 lnstallation 20-40 ComponentLocationIndex ............ Center Dashboard Lower Cover Mirrors 20-50 Removaland lnstallation ............ 20-26 ComponentLocationIndex .........,,, CenterPanelRemovaland Moldings .........20-50 lnstallation 20-84 Roof Molding Replacement............ Power Window Switch Removaland 20-85 Door MoldingsReplacement.......... lnstallation .........20-51 Openers CenterAir Vent Removaland 20-92 ComponentLocationIndex ............ lnstallation .........20-51 RearHatchGlass Side Air Vent Removaland .........20-52 fnstallation .........20-74 Replacement Side DefoggerTrim Removaland Disassemblyand Reassembly........20-79 fnstallation .........20-52 ............20-81 Adiustment DashboardRemovaland RearWeatherstripReplacement....20-83 .........20-53 lnstallation Seats DashboardFrameReplacement.....20-55 20-56 ComponentLocationIndex ............ Doors Side Sill Panel Component Location Index .........20-87 Repfacement FrontDoor ,,...,,,,20-2 SpareTire Cover ...........20-4 RearDoor 20-88 EmblemInstallation........................ TailgateDoor ................................ 20-6 ..................20-104 Sub-frame Fenderwell Wiper/Washer Front Wheelwell Protector 20-97 ComponentLocationlndex ,,,,,....... Replacement .....20-89
Bumpers Front Bumper Removaland fnstaflation RearBumper Removaland fnstaflation 'Dashboard
Inner FenderReplacement.,.....,.,.... 20-89 www.emanualpro.com
Doors ComponentLocationIndex Front Door: NOTE:Refertothe 1997SeriesHondaCR-VBody RepairManual(P/N61S1030) forfrontdoor removat.
OOORCHANNELTAPE INNER W€ATHERSTRIP
OUTERMOLDING
v MIRRORMOUNT COVER
PLASTIC COVER
----s -re
,\//. r =::rR ffi
*Y l
POWERDOORLOCK CONTROLUNIT
HINGE
€fl "\-,-.*
FRONTDOOR PositionAdjustment, page 20-22
t\q
efl-Nr2
/ *-8
ARMREST
FRONTDOORPANEL Removaland lnstallation, page20,7
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20-2
GLASSRUN CHANNEL
REAR LOWER CHANNEL
\ f \i \ \ \ \
t\\\ \\II za\\l
@'-ua$ REGULATOR page20-10 Replacement,
k'"""'
POWERWINDOW MOTOR
CYLINDEB PROTECTOR
OUTERHANOLE page20-8 Replacement,
INNERHANOLE
@,
LATCH PROTECTOR
,;@ I POWEN
POWEF ACTUATOB
wtNDow swtTcH
(cont'd)
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20-3
Doors GomponentLocationIndex(cont'dl Rear Door: NOTE: Refertothe 1997 Series Honda CR-V Bodv RepairManual (P/N 6151030)for rear door removal. DOORCHANNELTAPE INNERWEATHERSTRIP
OUTERMOLOING
DOORPROTECTION
D \FR,
\a)Ei
tu4
PositionAdiustment, page 20-22
ARMREST
@
ARMREST BRACKET
HINGE
REARDOORPANEL 1'99- 00 models) Removaland Installation, page20 '11
dP @
REARDOOR ('97-98 models) Bemovaland Installation, page20-11
o
(Left side only, '97 - 98 models)
\
('99- 00 models)
20-4
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@
OUARTER SEAL
OUARTER GLASS Replacement, page20-13 GLASSRUN CHANNEL
REARCHANNEL-\ -.-----_----_-"" UPPERCOLLAR
trw -flHiili^'i--_Fffi
,6S FRONTLOWER CHANNEL
POWERWINDOW MOTOR
REGULATOR page20'13 Replacement,
STRIKER Adjustment,page20 2L
l I W* LATCH Replacement, page20'13
INN€RHANDLE
/
I
s /*
eoweawrruoow
sYtfcH
/
M-q/ -\
fl
s
LOCKROD PROTECTOR
g
CItr' 6,1-
POWEBDOOR LOCKACTUATOB
LATCH PROTECTOB
iI
\
LOCK CRANK
(cont'd)
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20-5
Doors Component Location Index (cont'dl Tailgate Door: NOTE: Referto the 1997SeriesHondaCR-VBody RepairManual{P/N61S1030) for tailgatedoor removal.
TAILGATEOOOR PositionAdjustment,page20-23
HINGE COVER \
LICENSEPLATE TRIM page20-16 Replacement,
TAILGATEDOOR WEATHERSTRIP
HINGE
V
\
I
illt
N
REARHATCHGLASSLATCH page20 18 Replacement,
SUPPORTSTRUT
REARHATCHGLASS ACTUATOR page20-19 Replacement,
lVr d
d+-BA^cKEr LATCHSTOP page20-17 Replacement,
REARHATCHGLASS
€\A Replacement, page20'19
TAILGATEDOORLATCH page20-17 Replacement,
TAILGATEDOOR HANDLE page20-16 Replacement,
TAILGATEDOOR STRIKER Adjustment,page20-25
k @ /
-6 %
\ TAILGATEDOORWEDGE Adiustment,page 20-25
d\ FLEXIBLECARGO HOOK TAILGATEDOORPANEL page20-15 Removaland Installation, www.emanualpro.com
20-6
Front Door PanelRemovaland Installation NOTE:Takecarenot to scratchthe door paneland other pans. L
Removethe innerhandle(seepage20-3).
2.
Removethe speakercover,then removethe screws.
>: Screw location3,3
I
eF**I
>:Clip locttions g>,3 A>, 1
f- fwi l.$ ; ^ r * l ttv il F:I
3 >: Scr€wlocations,
I
FRONTOOORPANEL
SPEAKER COVER
Removethe screwsfrom the armrest.Releasethe clipsthat hold the door panel,then removethe door panel by pulling it upward.Disconnectthe speaker connector. NOTE:Removethe door panel with as little bending as possibleto avoidcreasingor breakingit.
lnstallationis the reverseof the removalprocedure.
TRIM PAD REMOVER (Commercially avaalable) Snap-on *4177,ol equivalent {0.04in.) r
'..4'
,mm+,----ZY" -i F 45 mm
NOTE:Makesurethe connectoris pluggedin propefly.
I
{1.77in.}
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20-7
Doors FrontDoorOuterHandleReplacement CAUTION: Put on gloves to protect your hands.
4.
NOTE;Raisethe glassfully.
NOTE: . To easereassembly, note location@ ofthe outer handlerod on the joint beforedisconnecting it. . Takecare not to bendthe outer handlerod. . Use a shop towel to protectthe opening in the door.
1 . Removel . Door panel(seepage20-7) . Plasticcover{seepage2O-2)
2.
Disconnectthe cylinder rod. Removethe retainer clip,then removethe lockcylinder.
LOCK CYLINDER
5.
Pull out the outer handle,Pry the outer handlerod out of its joint usingdiagonalcutters.
RETAINEB CLIP
Removethe bolts securingthe o u t e r h a n d l e , t h e n remove the cylinder protector.
>: Eolt locations,2 6 x ' 1 . 0m m I N.m {0.9kgt.m, 7 rbf.ftl
OUTEB HANDLE
5.
Installationis the reverseof the removalprocedure. NOTE: . Makesureeachrod is connectedsecurely. . Makesurethe door locksand opensproperly.
HANDLE
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20-8
FrontDoor LatchReplacement CAUTION: Put on gloves to protect your hands, NOTErRaisethe glassfully. '1. Remove: . Door panel(seepage20-7) . Plasticcover (see page 20-21 . O u t e rh a n d l e 2.
3.
Disconnectthe connector,and detachthe harness clip from the door. Removethe screws,and remove t h e l a t c ht h r o u g ht h e h o l ei n t h e d o o r . NOTE:Takecarenot to bendany of the rods. >: Screw locations,3
6x1.0mm 6 N.m 10.6kgt m, 4 tbf.ft)
Removethe bolt,then move the rear lower channel forward.
CYLINDER ROD
>: Bolt location, 1
6xl.0mm 8 N.m (0.8kgf m, 6 tbf ft)
OUTER HANDLE ROD LOCKROD PROTECTOR
CONNECTOR
HARNESS CLIP
Installationis the reverseof the removalprocedure. NOTE: . Make sure the connectoris pluggedin properly, and eachrod is connectedsecurely. a Makesurethe door locksand opensproperly.
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20-9
Doors FrontDoorGlassand RegulatorReplacement CAUTION: Put on gloves to protect your hands, 1.
2.
Remove; . Door panel(seepage20-7) . Plasticcover (see page 20-21 Carefullymove the glassuntil you can seethe bolts, then loosenthem. Slidethe guide to the front, then removethe glassfrom the guide.Carefullypull the glassout throughthe window slot. NOTE:Takecare not to drop the glassinsidethe door.
3.
Disconnectthe connector,and detachthe harness clip,then removethe regulatorthrough the hole in the door. NOTE: . Scribea line aroundthe rear roller guide bolt to show the originaladjustment. . When installingthe regulator,align the hole of the rollerguidetowardth€ rear.
>: Bolt locations,6 6x1.0mm 8 N.m {0.8kgt.m, 6 rbtft)
>: Bolt locations,2 6xl.0mm 9.8Nm(1.0kgt.m. 7.2 tbt.ftl
Roaru/ard
GLASS
Loosen, REGULATOR
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20-10
RearDoor PanelRemovaland lnstallation 4.
Greaseall the slidingsurfacesof the regulatorwhere shown. NOTE:lf it is necessaryto removethe power wrndow motor from the regulator,scribea line across the sectorgear and regulatorbeforeyou removethe power window motor.
NOTE:Takecarenot to scratchthe door paneland other parts. 1. 2.
R€GULATOF
Removethe innerhandle(seepage20-5). '99 - 00 Removethe screwsfrom the armrest.On models,removethe screwfrom the beverageportion. Releasethe clipsthat hold the door panel,then removethe door panelby pullingit upward. NOTE:Removethe door panel with as little bending as possibleto avoidcreasingor breakingit.
TBIM PAD REMOVER (Commercially available) Snap-on t_ #4177,or lmm equivalent {0.04in.)
T r-----
>: Boh locations,3 6x1.0mm 7 N.m lo.t kgf.m, 5 tbf.ftl
/t5 mm I 11.77in.)
>i Clip locations,6
>: Screw locelions '97 - 98 models.3 '99 - 00 modols,4
POWERWINOOWMOTOR REGULATOR
DOOBPANEL ARMREST
o
i
4
EEVERAGE HOLDEN ('99 00modelsi
^mi A
A '99 - 00 models:
Installationis the reverseof the removalprocedure. NOTEi Rollthe glassup and down to see if it moves freelywithout binding.Also make sure that there is no clearancebetlveenthe glassand glassrun chan nel when the glassis closed.Adjust the positionof (seepage20-20). the glassas necessary
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\ (,1
3.
Installationis the reverseof the removalprocedure.
20-11
Doors RearDoorOuter HandleReplacement CAUTION: Put on gloves to protect your hands.
4,
NOTE:Raisethe glassfully. 1.
2.
Pull out the outer handle.Pry the outer handlerod out of its joint usingdiagonalcutters. NOTE; o To easereassembly, note location@ of the outer handlerod on the joint beforedisconnecting it. . Takecarenot to bendthe outer handlerod. . Use a shop towel to protectthe opening in the door.
Remove: . Door panel(seepage20-11) . Plasticcover(seepage20-4) Remove the lock crank. then remove the screws securing the latch. >: Screw locations A>.3
OUTERHANDLE ROD
B>,'l
6x1.0mm 6 N.m 10.6kgf.m. 4 tbf.ft)
^
PCtlTn-i
I
l
LOCKROD PROTECTOR
Move the latch down, and remove the bolts securing the outer handle,
SHOPTOWEL
>: Bolt locations. 2 6x1.0mm 9.8 N.m {1.0 kgf.m, 7.2 rbf.ft)
5.
Installationis the reverseofthe removalprocedure. NOTE: a Makesurethe door locksand opensproperly. . M a k e s u r e t h e o u t e . h a n d l er o d i s c o n n e c t e d properly.
20-12
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.
Rear Door Latch Replacement
RearDoorGlass,OuarterGlassand RegulatorReplacement
CAUTION: Put on gloves to protect your hands, CAUTION: Put on gloves to protect your hands. NOTE:Raisethe glassfully. 1.
2.
Removel . Door panel(seepage20-11) . Plasticcover(seepage20-4) . Outerhandle(seepage20-121 D i s c o n n e ctth e c o n n e c t o ra n d h a r n e s sc l i p , t h e n removethe latchthroughthe hole in the door.
1.
Remove: o Door panel(seepage20-11) . Plasticcover(seepage20-4)
2.
Carefullymove the glassuntil you can seethe bolts, then loosenthem. Slide the guide to the rear,then removethe glassfrom the guide. NOTE:Takecarenotto dropthe glassinsidethe door.
NOTE: Takecare not to bend any of the rods. >: Boll locations,2
6x1.0mm 9.8N.m (1.0kgtm, 7.2 tb{ft)
GLASS
3.
Installation is the reverse of the removal procedure.
NOTE: . Makesuretheouterhandlerod andinnerhandle properly. rodareconnected . Makesurethedoorlocksandopensproperly.
(cont'd)
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20-13
Doors RearDoorGlass,OuarterGlassand RegulatorReplacement(cont'd) 3.
C a r e f u l l yl o w e r t h e g l a s s .R e m o v et h e b o l t s a n d s c r e w f r o m t h e r e a r c h a n n e l ,t h e n p u l l t h e r e a r channelup as shown. Removethe glass from the r e a rc h a n n e lC . a r e f u l l yp u l l t h e g l a s so u t t h r o u g h the window slot.
4.
Removethe quarterglass.
NOTE:Takecare not to drop the glassinsidethe door. >: Bolt,screwlocations A>, t B>,1 -4 rTmtl-larR
WPU
f\ '^S\\\-.-
W)+
-6 x 1.0 mm
I N m i o . 8 k sm f, 6 tbf.ftt
c>,1
CLIP
Disconnectthe connector.and detachthe harness clip, then removethe regulatorthrough the hole in the door. >: Bolt localions,4 6x1.0mm 8 N.m 10,8kgf.m, 6 tbtftl
REGULATOR
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20-14
''
TailgateDoor PanelRemovaland lnstallation 6.
Greaseall the slidingsurfacesof the regulatorwhere shown. NOTE:lf it is necessaryto removethe power window motor from the regulator,scribea line across the sectorgear and regulatorbeforeyou removethe powerwindow motor.
N O T E :T a k e c a r e n o t t o s c r a t c ht h e d o o r p a n e l a n d other parts. 1.
R e m o v et h e c o v e r ,and remove the flexible cargo hook and base. >: Screwlocations.2
REGULATOR SECTORGEAB
FLEXIBLECARGO HOOKBASE
@t" COVER
POWER
wtNDow MOTOR
i
>: Bolt locations.3 6x1.0mm 7 N.m 10.7kgf.m, 5 rbnftl
FLEXIBLE CARGOHOOK
POWERWINDOWMOTOR
2.
Removethe tailgatedoor lid,then removethe screws. >: CliP locations.
>: Screwlocations.2
?11 |
HPI
,4|
|
I
REGULATOR
7.
lnstallationis the reverseof the removalprocedure. NOTErRollthe glassup and down to seeif it moves freelywithout binding.Also make sure that there is no clearancebetweenthe glassand glassrun channel when the glassis closed.Adjustthe positionof the glassas necessary {seepage20 20).
TAILGATE DOORLIO 3.
Releasethe clips that hold the tailgatedoor panel, then removethe tailgatedoor panel. Installationis the reverseof the removalprocedure. replaceany damagedclips. NOTE:lf necessary,
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20-15
Doors LicensePlateTrim Removaland Installation
TailgateDoorHandleReplacement CAUTION; Put on gloves to protecl your hands,
CAUTION: Put on gloves to prolest your hands. NOTE:Takecarenot to scratchthe tailgatedoor. NOTE: Take care not to scratchthe licenseplate trim and tailgatedoor.
1.
Remove: . Tailgatedoor panel(seepage20,15) . Licenseplate . Licenseplatetrim
2.
'1. Remove the licenseolate. 2.
Removethe tailgatedoor panel(seepage20-15).
3.
Removethe nuts, detachthe clip, then removethe licenseolatetrim.
Disconnectthe handlerod. Removethe nuts securing the tailgatedoor handle,then removethe tailgatedoor handleby pullingit out.
NOTE: Take care not to drop the nuts inside the tailgatedoor.
NOTE:Takecarenot to bendthe handlerod. a: Nut locations,2
a: Nut loc.lions.4 5x0.8mm 1.8Nm(0.18kgt.m. 1.3 rbf.ft)
TAILGATEDOOR
6x1.0mm 9.8 N.m {1.0kgtm, 7.2 rbtft)
,Is TAILGATE DOOR HANDLE Installationis the reverseof the removalprocedure. NOTE: . Makesurethe handlerod is connectedproperly. . Makesurethe tailgatedoor openspropedy.
4.
Installationis the reverseof the removalprocedure. NOTE:lf the clip is damaged,replaceit.
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20-16
TailgateDoor Latchand LatchStop Replacement CAUTION: Put on gloves to protect your hands. NOTE:Takecarenotto scratchthe tailgatedoor. '1.
Removethe tailgatedoor panel(seepage20-15).
2.
Disconnect the handlerod. Removethe bolts securing the latchstop and screwssecuringthe latch. >: Bolt,screwlocations A>,3
3.
Move the latch stop and latch down, then pry the latchstop rod out of its joint usingdiagonalcutters. Removethe latchstop and latchthroughthe hole in the tailgatedoor. NOTE: . To easereassembly,note location@ of the latch stop rod on the joint beforedisconnecting it. . Takecare not to bend the latch stop rod.
B>,3
6x1.0mm
''-t.-N
gta
-\S/r
t
BUSHING
(cont'd)
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20-17
Doors TailgateDoor Latchand LatchStop Replacement(cont'd) 4.
lnstallationis the reverseof the removalorocedure. NOTE: . Makesure the handlerod and latchstop rod are connectedproperly. a Make sure the tailgatedoor locks and opens propenv. . After installingthe latch stop and tailgate door latch,makesure that there is about 1 mm {0.039 in.l betweenthe linkA and link B of the latchstop. Adjust the joint position of the latch stop rod as needed,then checkthe latchstop operation.(Pull the tailgatedoor handlewhile you push on the l a t c h s t o p k n o b ; t h e t a i l g a t ed o o r s h o u l d n o t oDen.)
RearHatchGlassLatch Replacement NOTE: Takecare not to scratchthe tailgatedoor. ' 1 . R e m o v et h e t a i l g a t ed o o r p a n e (l s e e p a g e 2 0 - 1 5 ) . 2.
Disconnectthe connector.Removethe bolts securing the latch,then removethe latch. >: Boh locations,3 6x1.0mm 9.8N.m {1.0kgI.m, 7.2 tbl.Itl REARHATCH GLASSLATCH
LATCHSTOP KNOE
3.
Installationis the reverseof the removalprocedure. N O T E : M a k e s u r e t h e r e a r h a t c h g l a s s l o c k sa n d opensproperly.
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20-18
RearHatchGlassLockCylinder Replacement
RearHatchGlassActuator Replacement
NOTE:Takecarenot to scratchthe tailgatedoor.
CAUTION: Put on gloves to protsct your hands.
1.
Removethe tailgatedoor panel(seepage20-15).
NOTE:Takecarenot to scratchthe tailgatedoor.
2.
Removethe bolt securingthe lock cylinder. Turn and pull out the lock cylinder,and disconnectthe cylinderrod,
1.
Remove; o Tailgatedoor panel(seepage20-'15) . Rearhatchglasslockcylinder
NOTE:Takecarenot to bendthe cylinderrod.
2.
Disconnectthe connectorand the connectorclip. R e m o v et h e b o l t s s e c u r i n gt h e a c t u a t o r ,t h e n removethe actuator.
>: Boltlocation.1 6x1.0mm 9.8N.m {1.0kg .m, 7.2 tbt.lll
NOTE: Take care not to bend the cylinder rod or damagethe joint. >: Boltlocations, 3 6x1.0mm 9.8N.m 11.0kgt.m, 7.2 tbt.ft)
REARHATCHGLASS
CONNECTOR CONNECTOR
J.
Installationis the reverseof the removalprocedure. NOTE: . Makesurethe cylinderrod is connectedproperly. . Makesurethe rearhatchglassopensproperly.
REARHATCH GLASS ACTUATOR
JOINT
-6{
Installationis the reverseof the removalprocedure. NOTE: . M a k e s u r e t h e c y l i n d e rr o d a n d c o n n e c t o ra r e connectedproperly. . Greasethe joint of the cylinderrod. . Makesurethe rearhatchglassopensproperly.
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20-19
Doors TailgateDoorWeatherstrip Replacement
Frontand RearDoorGlass Adjustment
asshown. Installthetailgatedoorweatherstrip NOTE; . Cleanthetailgate witha sponge doorbondingsurface in alcohol. dampened
NOTE: . Placethe vehicleon a firm, levelsurfacewhen adjusting the glass. . Checkthe weatherstripsand glassrun channelfor damage or deterioration,and replacethem if necessary,
a Makesurethereare no wrinklesin the weatherstrip. a Checkfor water leaks.
1.
Remove: . D o o rp a n e l( s e ep a g e s 2 0 - 7l l,l . Plasticcover(seepages2O-2,41
2.
Adjustthe glass.
> : Clip locations,2
i-t] /[L
| I oouere-rrceo
ll 1T
I Thickness:
lE lll
rAPE I aDHEsrvE I
Front:
r.2mmlo.o5 in.)
Raisethe glassas far up as possible.and hold it againstthe glassrun channel.
A
lM /L)
Loosenthe roller guide bolts, and adjust the glassso it is parallelwith the glassrun channel.
DOUBLE.FACED ADHESIVETAPE Thickne$: 1.2mm 10.05in.)
g\
GLASSRUN CHANNEL
BUTYL SEALANT Sealantarea,
ROLLER GUIDEBOLTS 6x1.0mm 8 N.m{0.8kgf.m, 5 tbffi) Tightenthe rollerguide bolts. Loosenthe front channelbolt.
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20-20
e.
Lowerthe glass.
l.
Pushthe front channelagainstthe glass,then tightenthe tront channelbolt.
Loosenthe rearchannelmountingbolts, f.
Lowerthe glass. Push the rear channelagainstthe glass,then tightenthe mountingbolts. >: Bohlocationt2 5x1.0mm 8 N.m(0.8kgtm.6lbtft) GLASS
6x1.0mm 8 N'm108 kg{m' 6 tbf.ftl a,
Raisethe glassfully.
o.
Loosenthe regulatormountingbolts.
c.
Pushthe glassforward.
o.
Tightenthe regulatormountingbolts. il >: Bohlocations, 6x1.0mm 8 N.m(0.8kgf.m,6 lbf.ft) GLASS
3.
Checkthat the glassmovessmoothly.
4.
Raisethe glassfully and checkfor gaps.
5.
Checkthe glassoperation. NOTE:Checkthat the glass contactsthe glass run channelevenly.
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20-21
Doors Frontand RearDoorGlass Adiustment(cont'dl 6.
NOTE: Placethe vehicleon a firm, level surfacewhen adiustingthe doors.
Checkfor water leaks. Spray water over the roof and on the sealingarea as snown. NOTE: . Adjustthe water pressureas shown. . Do not soueezethe tio of the hose.
#
,'r)"f
(r\ "1
tl
After instailingthe door, checkfor a flush fit with the body,then checklor equal gaps betweenthe front, rear. a n d b o t t o m d o o r e d g e sa n d t h e b o d y . T h e d o o r a n d body edgesshouldalso be parallel.Adjustat the hinges as shown. CAUTION:Placaa shop towel on the iack to prevent damageto the door when loosening the door and hinge mounting bolts lor adiustment.
-"'*r"i
12 mm {0.47in.l
Frontand RearDoorPosition Adjustment
0.5 m (1.6ftl
HOSE
DOORMOUNTING BOLTS I x 1.25mm 21 lbI.ftl 28 N.m12.9kgtr.m, Loosenthe doormountingbolrsslighrly to movethedoorlN or OUTuntil it'sflushwith the bodv.lf necessary, youcaninstallashimbehindone hingeto makethedooredges PARALLEL with the bodv.
300mm 111.8in.)
HINGEMOUNTINGBOLTS 8 x 1.25mm 28 N,m 12.9kgt.m. 21 lbl.ftl Removethe innerfender, loosenthe hingemounting bolts,and movethe door BACKWARDor FORWARD, UP or DOWNas necessary to equalizethe gaps.
Lowerthe glass.
7.
Attachthe plasticcover,then installthe door panel (seepages20-7,'l 1),
20-22
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..-
TailgateDoor PositionAdjustment The door and body edges should be parallel.lf necessary,adjustthe door cushion.
NOTE: Placethe vehicleon a firm, level surfacewhen adjustingthe tailgatedoor. A f t e r i n s t a l l i n gt h e t a i l g a t ed o o r . c h e c kf o r a f l u s h f i t with the body, then checkfor equal gaps betweenthe tailgatedoor edgesand the body.The tailgatedoor and body edgesshouldalso be parallel.Adjust at the hinges assnown. CAUTION:Placea shop towel on the iack lo prevent damage to the tailgale door when loos€ningthe tailgate door and hinge mounting bolts for adiustment.
ry.
oooRcusHroNs
DOOR CUSHION Checkfor water leaks.
NOTE:Do not squeezethe tip ofthe hose.
HINGEMOUNYING BOLTS 8 x 1.25mm 25 N.m 12.6kgt m, 19 rbf.ftl
TAILGATE DOOR MOUNTINGsOLTS 8 x 1.25mm 25 N.m {2.6 kgf.m, 19 tbf.ft)
8x1.0mm 22 N'rrl 12.2kgl.m, 16 tbt.ftl
6xl.0mm 9.8N.m {1.0kgt m, 1.2 tbl.ltl
(cont'd)
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20-23
Doors TailgateDoor PositionAdiustment
Frontand RearDoorStriker Adjustment
The door and body edgesshouldbe parallel.
Make sure the door latchessecurelywithout slamming it, lf necessary,adjust the striker:The striker nuts are fixed. The strikercan be adjustedslightly up or down, a n di n o r o u t .
(cont'd)
1.
Loosenthe screws,then insert a shop towel between the body and striker.
STRIKER Inserta shoptowel betweenthe body and
Checkfor water leaks. Spray water over the tailgatedoor and on the sealing areaas shown. NOTE: . Adjustthe water pressureas shown. . Do not squeezethe tip ofthe hose.
scREws 8 x 1.25 mm 18 N.m (1.8kgt.m, 13 rbf.ft)
-€*4
l2 mm (0.47in.)
.*1:]* d3 "1
,'r)"C
II
0.5m {1.6ft}
2. J.
HOSE
Lightlytightenthe screws. Wrap the strikerwith a shop towel, then adjustthe strikerby tappingit with a plastichammer. CAUTION: Do not tap the striksr loo hard.
300 mm {11.8in.l
20-24
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4.
Loosenthe screws.and removethe shop towel.
5.
Lightlytightenthe screws.
6.
Holdthe outer handleout, and pushthe door against the body to be sure the strikerallows a flush fit, lf the door latchesproperly.tightenthe screwsand recheck.
TailgateDoorStrikerAdjustment
TailgateDoorWedgeAdjustment
Make sure the door latchessecurely without slamming it. lf necessary,adjust the striker:The striker nuts are fixed. The strikercan be adjustedslightly up or down, a n di n o r o u t .
1.
1.
Removethe tailgatedoor wedge.
2.
L o o s e nt h e s c r e w s ,t h e n i n s e r t a s h o p t o w e l betweenthe body and striker.
Loosenthe bolts,and move the tailgatedoor wedge UP or DOWNto align it with the tailgatedoor wedge striker.Move the tailgatedoor wedge lN or OUT to centerit. Then lightlytightenthe bolts.
STRIKER Insen a shoptowel between the body and
Forward
TAILGATEOOOR 8 x 1.25mm 18 N.m (1.8kgf.m, r 3 tbf.ft)
Lightlytightenthe screws. 4.
Holdthe tailgatedoor handleout, and push the tailgate door againstthe body to be sure the tailgate door wedge allows a flush fit. lf the tailgate door latchesproperly,tightenthe boltsand recheck.
Wrap the strikerwith a shop towel, then adjustthe strikerby tappingit with a plastichammer. CAUTION: Do not tap the striker too hard. Loosenlhe screws,and removethe shoptowel. Lightlytightenthe screws.
1.
Hold the tailgatedoor outer handle out, and push t h e t a i l g a t ed o o r a g a i n s t h e b o d y t o b e s u r e t h e strikerallows a flush fit. lf the tailgatedoor latches properly,tightenthe screwsand recheck. Installthe tailgatedoor wedge,and adjustit.
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20-25
Mirrors ComponentLocationIndex
MIRRORMOUNT COVEB
POWERMIRBOR page20 27 Replacement,
,//
MIRRORHOLDER page20-27 Beplacement,
@ DAMPER
@
v
W
w REARVIEWMIRROR page20-28 Replacement,
q COVER
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20-26
PowerMirror Replacement
PowerMirror HolderReplacement
NOTE:Takocarenot to scratchthe mirror,mirror mount cover and door.
CAUTION: Put on glovss to protest you. hands. NOTE:Takecarenot to scratchthe mirror.
1.
Lowerthe door glassfully.
2.
Carefullypry out the mirror mount coverby hand,
1,
HOOK
,
C a r e f u l l yp u l l o u t t h e b o t t o m e d g e o f t h e m i r r o r holderbv hand. ADHESIVE
l
Disconnectthe connector.then remove the mirror mountingboltswhile supponingthe mirror, >: Bohlocations, 3
MIRROR
Separatethe mirror holder from the actuator bv slowly pullingthem apart. Reattachthe hooks of the mirror holder to the actuator, then Dositionthe mirror holder on the actuator. Carefullypush the clip portions of the mirror holderuntilthe mirror holderlocksinto place. Checkthe actuatorooeration.
Installationis the reverseof the removalprocedure, NOTE:Make sure the connectoris connectedpropefly.
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20-27
Mirrors RearviewMirror Replacement CAUTION: When prying with a flat-tip screwdrivor, wrap it whh a shop towel to prevent damage. NOTE: Take care not to scratchthe cover or tear the headliner. 1.
Removethe cover usingthe end of a flat-tipscrewdrtver.
HOOKS
Removethe rubberdamper. >: Screwlocations,3
Remove the screws, then remove the rearview mirror. Installationis the reverseof the removalprocedure.
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20-28
Glass ComponentLocationIndex NOTE:The numbersafterthe part namesshow the quantitiesof the pans used. Windshield: MOLOING U P P E RS E A L , 2
UPPERRUBBERDAM 1'00model)
UPPERFASTENER ('97- 99 models,and requiredfor replacement or reinstallation on '00 model) FASTENER,2 (Self'adhesive type,glassside) ('97- 99 models,and requiredfor replacement or reinstallation o n ' 0 0m o d e l )
WINDSHIELD page20-30 Replacement, FASTENER,2 (Self-adhesive-type, body side) ('97- 99 models,and requiredlor replacement or reinstallation on '00 model)
tE-r
*@ LOWERRUBBERDAM ('00model)
Ouarter Glass:
LOWERRUBBERDAM l'97 99 models,and requiredfor reDlacement or reinstallation on'00 modeli
SIDERUBBERDAM, 2 {'97-99 models,and requiredfor replacement or reinstallation on '00 model)
OUABTERGLASS page20-35 Replacement, FASTENER, 1 (Clip-type, body side)
\,o,,.,.*,,, ( S e l f a d h e s i v e - t y p e ,g l a s s s i d e )
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Glass WindshieldReplacement CAUTION: . Put on gloves to protect your hands. . Use seat coversto avoid damaging any surfaces. 1.
2.
4.
To removethe windshield,first removethe: . Rearviewmirror (seepage20-28) . Sunvisorsand holders(seepage20-44l' . Ceilinglight (seesection23) . Grabhandle(seepage20-44) . Frontdoor trim (seepage20-41) . F r o n tp i l l a rt r i m ( s e ep a g e2 0 - 4 1 ) . Windshieldwiper arms and cowl cover (seepage 20-98)
Apply protective tape along the edge ot the dashboard and body as shown. Using an awl, make a hole through the rubber dam and adhesivefrom inside the vehicle. Push a piece of piano wire through the hole, and wrap each end around a piece of wood. PROTECTIVE TAPE
PIANO WIRE
RUBBER UPPER
WINDSHIELD
Removethe moldingand glassbrackets. ADHESIVE
NOTE:lf removingthe molding is difficult,cut the moldlngwith a utility knife.
PROTECTIVE TAPE PIANO
WINDSHIELO MOLDING
PROTECTIVE TAPE
DASHBOARD
WINDSHIELD ADHESIVE
LOWERRUBBER DAM
CAUTION: Hold the piano wire as closeto the windshield as possibleto prevent damageto the body and dashboard.
3.
5.
W i t h a h e l p e ro n t h e o u t s i d e ,p u l l t h e p i a n o w i r e backand fo(h in a sawingmotion,and carefullycut through the rubber dams and adhesivearoundthe e n t i r ew i n d s h i e l d .
6.
C a r e f u l lrye m o v et h e w i n d s h i e l d .
P u l l d o w n t h e f r o n t D o r t i o no f t h e h e a d l i n e r( s e e page20-44). CAUTION: Take care not to bend the headliner excessivsly,or you may break it.
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20-30
7.
Using a knife,scrapethe old adhesivesmooth to a thicknessof about 2 mm (0.08in.) on the bonding surfacearoundthe entirewindshieldopeningflange. NOTE: a Do not scrapedown to the paintedsurfaceof the body; damaged paint will interferewith proper bonding. . Removethe rubberdams and fastenersfrom the oooy, . Maskoff surroundingsurfacesbeforepainting.
8.
Cleanthe body bondingsurfacewith a spongedampenedin alcohol.
10. Glue the rubber dams and fastenersto the inside faceof the windshieldas shown 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 w i n d s h i e l d where adhesivewill be applied, >r Fastenerlocrtions. 2 FASTENEB
\,@,--
w,{,. '>Yl 14mm 0.55in.l
-'-
\l ALIGNMENT MARKS 1 3m m (0.51in.)
NOTE: After cleaning,keep oil, grease and water from gettingon the surface. 9.
--r-r
lf the old windshieldis to be reinstalled, use a putty knjfeto scrapeoff all tracesof old adhesiveand the r u b b e r d a m s , t h e n c l e a nt h e w i n d s h i e l ds u r f a c e with alcoholwhere new adhesiveis to be applied.
ALIGNMENT MARKS
NOTE:Make sure the bonding surfaceis kept free of water,oil and grease. 1 3m m (0.51in.l
CAUTION:Avoid setting tho windshieldon its edges; small chips m8y later devolopinto cracks.
1 3m m in.) 10.51
NOTE:Cleanthe shadowedarea.
*ffi
ALIGNMENT MARKS
1 2m m (0.47in.l
WINDSHIELD
(cont'd)
www.emanualpro.com
20-31
Glass WindshieldReplacement(cont'dl 1 1 . G l u et h e m o l d i n gs i d es e a la n d m o l d i n gu p p e rs e a l to the moldingon eachside.
1 2 . A l i g na n d g l u et h e m o l d i n gt o t h e e d g eo f t h e w i n d shield. 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 w i n d s h i e l d w h e r ea d h e s i v w e illbeapplied. a. With a brush,apply a light coat of primer (3lvlN200,or equivalent)to the edge ot the windshield as shown, b. Gluethe adhesivetapes l3M 4212,or equivalent) to both bottomedgesof the windshield. c . A l i g nt h e a l i g n m e n m t a r ko n t h e m o l d i n gt o t h e alignmentmarkof the windshield. d. Gluethe moldingto the edgeof the windshield.
>: Alignment mark locations ALIGNMENT Applyprimer MARK here. \ ln3ide , /
@
100mm {3.9in.l
100mm {3.9in.}
ADHESIVETAPE Thic*ness:1.2mm (0.05in.) W i d t h4 r m m ( 0 . 1 6i n . )
r0 mm (1.6in.l
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20-32
'13. Installthe glass bracketsand fastenersto the body as shown.
16. With a sponge, apply a light coat of glass primer around the edge of the windshieldas shown, then lightlywipe it off with gauzeor cheesecloth.
2 >: Fastener locations, NOTE: Do not apply body primerto the windshield,and do not get body and glassprimerspongesmixed up. N e v e r t 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 windshieldproperly,causinga leakafter the windshieldis installed. . Keep water, dust, and abrasivematerialsaway from the primedsurface.
R-
//fu
14. Set the windshieldon the glassbrackets.then cen ter it in the opening.Make alignmentmarks across the windshieldand body with a greasepencilat the four pointsshown.
: Applyglassptimar hea.
Applyglassprimer WINDSHIELD
NOTE|Be carefulnot to touch the windshieldwhere adhesivewill be applied. ALIGNMENT MABK
Applyglassprimer to the molding.
1 0 m m RUBBERDAM {0.4in.}
WINDSHIELD WINDSHIELD GLASS BRACKETS NOTE: Adjust the glass bracketsto centerthe windshieldin the opening,then tightenthe
15. Removethe windshield.
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MOLDING
12 mm 10.5in.)
(cont'd)
20-33
Glass (cont'dl WindshieldReplacement 17. With a sponge,apply a light coat of body primerto t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n dt h e w i n d shield openingflange,Let the body primer dry for at least10 minutes.
20, 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 do f a d h e s i v ea r o u n d the edgeof the windshieldas shown.
NOTE: . Do not apply glassprimerto the body, and be careful not to mix up glassand bodyprjmersponges. . Nevertouch the primed surfaceswith your hands. . Maskoff the dashboardbeforepaintingthe flange.
NOTE:Apply the adhesivewithin 30 minutesafter applyingthe glassprimer.
///////l
, apptvaoav primorhere.
16 mm {0.63in.l
12mm (0.47in.)
Ff oo*tt'u'
Makea slightlythicker beadat eachcorner.
8 mm {0.31in.l
7.8mm 10.30in.) 8mm 16 mm 10.fi in.) (0.31in.) FASTENER
14.6mm (0.57in.l 16 mm {0.63in.)
WINOSHIELD
't8, Thoroughlymix the
adhesiveand hardenertogether on a glassor metalplatewith a putty knife. NOTE: . Cleanthe platewith a spongeand alcoholbefore mixing. . Followthe instructionsthat come with the adhesive.
'19. Beforefilling a
cartridge,cut the end of the nozzle
as shown. WINDSHIELO Cut nozzleend 10 mm {0.39in.)
RUBBER DAM 3mm {0.1in.l
7 mm {0.27in,}
20-34
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OuarterGlassReplacement 2 1 . U s e s u c t i o nc u p s t o h o l d t h e w i n d s h i e l do v e r t h e opening,align it with the alignmentmarksmade in s t e p 1 4 , a n d s e t i t d o w n o n t h e a d h e s i v eL. j g h t l y push on the windshielduntil its edge is fully seated on the adhesiveall the way around. NOTErDo not open or closethe doors until adhesive is dry. SUCTTON
ALIGNMENTMARK
CAUTION: . Put on gloves to prot€ct your hands. . Use seat covers to avoid damaging any surfaces. 1. To removethe quarterglass,first removethe: . Rearseat(seepage20-63) . Cargofloor lid and cargo storagebin (seepage 20 431 . R e a rt r i m p a n e l a n d r e a r s i d e t r i m p a n e l ( s e e page 20-421 . Rearhatchglasssupportstrut (seepage20-78) . Ouarterpillartrim panel(seepage20-421 . Taillight(seesection23) NOTE:With the rear hatch glass support strut removed,you will need to support the rear hatch glassby hand. 2.
22. Scrapeor wipe the excessadhesiveoff with a putty knifeor towel. NOTE:To removeadhesivefrom a paintedsurface o r t h e w i n d s h i e l d ,w i p e w i t h a s o f t s h o p t o w e l dampenedwith alcohol.
From insidethe vehicle,use a knife to cut through the quarterglassadhesiveall the way around. NOTE: . lf the quaner glassis to be reinstalled, take care not to damagethe molding. . lf the molding is damaged.replacethe quarter glass,molding,and clipsas an assembly. . The quarter glasscan be reinstalledusing butyl tape.
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 t o 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 w i n d s h i e l da n d c h e c k f o r l e a k s .m a r k l e a k i n ga r e a s ,a n d l e t t h e w i n d s h i e l d dry, then sealwith sealant. NOTE: . Let the vehiclestandfor at leastfour hours after w i n d s h i e l di n s t a l l a t i o nl f. t h e v e h i c l eh a s t o b e usedwithin the first four hours,it must be driven . .
Keep the windshielddry for the first hour after installation. Checkthat the ends of the side molding are set underthe cowl cover.
2 4 . Reinstallall remainingremovedparts. NOTE: . Installthe rearviewmirror rubber damper after t h ea d h e s i vh e a sd r i e dt h o r o u g h l , . . A d v i s e t h e c u s t o m e rn o t t o d o t h e f o l l o w i n g thingsfor two to threedays: - S l a m t h e d o o r sw i t h a l l t h e w i n d o w sr o l l e d up. - Twist the body excess,vely{such as when going in and out of drivewaysat an angle or drivingover rough.unevenroads). www.emanualpro.com
(cont'd)
20-35
Glass Ouarter Glass Replacement(cont'd) lnside:
Using a knife,scrapethe old adhesivesmooth 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 s o p e n i n g flange. NOTE: . Do not scrapedown to the paintedsurfaceof the body; damaged paint will interferewith proper b o n di n g . . lf any of the clips are broken.removelhem trom the body. . Mask off surroundingsurfacesbefore applying pnmer.
v\//,
/6\ /l
Cleanthe body bondingsurfacewith a spongedampenedin alcohol. NOTE:After cleaning,keep oil, grease and water from gettingon the surface. l f t h e o l d q u a r t e rg l a s si s t o b e r e i n s t a l l e du, s e a putty knife to scrapeoff all tracesof old adhesive, t h e n c l e a nt h e q u a r t e rg l a s ss u r f a c ew i t h a l c o h o l where adhesiveis to be applied. NOTE:Make sure the bonding surfaceis kept free of water,oil and grease. CAUTION: Avoid setting the quarter glass on its edges;the molding can be permanently detormed. NOTE:Cleanthe shadowedarea.
ADHESIVE
3.
Carefullyremovethe quarterglass. NOTEj Checkthe molding for damage,replacethe qua.terglassif necessary.
20-36
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7.
Gluethe fastenerto the insideface of quarterglass as shown.lf the old quarterglassis to be reinstalled, applya lightcoatof primer(3M C-100,or equivalent), then applybutyltapeto the quanerglassas shown.
9. lf the old quarterglassis to be reinstalled, sealthe body holewith pieceof urethanetape,Set the quar ter glassuprightin the openingand makealignment m a r k s a c r o s st h e q u a r t e rg l a s s a n d b o d y w i t h a greasepencilat the threepointsshown.
NOTE: . Be carefulnot to touch the quarterglasswhere adhesivewill be aDplied. . Do not peelthe separatoroff the butyl tape. | Bttryl taee locationsl3M 8628,or equivalent) Thickness:3.2 mm 10.13in.l
/'/.////
Width:5.4mm 10.25 in.) BUTYLTAPE
I wmr > t \ /
GLASS
>: Fastenoalocation, I MOLDING FASTENER
1l mm (0.43in.) GLASS
\
MOLDING
ALIGNMENTMANK
400 mm (15.75in.)
8.
lnstallthe fastenerto the bodv as shown. >: Fastenerlocation, 1
r lass. 1 0 . R e m o v et h e q u a r t e g
(cont'd)
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20-37
Glass (cont'd) OuarterGlassReplacement 11. With a sponge,apply a light coat of glassprimer to the insideface of the quaner glass,as shown,then lightlywipe it off with gauzeor cheesecloth. NOTE: . Do not apply body primer to the quarter glass, a n d d o n o t g e t b o d y a n d g l a s sp r i m e rs p o n g e s m r x e du p . . Nevertouchthe primedsurfaceswith your hands. It you do, the adhesivemay not bondto the quarter glass properly.causinga leak after the quar ter glassis installed. . Keep water, dust, and abrasivematerialsaway from the primedsurface.
7///f
With a sponge,apply a light coat of body primerto the originaladhesiveremainingaroundthe quaner glassopeningflange.Let the body primer dry for at least10 minutes. NOTE: . Do not apply glass primer to the body, and be 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. . Nevertouchthe primedsurfaceswith your hands. '/fu,
: Applybody primerhere.
' aeerysra$primerhere. 1 0m m {0.39in.)
BUTYLTAPE
'13.
Thoroughlymix the adhesiveand hardenertogether on a glassor metalplatewith a putty knife. NOTE: . Cleanthe platewith a spongeand alcoholbefore mi x i n g . . Followthe instructionsthat came with the adheslve.
BUTYLTAPE 1 4 . Beforefilling a cartridge,cut the end of the nozzle MOLOING
23 mm 10.90in.) 10 mm 10.39in.)
as snown. Cutnozzleend 10 mm {0.39in.)
GLASS 7 mm {0.27in.)
20-38
www.emanualpro.com
15. Packadhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery,Putthe canridgein a c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d the edgeof the quarterglassas shown. NOTE: . lf the old quarterglass is to be reinstalled,peel the separatoroff the butyltape afterapplyingthe adhesive. . Apply the adhesivewithin 30 minutesafterapplying the glassprimer.
16. Use suctioncups to hold the quarterglassover the opening,alignthe clipsor the alignmentmarksmade in step 9, and set it down on the adhesive.Lightly push on the quaner glass until its edges are fully seatedon the adhesiveall the way around. N O T E :D o n o t o p e n o r c l o s et h e d o o r s u n t i l t h e adhesiveis drv. AUGNMENT
i:.8T".,1,/:AoHEsrvE I rnm (0.31in.)
BUTYL TAPE
SUCTIONCUPS
1 1 . Scrapeor wipe the excessadhesiveoff with a putty knifeor towel, NOTE:To removeadhesivefrom a paintedsurface or the quarter glass,wipe with a soft shop towel dampenedwith alcohol. 1 8 . 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 t o n e h o u r . t h e n spray water over the quarter glass and check for leaks.Mark the leakingareas,let the quarterglass dry, then sealwith sealant. NOTE:Let the vehiclestand for at leastfour hours after quarterglass installation.lf the vehiclehas to be usedwithin the first four hours,it must be driven slowly. GLASS
1 9 . Reinstallall remainingremovedparts. NOTE:Advisethe customernot to do the following thingsfor two to threedays: . .
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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 t a n a n g l eo r d r i v i n g over rough,unevenroads).
20-39
lnteriorTrim ComponentLocationIndex SRScomponentsare locatedin the areasmarkedwith an asterisk(*). Reviewthe SRScomponentlocations,precautions, and proceduresin the SRSsection(24)beforeperformingrepairsor service. CENTERPILLAR FRONTPILLAR UPPER TRIM TRIM (seepage20 41) (seepage20-41) CENTERPILLAR FRONTSIDE LOWERTRIM PANEL TRIM (seepage20 41) (seepage20-41) BEARSIDE TEIM (seepage20'41)
HEADLINER Removaland lnstallation, page 20-44
OUARTERPILLAR TRIM PANEL (seepage20 42)
*CARPET Replacement, page20 45
CENTERCONSOLEIM/T} Replacement, page20-47 CENTENTABLE (seepage20-45)
PARKINGBRAKE COVER (seepage 20-45)
CARGOFRONT SPACER (seepage20 43)
TRIM
20-40
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TRUNKFLOOR EXTENSION (seepage20 43)
Removaland Installation CAUTION: . Put on gloves to protect your hands, . When prying with a tlat-tip screwdrivel, wrap it with protective tape to prevent damage. . When removing the support strut of the rear hatch glass,you will need to open or closethe rear hatch glass by hand. NOTE:Takecarenot to bendor scratchthe trim and panels. >: Cliolocations a>,5 B> , 8
c>,1
e>,2
o>.2
,
|
'rrl
sl elElw"lel I
l_lss-l
REARDOOR TRIM
FRONTSEATBELT UPPER BOLT 7/16- 20 UNF 32 N.m {3.3 kgf.m, 24 rbt.ft) Apply liquidthread
PILLAR CENTER LOWERTRIM PANEL REARSIDE LOWER ANCHOB COVER ('98 00 models) FRONTSEATBEL LOWERANCHOR BOLT 7/15- 20 UNF 32Nm(3.3kgf.m, 24 tbt.ftl
REARSIDETRIM tlemovethe rearseat (seepage20 63).
ANCHOR CAP ('97model)
{cont'd)
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20-41
InteriorTrim Removaland Installation(cont'd) >i Clip loc.tions
a>,21
B>,4
c>,1
D > ,1
E>.!
F> , 3
@wt we@M REANSEATBELT UPPERANCHORBOLT 7/16-20UNF 32 N.m {3.3kgt.m, 24 rbt.ft)
OUARTERPILLAR TNIM PANEL Removethe rear hatch glass supportstrut (seepage 20-741.
REARDOOR REARSIOE TRIM PANEL Removethe reat seat (seepage20-63).
REAR
Disconnectthe accessory socketconnectors, F CONNECTOR
2
5x1.0mm 9.8N.m (1.0kgf.m, 1.2lbt-lrl
TIEDOWN HOOK
ffi
TIE oowN HOOK
6x1.0mm 9.8N.m (1.0kgt m, 7.2 tbf.ft) STRIKER REARTRIM PANEL Removethe cargo areafloor and cargosloragebin.
20-42
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6x1.0mm 9.8 N.m (1.0kgtm, 7.2 tbf ftl
O\A D
v
REARSEATBELT LOWERANCHOREOLT 7/16- 20 UNF 32 N.m {3.3kgt.m, 24 tbl.frl
o: Nut locations,2 >: Clip locations
>: Bolt, screw locations a>,3 B>,4 /\
rr.
m)b -
0>,2
c>,2
6xl.Omm
I
tbr.rrl
I
I
At
Nmr1.o ksnm.l D GlrrIIITTpl -<_/lbe.8 0pE 7.2
v
B>,r
A>,8
|I
.€\
tl1|r' t
l| w
|I
r-
I
l--Tr@HP I v
l'---llH-
|
|
-E
v
v
TRUNK MAT
LOCKASSEMBLY
BUSHING
l V^
I
> '%L i l v "ro"*i* TRUNKFLOOR EXTENSIONS
CARGOAREAFLOOR
FLOOR SrO€ LID
l*,hl
CARGOSTORAGEBIN
FLOORSIDEFRAME
CARGO FRONT TRIM Insta,lationis the reverseof the removalprocedure. NOTE: . lf necessary, replaceany damagedclips. r Beforeinstallingthe anchorbolts,makesurethereare no twistsor kinksin the seatbelts.
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20-43
lnteriorTrim Headliner Removaland Installation CAUTION: When prying with a tlat-tip screwdriver, wrap it with protective tape to prevent damage.
3.
>r Screw locations,6
NOTE: . Takecarenot to bendand scratchthe headliner. o Be careful not to damagethe dashboardand other interiortrim. 1.
2.
Remove: . Frontand reardoor sidetrim (seepage20-41) . F r o n tp i l l a r t r i m( s e ep a g e2 0 - 4 1 ) . Centerpillarlowertrim panel(seepage20-41) . Centerpillaruppertrim (seepage20 41) . Rearseat(oneside,seepage20-63) . Cargoareafloor and cargostoragebin {seepage20-43) . Reartrim panel (see page 20-421 . Rearsidetrim panel(oneside,see page20-42l, . R e a rh a t c hg l a s ss u p p o r ts t r u t ( o n e s i d e , s e e page20-78) . Ouanerpillar trim panel {one side, see page 2042) . Ceilinglight,interiorlight and trunk light (seesection23) . Rearviewmirror (seepage20-28)
R e m o v et h e g r a b h a n d l e sf r o m the front and rear passenger's sides.
ry_l
COVER
4.
Removethe clips,then removethe headliner. NOTE:An assistantis helpful when removing the headliner. >: Clip locations,9
Removethe sunvisorand holderfrom eachside. HEADLINER >: Scaew location3, 4
A\"rYr*
I | ||
-
Pullout. OUARTER TRIM PANEL
suNvtsoR 5.
Removethe headlinerthrough the rear hatch glass openrng.
6.
Installationis the reverseof the removalprocedure. NOTE: . W h e n r e i n s t a l l i ntgh e h e a d l i n etrh r o u g ht h e r e a r h a t c h g l a s so p e n i n g ,b e c a r e f u ln o t t o f o l d o r bend it, Also, be carefulnot to scratchthe body. . C h e c kt h a t b o t h s i d e s o f t h e h e a d l i n e ra r e securelyattachedto the trim.
20-44
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Carpet Replacement are locatedin this area.Reviewthe SRS SRScomDonents and proceduresin the componentlocations,precautions, SRSsection{24)beforeperformingrepairsor service.
4.
Removethe centertable and tableframe bracket. >: Bolt locations,4
CAUTION: Put on glovesto protect your hands. ' 1 . Remove: . Frontseat(seepage20-571 . Rearseat(seepage20 63) . Kickpanel(seepage20-41) . C e n t ep r i l l a rl o w e rt r i m p a n e l( s e ep a g e2 0 4 1 ) . Frontsidetrim {seepage20-41) . Lowerconsolecover1A,/T model,see page20-49) . Centerconsole(lM/Tmodel,see page2o-47)
a: Nut locations,4
8 x 1.25mm 22N.m l2.2kgl.n, 16 tbt ft)
8 x 1.25mm 22 N.m 12.2kgf.m, 16 tbtfrl
>: Clip locations,4
i l l
, l CENTERTABLE
2.
Removethe footrest. Forwaad
>: Eoltlocaiions,2 6x1.0mm 9.8N.m {1.0kgf.m, 7.2 tbt.ttt
FOOTREST
3.
Removethe parkingbrakecover. >: Screwlocations,2
"
l
6bo" I
COVER
TABLEFRAME BRACKET
{cont'd)
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20-45
lnteriorTrim (cont'dl CarpetReplacement 5.
Removethe centerlowercover(M/Tmodel).
8.
Removethe clips, and releasethe fasteners.then removethe carpet.
>: Cliplocations,2
-ffi]
NOTE:Takecarenot to damage,wrinkleor twist the carpet.
lN'
>: Cliplocations.3
FASTENER
COVER
6.
lnstallationis the reverseof the removalprocedure.
Removethe SRSunit covers. >: Clip locations,2
.dL I tEu( | - qf
I
SNSUNIT
FASTENER ('98- 00 models)
cARPET
COVER
7.
'97 model: Cut areas and @ @ in the carpet,then pullthe carpetback. '98 - 00 models:Releasethe fastenerand cut area @ in the carpet,then pull the carpetback.
20-46
www.emanualpro.com
NOTE: . Take care not to damage. wrinkle or twist the carper. . Makesurethe seatharnessis routedcorrectly. . lf necessary, replaceany damagedclips. . Reaftachthe cut areas@ and @ ('97 model)or cut area @ ('98 - OOmodels)in the carpetwith wire ties.
Dashboard GenterConsoleReplacement
lnstrumentPanelRemovaland Installation
M/T model: NOTE;Takecare not to scratchthe dashboardand related parts, 1,
Removethe shift lever knob.screwsand clips.then removethe centerconsole. >: Screw location3,4
>: Clip locations.2
CAUTION: . When prying with a flat-tip screwdriver.wrap it with protestive tape, and apply prolestive tape around the related parts, to provont damago, a Put on glovss to protect your hands. NOTE: Takecare not to scratchthe dashboardand related pans.
I
*K/ 6-Emmmn> | #\
I
1. Tilt the steeringcolumndown. 2.
Removethe screws,and detachthe clips,then carefullv removethe instrumentoanel. >: Screw locations,2
^
l
arl l
>: Clip locations,2
r#sr\
= -, l
| ]
Remove the screws, then removethe centerupper pocket. >: Screw locations,4 PANEL
3.
3.
Installationis the reverseof the removalprocedure.
Installationis the reverseof the removalprocedure. NOTE:lf necessary, replaceany damagedclips.
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20-47
Dashboard Driver'sDashboardLowerCoverand KneeBolsterRemovaland Installation SRScomponentsare locatedin this area.Reviewthe SRS componentlocations,precautions, and proceduresin the SRSsection(24)beforeperformingrepairsor service.
2.
Removethe bolts.then removethe kneebolster. >: Boh locations,3
GAUTION: . When prying with a tlat-tip screwdriver,wrap h with proteqtive tape, and apply protective tape around the relat€d parts, to prevent damage, . Put on glovgsto protect your hands.
6x1.0mm 9.8N.m ('1.0kgtm. 7.2 tbtftl
NOTE:Takecare not to scratchthe dashboardand related pans. 1.
R e m o v et h e s c r e w s ,a n d d e t a c h t h e c l i p s , t h e n removethe driver'sdashboardlower cover.Disconnectthe rearhatchglassopenerswitchconnector. >: Screw locations,2
I GlTtrrrb I . - l
>: Cliplocations A>,3 B > ,1 rr.- | lr, l
@, r ' "| €{l |'l 1
REARHATCHGLASS OPENERSWITCH CONNECTOR
KNEEBOLSTEF
3.
Installationis the reverseof the removalprocedure. NOTE:Make surethe connectoris connectedproperly.
20-48
www.emanualpro.com
Glove Box Removaland
Installation
CenterPocketRemovaland Installation
CAUTION: . When prying with a flat-tip 3crewdriver,wrap it with protective tape, and apply protoqtivetape around ths related parts, to prgveni damage. . Put on glovegto protect your hands.
CAUTION: When prying with a tlat-tip screwdriver, wrap it with protestive tape, and apply protective tape around the related parts to prevent damage.
NOTE: Takecare not to scratchthe dashboardand related oarts.
NOTE:Takecare not to scratchthe dashboardand related oans.
1.
Removethe glove box stopsfrom eachside.
A/T model:
1.
Remove the lower console cover. >: Scrgw locations,6
GLOVEBOX STOPS
6F@'' Il -
>: Clip locations A>,2 B>,2
elsl
GLOVEBOX
Removethe bolts,then removethe glove box. >i Boltlocations,2 COVER
Removethe screws,then carefullyinsert a flat-tip screwdriverand push down on the top of the hook. Removethe centerpocketwith the beverageholder, Separatethe center pocket, beverageholder and beverageholderbracket.
3.
Installationis the reverseof the removalprocedure. 4.
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Installation is the reverseof the removalorocedure.
20-49
Dashboard CenterDashboardLowerGover Removaland Installation
CenterPanelRemovaland lnstallation
SRScomponentsare locatedin this area.Reviewthe SRS and proceduresin the componentlocations,precautions, SRSsection{24)beforeperformingrepairsor service
SRScomponentsare locatedin this area.Reviewthe SRS and proceduresin the comDonentlocations,precautions, (24) performing repairsor servace. before SRSsection
CAUTION: . Wh€n prying with a flat-tip screwdrivet,wrap it with protective tap€, and apply proteclive tape around the rslated parts to prevenl damage. . Put on glovgsto protect your hands. NOTE:Takecare not to scratchthe dashboardand related oarts. 1.
Remove: . Driver'sdashboardlowercover(seepage20-48) . Glovebox (seepage20-49) . Centerpocket(AVTmodel.seepage20-49) . Centerconsole (M/f model, see page 20-41l, . Centerupperpocket(M/Tmodel,see page2O-47J
2.
R e m o v et h e s c r e w s ,a n d d e t a c h t h e c l i p s . t h e n r e m o v e t h e c e n t e r d a s h b o a r dl o w e r c o v e r . the connectors. Disconnect >: Screw locationa,.a
I
6br" - Il
CAUTION: . When prying with a flat-tip screwdriver,wrap it with protective tape, and apply protectivetape around the relatgd parts to prevent damage. . Put on glovesto protect your hands. NOTE:Takecare not to scratchthe dashboardand related parts. 1.
Remove: . Driver'sdashboardlowercover(seepage20-48) . Glovebox (seepage20-49) . Centerpocket(A,/Tmodel,seepage20-49) . Centerconsole(M/Tmodel,see page20-47) . Centerupperpocket{M/Tmodel,see page20-47) . Centerdashboardlowercover
2.
Removethe bolts, and releasethe clips. then pull the connectorsand out the centerpanel.Disconnect antennalead.then removethe centerpanel. >: Bolt locations,2
>: Clip loc.tion6,3
(8NEDL l
I5
\"P
I AccEssoRy I socKET
CENTERPANEL
3.
3.
Installationis the reverseof the removalprocedureN O T E : M a k e s u r e t h e c o n n e c t o r sa r e c o n n e c t e d properly.
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20-5 0
>: Cliplocation3 A> , 4 B>,2 .t !^ \lJS>,,
I is
tt
u .
I
t
\>ry
I r-,/'
AUOIOUNIT
CLIMATE CONTBOL UNITCONNECTORS Installationis the reverseof the removalprocedure. NOTE:Make sure the connectorsand antennalead are connectedproPerly.
Power Window Switch Removal and Installation
CenterAir Vent Removaland
CAUTION: . When prying with a flat.tip screwdriver,wrap it with protective tape, and apply protective tape around th€ related parts to ptavgnt damage. . Put on glovesto protect your hands.
CAUTION: . When prying with a flat.tip screwdriver,wrap h with protective tape, and apply proteqtivetape around the rolated parts to prevont damage. . Put on gloves to protect your hands.
NOTE:Takecare not to scratchthe dashboardand related parts.
NOTE:Takecare not to scratchthe dashboardand related pans.
Installation
'L
Removethe driver's dashboard lower cover (see page20-48).
2.
Gentlypush out the powerwindow switchfrom the dashboard lower cover opening by hand. Disconnect the connectors.
NOTE:Carefullvinsen a flat-tio screwdriverunder the clips,then pull out the centerair vent while prying up the clips.
>: Cliplocations, 4
>:Cliplocations.,l
1.
R e m o v et h e c e n t e ra i r v e n t . t h e n d i s c o n n e c t h e connector.
I
ffil
CENTERAIB VENT
POWER WTNOOW SWITCH Installationis the reverseof the removalprocedure. Installationis the reverseof the removalprocedure, NOTE;Make surethe connectoris connectedpropN O T E : M a k e s u r e t h e c o n n e c t o r sa r e c o n n e c t e d properly.
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20-51
Dashboard Side Air Vent Removaland lnstallation
Side DefoggerTrim Removal and lnstallation
CAUTION: . When prying with a flat-tip screwdriver,wrap it with protec'tivetape, and apply protcctive tape around the related parts to provent damage. . Put on glov€sto protect your hands.
CAUTION: . when prying whh a flat-tip sctewdriver, wrap it with protective tape, and apply protectiv€ tape around the relatgd parts to prevent damagg. . Put on gloves to protect your hands.
NOTE:Takecare not to scratchthe dashboardand related parts.
NOTE:Takecare not to scratchthe dashboardand related oarts.
1.
Driver'sside:Removethe Dowerwindow switch.
1.
Driver'sside:Removethe sideair vent.
2.
Driver'sside:Closethe vent, and gentlypushout the c l i p s f r o m t h e p o w e r w i n d o w s w i t c h o p e n i n gb y the hand,then pull out the side air vent. Disconnect connector. Passenger'sside:Carefullyinsert a flat-tip screwdriver underthe clips.then pull out the side air vent while pryingup the clips.
2.
Driver'sside:Gentlypush out the clipsfrom side air vent openingby hand,then pull out the side defogger trim. Disconnect the connector. Passenger'sside: Carefullyinsert a flat-tip screwdriver underthe clips,then pull out the side defogger trim while prying up the clips. >: Clip locations,2
>: Cliplocations B > ,1 A>,2
c
1
f f- it l
sl4
POWERMIRROR SWITCHCONNECTOR
TRIM SIDEAIB VENT
3. 3.
Installation is the reverseofthe removalprocedure.
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20-52
Installationis the reverseof the removalprocedure.
DashboardRemovaland Installation SRScomponentsare locatedin this area.Reviewthe SRS componentlocations,precautions, and proceduresin the SRSsection{24)beforepreformingrepairsor service.
5.
CAUTION: . When prying with a flat-tip screwdriver,wrap h with protective tap€, and apply protective tape around the related parts to prevgnt damage. . Put on glovesto prot€ct your hands.
Removethe dashboardside cover. Disconnect the dashboardwire harnessconnectors, removethe nuts, then move the under-dashfuse/relaybox. Disconnect t h e a n t e n n al e a d , a n d d e t a c ht h e h a r n e s sc l i p s . Removethe connectorholder from the dashboard frame. Unbolt the control unit/relay bracketfrom behindthe middleof the dashboard. >: Clip locations.
r t t l
sl l l l
NOTE: . An assistantis helpfulwhen removingand installing the dashboard. . T a k ec a r e n o t t o s c r a t c ht h e d a s h b o a r db, o d v a n d other relatedparts.
ANTENNA LEAD
l
HARNESS SRSMAIN HARNESS
1 . M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e radio'spresetbuttons. 2.
UNDER.DASH FUSE/RELAY
Disconnectthe negativebatterycable.and wait at leastthree minutesbeforebeginningwork.
BOX OASHBOARD SIDECOVER
Removei a Driver'sdashboardlower cover and knee bolster (seepage20-48) . Glovebox (seepage20-49) . L o w e r c o n s o l ec o v e r a n d c e n t e r p o c k e t ( A / T model,seepage20-49) . C e n t e rc o n s o l ea n d c e n t e ru p p e r p o c k e t( M / T model,see page20-47) . Centerdashboardlower cover(seepage20-50) . Powerwindow switch(seepage20-51) . Driver'sside air vent (seepage20-52) . Driver'sside defoggertrim (seepage20-52) Disconnect the driver'sairbagconnector,and lower the steeringcolumn(seesection17)
6x1.0mm DASHBOARD9 . 8 N m 1 1 . 0 k g f . m , FFAME 7.2tbt.ftl CONNECTOR HOLDER
6.
Removethe passenger's dashboardlowercover. >: Scr€w location, 1
NOTE:To preventdamageto the steeringcolumn, wrap it with a shop towel.
I SF:oo lI
D: Clip locations,
n
l
-$t- I ssj PASSENGER'S DASHBOARD LOWERCOVER
I {cont'd)
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Dashboard DashboardRemovaland Installation(cont'd) 7.
Disconnect the connectorsand harnesscliDS. >: Boli loc.lions B>,1 a>,5
c>,1
^5\h'.'_. 4fl\',r,' r$\'rmTrr':j,1.ff,ry-r,.,". \fl)Prtu' tltbt.ttl W/*
W)-
OASHBOARD GUIDEPIN
c)-
CONNECIORS
CONNECTOR
Removethe bolts.then lift and removethe dashboard. CAUTION: Use protective iape on the botlom of ths tront pillar trim. lnstallationis the reverseof the removalprocedure. NOTE: . Makesurethe dashboardfits onto the guide pinscorrectly. . Beforetighteningthe bolts,makesurethe dashboardwire harnessesare not pinched. . Makesurethe connectorsand antennalead are connectedproperly.
20-54
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DashboardFrameReplacement CAUTION: Put on gloves to prolect your hands. NOTE:Takecarenot to scratchthe dashboardand relatedparts. a: Nut locations,3 6x1.0mm 9.8 N.rn 11.0kgf.m, 7.2 tbt.ftl
>i Screwlocations A>,16
I
INSTRUMENT PANEL (seepage20 47)
\,.\ / ,.-------f,\
lu
w
GAUGE
CENTERPANEL {seepage20 50)
/A
\,r* B>,2 ^
S@t' -
l
1l
c >,2 I
0" @ ll D>.a
^
l
DASHBOARD wlRE HARNESS
0- F ll
DASHBOARD FRAME
>: Clip localions.2
.dr -wr I
Ihll'rifi-
|
i
FRONTPASSENGER'S
Installationis the reverseoI the removalorocedure. NOTE: . Makesurethe dashboardwire harnessesare not Dinched. . Makesurethe connectorsand antennaleadare connectedproperly.
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Seats ComponentLocationIndex
REARSEAIS page20 63 Removaland lnstallation, page20 65 Disassembly and Reassembly, page20-67 and Reassembly, SeatLinkageDisassembly page20-69 ArmrestReplacement, page20-69 SeatCoverReplacement,
Removaland Installation, page20 57 Disassembly page2O-58 and Reassembly, SeatLinkageDisassembly page20-60 and Reassembly, ArmrestFleplacement, page20 61 SeatCoverReplacernent, page20 61
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20 -5 6
Front Seat Removaland Installation CAUTION: When prying whh a tlat-tip screwdrivor,wrap it with proteqtivetape to prevent damage. NOTE:Takecare not to scratchthe bodv or tear the seat covers. 1.
2.
Lift up the driver's front seat,then disconnectthe seatbeltswitchconnectorand harnessclips. >: Hrrnosscliploc.lions
Removethe seat track end cover, and removethe bolts. >: Bolt loc.tions A>.3 I x 1.25mm 22 N.m i'2.2 kgl.m, 16 rbf.ftl
B > ,1 10x 1.25mm 37 N.m 13.8kgt.m, 27 tbt.ftl
SEATBELTSW]TCH CONNECTOR Carefullyremove the front seat through the door opening. NOTE:An assistantis helpful when removingthe front seat. Installationis the reverseof the removalprocedure. NOTE:Make sure the seat belt switch connectoris connectedproperly(driver'sfront seat).
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20-57
Seats and Reassembly FrontSeatDisassembly CAUTION: When prying with a flat-tip screwdriver,wrap it with protsqtive tape to prevent damage. NOTE:Takecarenot to scratchthe bodv or tear the seatcovers. Driver's seat lmanually adiustablewith manual height adiustmentl: removal: barremoval: Torsionbar Torsion
>: Cliolocations
HOOK
SEATCUSHION
10x 1.25mm ,17N.m (,1.8kgt m, 35 tbt.ft)
PIVOTNUT 8 x 1.25mm 22 N.n 12.2kgl.m, 16 rbI.ft) 10 x 1.25mm 47 N.m (4.8 kgf.m, 35 tbtfr) HOOKS 10 x 1.25mm 47 N.m {,1.8kgl.m. 35 rbt.ft)
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20-5 8
Passenger's seat (manuallyadiustablel: >: Clip locations HOOK
HEADREST
SEAT.BACK PIVOTWASHER PIVOTNUT 8 x 1.25mm 22 N.m 12.2kgl..n, 16 tbt.ftl
SEATCUSHION
CENTERCOVER
BUSHING 1 0x 1 . 2 5m m ,U N.m 14.8 35 rbt.ft)
'10x 1.25mm 47 N.m {4.8 kgf m, 35 rbl.ft)
UNDER-SEAT TRAYGUIDE
1 0x 1 . 2 5m m 17 N.m {4.8kgl.m, HOOKS 35 tbf.ft)
d
COVER
Reassembly in the reverseorderof disassembly. NOTE: . Makesurethe bushingand pivotwasherare installedproperly. . To preventwrinkleswhen installingthe seat-back cover,makesurethe materialis stretchedevenlyover the pad. . Greasethe movingportion. www.emanualpro.com
Seats and Reassembly FrontSeatLinkageDisassembly CAUTION: Put on gloves to protect your hands.
RECUNEADJUSTER 8 x 1.25 mm 22 N.m 12.2kgl.m, 16 tbf.fi)
8 x 1.25mm 22 N.m 12.2kd-m, 16 tbtf0 CROSSBRACE
8 x 1.25mm 22 N.m 12.2kgl.m, 16 tbf.f0
INNERSLIDE ADJUSTER
cRoss BRACE
CONNECTING WIRE To connect,twist 180". OUTERSLIDE AOJUSTER
8 x 1.25mm 22 N.rn l.2.2kgl-m, 16 rbr.ft)
in the reverseorderof disassembly. Reassembly NOTE:Greasethe moving portions.
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20-6 0
FrontSeatArmrestReplacement
FrontSeatCoverReplacement
NOTE:Takecare not to tear the seamsor damagethe seatcoverS.
CAUTION: Put on gloves to protect your hands. NOTE:Take care not to tear the seamsor damagethe seatcovers.
>: Boltlocations.2 6r1.0mm 9.8N,m ll.0 kgl.m, 7,2 tbf.ft)
Seat-backcover: '1. Slide the front seatforward,and fold the seat-back forward. 2.
Removethe armrestfrom the driver'sseat.
3.
Release the hook,and fold backthe seat-backcover. SEAT-BACK
1 0x 1 . 2 5m m kgf,m, 47 N.m 1,1.8 35 tbt{t)
4.
Releaseall insidesprings,then fold backthe seatbackcover.and removethe clios. WIRE {Padsidei
Installationis the reverseof the removalprocedure.
(Seatback frame sjde)
cover on
'00
model)
(cont'd)
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20-61
Seats FrontSeatCoverReplacement(cont'dl Removethe headrestguide,then removethe seatDacxcover.
3.
Pull backthe edge of the seat cushioncover all the way around,then releasethe clips.and removethe seatcushioncover.
COVER
6.
(padside)
is the reverseof the removalprocedure. Installation
lnstallationis the reverseof the removalprocedure.
NOTE: To preventwrinkleswhen installinga seatbackcover,makesure the materialis stretchedevenly over the pad before securingthe hook and inside springs.
NOTE: . To preventwrinkleswhen installinga seatcushion cover. make sure the material is stretched evenlyoverthe pad beforesecuringthe clips. . Replacethe releasedclipswith new ones.
Seat cushion cover: 1.
Removethe seatcushion(seepages20-58,59). Removethe clipsfrom underthe seatcushion.then loosenthe seatcushioncover.
RINGPLIERS UPHOLSTERY available) lCommercially
CLIP
NEWCUP
SEAT FRAME
SEAT CUSHION COVER
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20-62
RearSeat Removaland lnstallation CAUTION: When prying with a llat-tip screwdrivsr, wrap it with protectivetape to prevent damage.
with tilt: NOTE:Beforeremovingthe rearseat,tilt it.
NOTE: Takecare not to scratchthe seatcoversand bodv. l
Removethe lower hinge covers,then remove the bolts.
>: Boh locations.2 8 r 1.25mm 2 N.m 12.2kgl,n, 16 tbf ttl
LOWERHINGE
covERs
LOWERHINGE COVER
(cont'd)
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20-63
Seats RearSeat Removaland Installation(cont'dl 2.
Foldthe seatcushionforward,and removethe base framecover,then removethe boltsand nut.
5.
removethe striker. With tilt: lf necessary,
NOTE:The rear seat without tilt is shown,the rear seatwith tilt is the same manner. >i Boh screw locetions
A>, 1
B>, 4 8 x 1.25mm 22 N.m {2.2 kgf.rn, 16 rbtft)
a: Nut loc.iion,
@ t
'l
8 x 1.25mm 22 N
lnstallationis the reverseof the removalprocedure. N O T E :M a k e s u r e t h e r e a r s e a t b e l t b u c k l e sa n d centerbelttongueare routedproperly(withouttilt).
SEATBELTBUCKTES (CENTERBELTTONGUEI SEATCUSHION
?
Removethe headrest.
4.
Carefullyremovethe rear seatthrough the door opening. NOTE:An assistantis helptulwhen removingthe rear seaI.
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20-64
and Reassembly RearSeat Disassembly CAUTION: When prying with a flat-tip screwdriver,wrap it with protective tape to prevent damage. NOTE:Takecarenot to scratchthe body or tearthe seatcovers. Without till:
SEAT-BACK
SEAT.AACK RECLINEROD
PIVOT COVER
PIVOTNUT 8 x 1.25mm 20 N.m 12.0kg{.m. 14 tbf.ftl
WASHER HOOKS
SEATCUSHION LATCH
SEAT CUSHION
SEATCUSHION STRAP
5x1.0mm 9.8 N'm (1.0kgf.m, 7.2 tbl.ltl
SEATLINKAGE
(cont'd)
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20-65
Seats (cont'd) RearSeat Disassembly and Reassembly with tilr:
SEAT-BACK
SEAT.BACK RECLINEROO
PIVOTNUT x 1.25mm 20 N{n (2.0kgt.m, 14 tbt-fr)
10 x 1.25mm 47 N.m {4.8kgfn, 35 tbtft)
I-ATCH COVER SEATCUSHION LATCH
SEAT CUSHION SEATLINKAGE
T;LT KNOB
CLIP
Reassemble in the reverseorderof disassembly. NOTE: . Makesurethe bushingand pivot washerare installedproperly. . Greasethe moving portion.
20-66
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6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 tbf.ftl
SEATCUSHION STRAP
and Reassembly RearSeat LinkageDisassembly CAUTION: Put on glovesto protect your hands' Without tilt:
REABSEAT FOOT
CENTER COVER
I
6x1.0mm 9.8 N{n 11.0kgt'm, 7.2 tbt ftl
N HINGE PIN
E-CLIPS Replace.
BASEFRAME
I I
b HINGEBRACKET
(cont'd)
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20-67
Seats RearSeat LinkageDisassemblyand Reassembly(cont'd) with tilt: NOTE:Referto section24 for the rearseatbelt bucklesand centerbelttongue removal TILTCONTFOL CABLE
CENTEBARM COVER
1 0x 1 . 2 5m m 47 N.m {i1.8kgt.m, 35 tbf.ft)
6x1.0mm 9.8 N.m n.0 kgt.m, 7.2 tbt.tll
n /
8 r 1.25mm 16 N.m (1.6kgf.m, 12 tbt.ftl
//-)
ASE FRAME DAMPER
6x1.0mm 9.8 N.m 11.0kgtm, 7.2 tbttr) TILTCONTROLROD
A @
SPRING UPPERHINGE
TILT CONTROL CABLE
Replace.
q
BUSHING H I N G EP I N
E.CLIP Reptace. Reassemble in the reverseorderof disassembly. NOTE: . Greasethe moving ponion. . lf necessary, adjustthe tilt controlcable.
20-64
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RearSeatArmrestReplacement
RearSeatCoverReplacement
NOTE:Take care not to tear the seamsor damagethe seat covers.
CAUTION: Put on gloves to protect your hands.
SEAT.BACK
NOTE:Takecare not to tear the seamsor damagethe sealcovers. Seal-backcover:
COLLAR
L
Removethe seat-back{seepage20-65).
2.
Remove: a Armrest . Headrest . Seat-back reclinerod (seepage20-65)
COLLAR
Removethe seat cushionstrap bolt and strap bolt trim, then removethe seat-backmat.
6x1.0mm 9.8 N.m {1.0kgf.m,
7.2rbr.ft) WASHER
NYLON WASHER VE WASHER
ARMREST
"'---.' t.-r"t-- i,': ""
'
ARMREST PIVOTBOLT 6x1.0mm 9.8 N.m (1.0kgt.m, 7.2lbllll
4.
Removeall the clips.
lnstallationis the reverseof the removalprocedure.
(cont'd)
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20-69
Seats RearSeatCoverReplacement(cont'dl Removethe headrestguide and latch knob collar, then removethe seat-back frame. SEAT.BACK FRAME i
Soat cushion cover: '1.
Removethe seatcushion(seepage20-65).
2.
R e m o v et h e s e a t c u s h i o nl a t c h a n d s e a t c u s h i o n strap(seepage20-66).
3.
P u l l b a c kt h e e d g e o f t h e s e a tc u s h i o nm a t , t h e n releaseall of the clips. SEATCUSHION MAT
€
--t)c/
l@ I
I
pio
t-t t l L]
HEADREST
GUroE
LATCHKNOB COLLAR
Pull backthe edgeof the seat-back coverall the way around.releasethe clips,and removethe seat-back cover. CUSHION COVER Pull backthe edge of the seat cushioncover all the way around,releasethe clips,and removethe seat cushtoncover. CLIPS
CLIPS ( L e a t h e rs e a t - b a c k
coveron '00model) 1.
WIRE (Padside,leatherseat,back
coveron ,00model)
Installationis the reverseof the removalprocedure. NOTE: o To preventwrinkleswhen installinga seat_back cover,makesure the materialis stretchedevenly over the pad beforesecuringthe hook and clips. . Replacethe releasedclipswith new ones.
20-70
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COVER
5.
Installationis the reverseof the removalprocedure. NOTE: o To preventwrinkleswhen installinga seatcushi o n c o v e r ,m a k e s u r e t h e m a t e r i a li s s t r e t c h e d evenlyover the pad beforesecuringthe clips. . Replacethe releasedclipswith new ones.
FING PUERS UPHOLSTERY (ComE|erciallY available)
PAD
WIRE (Padside)
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20-71
Bumpers FrontBumperRemovaland Installation CAUTION: Put on gloves to protec,tyour hands. NOTE: . An assistantis helpfulwhen removingthe front bumper. . Takecarenot to scratchthe front grille,lront bumperand body. o Firstremovethe front grille (seepage20-77). . lf necessary, removethe front licenseplatebaseand front licenseplatelower bracket. >: Boli screw locations A>,3 6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbt t0 FRONTGRILLE (seepage20-77)
>: Cliplocations,5
B > ,4
4
C>,4
\
t
.
<
\
S))PF | ffi)m>l v Y./ I
FRONTGRILLE EMBLEMCOVER (seepage20-77)
.r.,
l
|
I
w €l w
FENDER
tx\ \{_:
I B
FRONTBUMPER
20-72
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removethe front bumperbeam,front bumperupperbeamand guard bar. lf necessary, >: Bohlocations A>,5
c>.6
V.2
E>,6
D>,2
Gfu @p;i,li',ll-"-' >: Clip locations B>.3 A>, 5
10 x 1.25mm 38 N.rn {3.9 kgf.m, 28 rbl.ftl
@,,2
n l n - n l z n Ir
dE6 I #\Er+ ;lHl=| =.=r | € t:Wl
TIE DOWN HOOK
Yl-r
{to/
BEAM
TIE.DOWN HOOK
v1
Installationis the reverseot the removalprocedure. NOTE: . M a k e s u r e t h e f r o n t b u m p e re n g a g e st h e f r o n t bumperupperbeamsecurely. . It necessary,adjust the front bumper upper beam to obtainthe propergap. . lf necessary, replaceany damagedclips.
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FRONTBUMPEB
20-73
Bumpers RearBumperRemovaland Installation CAUTION: Put on gloves to proteqt your hands. NOTE: . An assistantis helpfulwhen removingthe rearbumper. . Takecarenot to scratchthe rearbumDerand bodv. >: Boli,screwlocations
a>,2
.f-.'
0f'"I trl
rgfi\\* ffi\\-. 3il;l-'lln*n,.., t.2tbtftl WJ/*
>: Clip locelions, 7
c>, 10
B>,4
-
Y)f
l
.
I
K
-
l l BEARBUMPER STEP
SIOEMARKER LIGHTCONNECTOF REARSPLASH Disconnect. GUARD
To body
To body
SIDE MARKER LIGHT
To body To body
REARBUMPER LIGHT
Installationis the reverseof the removalprocedure. NOTE: . lf necessary, replaceany damagedclips. . Makesurethe side markerlight connectorsare pluggedin properly. . Makesurethe rearbumperengagesthe sideclipson eachsidesecurely.
20-74
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Hood Replacement NOTE: . An assistantis helpfulwhen removingand installingthe hood. a Takecarenot to damagethe hood and body . When removingthe clips,usea clip remover. >: Bolt locations,4 6x1.0mm 9.8N.m {1.0kgt.m, 7.2tbtfr) HOOD WINDSHIELD WASHERNOZZLES (seepage20-100)
G {
\ WINDSHIELD WASHER TUBE (seepage20-100)
HOOD HINGE
Installationis the reverseof the removalprocedure NOTE: . Makesurethe hood opensproperlyand lockssecurely. . Adjustthe hood alignment. . Adjustthe aim of the windshieldwashernozzles(seepage20-102)
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20-75
Hood Adjustment NOTE: Beforeadjustingthe hood,looseneachbolt slightly. to make Turnthe hood edgecushions,as necessary, the hood fit flushwith the bodv at front and sideedges.
Adjustthe hood right and left,as well as fore and aft, by usingthe elongatedholeson the hood hinge
f sz
+
14--+ik-
HOODEDGE CUSHION
6x1.0mm 9.8N.m (1.0kgtm, 7.2 tbt.ttl
HOODHINGE
HOODHINGE
Adiustthe hood latchto obtainthe properheightat the forwardedge' Move the hood latchrightor left untilthe strikeris centeredin the hood latchas shown
\
?-9.8N.m (1.0kgf m, 7.2 rbf.ftl
20-76
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HOODLATCH
HOOD LATCH
Front Grille Replacement CAUTION: When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts to prevent damage. NOTE:Takecare not to scratchthe front orille and front oumper. 1.
Removethe front grille emblem cover. Loosenand removethe grille mountingscrews.and removethe front grille by pullingit forward. >: Screwlocations a>,5 s>,2
@-l@,"l
N O T E : I n s e r t a P h i l l i p ss c r e w d r i v e rt h r o u g h t h e holes in the front grille,then loosen the screws.
2.
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Installationis the reverseof the removalprocedure.
20-77
RearHatchGlass Replacement CAUTION: . Put on glovesto protecl your hands. . Use seal coversto avoid damaging any surfaces. . Do not damage the rear window delogger grid lines and terminals.
Harnosswiring locations:
REARWINDOWWIPER MOTORCONNECTOR Removethe rearwiper lower cover(seepage20-99i.
NOTE:An assistantis helpful when removingthe rear hatchglass. a: Nul locations Aa.4 Ba.4
€ @i!iff*-"REARSPOILER
.;=-
8 x 1.25mm 22 N-m l'2.2kgl.m, '16tbt fr) 8 x 1.25mm 22N.m l.2.2*ql.m, 16 tbf.ft| Installation is the reverse of the removal orocedure.
NOTE: . Adjustthe rearhatchglassalignment. . Makesurethe connector,terminalsand washertube are connectedproperly. . Adjustthe aim of the rearwindow washernozzle(seepage20-103).
20-78
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HARNESS' TRIM
Disassembly and Reassembly NOTE: . Takecarenot to scratchthe rearhatchglass. . lf necessary, replaceany damagedspacersand seals. . Referto page20-99fortherearwindowwiper motor removaland section23 for the high mount brakelight removal.
HINGEPLATE ('00model)
HINGESPACEN ('97- 99 models) HINGESPACERS
REARSPOILEB SPACER {'99 00 models)
HARNESS TRIM
HARNESS TRIM
6x1.0mm 9.8 N.m {1.0kgl.m, 7.2 tbt.ft) WASHER
STBIKER
s
REARSPOILER SPACER ('97- 98 models)
R€AFWINDOW WIPERMOTOR BASEPLATE
SEAL
REARWINDOW WIPERUPPER COVER
CAUTION LABEL
MOTORBASE PLATESEAL
/=
PIVOTNUT
FEAR TIME 4WD EMBLEM GLASSPROTECTOR
{cont'd)
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20-79
RearHatchGlass (cont'dl Disassembly and Reassembly NOTE:Beforeinstallingthe rear spoilerspacer,harnesstrim. cautionlabel,real time 4WD emblem and glass protector, cleanthe rearhatchglassbondingsurfacewith a spongedampenedin alcohol. >: Alignment mark locatioos
A>
_\
l |
r\,
ALIGNMENT MARK
w l : f \
ALIGNMENT HARNESS MARK TRIM
A
lnside:
Center line
REARSPOILERSPACER Centorline
Outside: o o o
O
REARSPOILER SPACER {'97 98 models)
REAR SPACERS {'99 00 models)
20- 8 0
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SPOILER SPACEBS ('99 00 models)
Adjustment NOTE: . After adjustingthe tailgatedoor,adjustthe rearhatchglass. . Loosenthe strikermountingboltsslightly. . Removethe rearspoiler,and removethe supportstrutfrom body side. 1. Loosenthe rearhatchglassmountingnuts. 2. Adjustthe rearhatchglassso thereare equalgaps betweenthe rearhatchglass,the taillights,and the tailgatedoor. NOTE:lf necessary,loosenthe rear hatchglasshinge mountingnuts and move the rear hatchglassbackwardor forward to fit the rearweatherstripand tailgatedoor weatherstrip. REARHATCI{ GLASSHINGES
REARHATCHGLASSHINGE MOUNTINGNUT 6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbt f Removethe rearedge otthe headliner (seepage20-44).
MOUNTINGNUT 6x1.0mm 9.8N.m 11.0kgtm, 7.2 rbf.ftt
Taillight side:
NOTE:Adjustfor equalgaps betweenthe right and left.
Tailgate door side:
I
About 7mm 1o.27in.l
REARH ATCHGLASS
(cont'd)
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20-81
RearHatchGlass Adjustment(cont'dl 3 . After adjustingthe rearhatchglass,tightenthe rear hatchglassmountingnuts,and installthesupportstrut. 4 . Adjustthe strikeralignment. NOTE: . Move the strikerfore or aft to makethe rearhatchglassfit flush with the tailgatedoor' . Move the strikerright or left until it's centeredin the rearhatchglasslatchas shown. REARHATCH GLASS LATCH
REARHATCHGLASS
STRIKER
6x1.0mm 9.8 N.m (1.0kgt'm, 7.2tbl.ftl NOTE:When equalizing the gap between the tailgatedoor and rear hatch glass,do not dglorm the rear hatch glass. TAILGATEDOOR
5. Tightenthe strikermountingbolts. 6. Recheckthe rearhatchglassalignment.and makesurethe glassopensproperly,and lockssecurely. 7. Installtherearspoiler.and adjustit. NOTE:Adjustthe rearspoilerso thereare four equalgaps betweenthe rearspoilerand the body.
REARSPOILER
REARHATCHGLASS
8. Checkfor water leaks. NOTE: Do not squeezethe tip of the hose.
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20-82
RearWeatherstripReplacement W h e n i n s t a l l i n gt h e r e a rw e a t h e r s t r i pa,l i g n t h e a l i g n ment mark of the rear weatherstripto the body flange notch.
'98 - 00 modols:
NOTE: . Makesurethereare no wrinklesin the weatherstrio. . T h e s t e e l c o r e i n t h e r e a r w e a t h e r s t r i pc a n n o t b e restoredto it originalshapeonce it is bend. Replace the rearweatherstripwhen the steelcore is bent. . Apply sealantto the areasindicatedby arrows. . Checkfor water leaks. Sealant: CemedineP/N 08712- 000i1,or equivalont
SEALANT WEATHERSTRIP
'97 model: area. Sealing
Sealingarea. BODY FLANGE
REAR WEATHERSTRIP
WEATHERSTRIP
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Moldings RoofMoldingReplacement CAUTION: . Put on glovgsto protect your hands. . Wh€n prying with a {lat-tip screwdriver,wrap it whh protective tape to prevent damage NOTE: . Takecarenot to scratchthe body. . The steelcore in the roof moldingcannotbe restoredto it originalshapeonce it is bend.Replacethe roof moldingwhen the steelcoreis bent. . Startingat the front, carefullypry off the roof molding. >: Clip locations A>,2
B>,3
Installationis the reverseof the removalprocedure. NOTE: . Takecarenot to damagethe windshieldmolding. . Makesurethe roof moldingis installedsecurely.
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20-84
ROOFMOLDING STEELCORE
DoorMoldingsReplacement CAUTION: . Put on gloves to protect your hands. . When prying with a flat-tip scrowdriver,wrap it with prot€stive tape to provent damag€. NOTE: . Takecarenot to scratchthe body. . Be carefulnot to damagethe front and reardoor moldings.
t Adhesive aleas,
Adhesivearea. FRONTDOOR MOLDING
>: Clip locations,14
REARDOOB MOLDING
a: Plasticnut location, 1
(cont'd)
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20-85
Moldings Door MoldingsReplacement(cont'd) 7 . G l u e t h e n e w a d h e s i v et a p e t o t h e m o l d i n g sa s snown,
It the old molding is to be reinstalled: The following materialsand tools are requiredto repair t h em o l d i n g .
: Adlesivetapelocations
N
instructions. NOTE:Followthemanufacturer's
Forwerd
Materials:(Reference) . Striperemover 3M 08907 . Stripeadhesiveremover 3M 08908 . Adhesivetape 3M SuperAutomotiveAttachmentTape Tools: . Protectivetape . Knifeor Cutter . Spongeor Shoptowel . Infrareddryer
. . .
45 mm ( 1 . 8i n . l 125mm 30 mm {4.92in.) { 1 . 2i n . } G l u eo n t h e r i b area, 26 mm (1.0in.) 440mm 117.3in.l
FRONT MOLDING
Film Plasticputty knife Alcohol
200 mm (7.87in.)
35 mm 125mm {1.4in.) {4.92in.)
replaceany damagedclipson the moldlf necessary, ang.
2.
Apply the striperemoverevenlyto the bondingsurfaceof the body and molding.
3.
Coverthe bondingsurfaceof the body and molding with a film, then heatto 104- 122"F(40- 50'C)for 5 - 10 minuteswith an infrareddryer.
25 mm {0.98in.l
8 2 0 m m 1 3 2 . 3i n . )
CAUTION: Put on gloves to protect your hands, 1.
L
REARDOOR MOLDING (Front/rear end)
Width:5 mm
NOTE: Use care when heatingto preventdeformation of the body and molding. 4.
Carefullyscrape the adhesivetape with a plastic putty knife. For removalof adhesivetape residue,follow-upwith stripe adhesiveremover,then scrapethe adhesive tape with a plastic putty knife. Removethe protectivetape,then cleanthe bonding surfacewith a spongedampenedin alcohol. NOTE:Makesurethe bondingsurfaceis keptfree or water,oil and grease.
t'.
Heatthe bonding surfaceof the door and molding with an infrareddryer. Door: 104- 140'F(40- 60'C) Molding:68 - 86'F (20- 30'C) NOTE:Use carewhen heatingto preventdeformation of the molding. A l i g n t h e m o l d i n gw i t h t h e c l i p l o c a t i o n sa, n d s e t the molding. Lightly push on the molding until its edgeis fully seatedon the adhesivetape. NOTE: Oo not spray water on the molding within the first 24 hoursafterinstallation.
all removedparts. 1 0 . Reassemble
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Side Sill Panel Replacement NOTE:Takecarenot to scratchthe body. >: Cliplocations
>: Screwlocations,4
A>.7
NOTE: Loosenthe screw, then removethe lowerclip usinga clip remover,
Remove the side clips from the body by turning them 45'
SIDE CLIP
NOTE:When removingthe side sill panel,the sideclipswill stay in the body.
S I O ES I L L P A N E L Remove the lower clips, then remove the side sill panel by sliding it forwatd.
To installthe side sill panel,removethe sideclipsfrom the body,installthem on the side sill panel,then installthe sidesill Danelon the vehicle. NOTE: . Takecarenot to twist the sidesill panel. . lf necessary, replaceany damagedclips.
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20-47
SpareTire Gover EmblemInstallation Hard spare tire cover {for some models}: Apply the emblemwhere shown. NOTE: . Beforeapplying,cleanthe sparetire coversurfacewith a spongedampenedin alcohol. . After cleaning,keepoil, greaseand water from gettingon the surface Attachment Point lR€ferencel: U n i t :m m ( i n . ) Honda/CR-vemblem:
APPLICATION TAPE
HONDAEMBLEM
CR.VEMBLEM
SPARETIRECOVEB
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20-88
Fenderwell FrontWheelwellProtector Replacement
InnerFenderReplacement NOTE: Takecare not to scratchthe body.
NOTE: a Take care not to scratchthe front wheelwell protector and body. . Use a T30 Torx bit to remove the Torx screw.
\
l
,,-C\
>: Screw locations,4
>: Clip locations,
ffi
A\
>: Screwlocations a >,3 B > ,1
/
Removethe front wheelwell protector,
s))pp> Y]
6'thp I sv.l/) D Y/
6x1.0mm 9.8Nm(1.0kgf.m, 7.2 tbf.ft)
)fl(
l#
:rl
>: Clip locations,
A I
4t
I
wt I a l
NOTE: Beforetemoving the remove frontwheelwellProtector, the screwfrom the front bumperand lowerthe front bumper.
INNER FENDER
Installationis the reverseof the removalprocedure. NOTE;lf necessary, replaceany damagedclips.
Installationis the reverseof the removalDrocedure. NOTE:lf necessary, replaceany damagedclips.
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20-89
Fenderwell RearWheelwellProtector
FuelPipeProtectorReplacement
Replacement NOTE: Take care not to scratchthe body. NOTE: . Take care not to scratch the rear wheelwell protector and body. . Use a T30 Torx bit to remove the Torx screw.
Removethe rearwheel (seesection18). >: Cliplocations,3
/ll
>: Screw locations B>,I a>,3
I ,.{\ 6x1.0mm N.m {1.0kgl.m. 6him" l FY-./),@ 9.8 7.2 rbtft) Y/
qK 1l
>: Clip locations
A> , 5
B > ,1 YnTn
|
/'d)Ul | +['Tl+l \=lHl | -_H_l tlrflJ -
| |
|
removinsthe INoTE:Before thescrew lclip.remove from the rearbumperand lowerthe rearbumper,
lnstallationis the reverseof the removalDrocedure. replaceany damagedclips. NOTE:lf necessary.
lnstallationis the reverseof the removalprocedure. NOTE:lf necessary, replaceany damagedclips.
20-90
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RearAir Outlet Replacement NOTE:Takecarenot to scratchthe body. Removethe rearbumper(seepage20-74).
>: Cliplocations, 4
Tt-
A\ -T[-r
Installation is the reverseof the removalDrocedure.
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20-91
Openers ComponentLocationIndex
FUELFILLOOORLATCH page20'96 Replacement, HOODRELEASEHANDLE page20'95 Replacement,
HOODLATCH page20'95 Replacement,
DOOROPENER FUEL CABLE Replacement, Page20 94 HOODOPENERCABLE page20'93 Replacement,
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20-92
FUELFILLOOOROPENER Replacement, Page20_96
HoodOpenerCableReplacement NOTE: . When removingthe clips,usea clip remover. . Takecarenot to bendthe openercable. Remove: . Frontwheelwellprotectorand innerfender{leftside,seepage20 89} . Frontgrille(seepage20-77) . Kickpanel(leftside.seepage20-411 >: Clip locations,3
'.--)r
I
@l
HOODLATCH (seepage20-95)
t"
HOODRELEASE HANDLE (seepage20 95) Routethe opener cablethroughthe hole in the body.
Installationis the reverseof the removalprocedure. NOTE: . lf necessary. replaceany damagedclips. . Makesurethe hood openercableis routedand connectedproperly. . Makesurethe hood opensproperly.
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Openers FuelFillDoorOpenerCableReplacement NOTE: . When removingthe clips,usea clip remover. . Takecare not to bendthe openercable. Removethe followingparts,then pull the carpetback,as necessary(seepage20-45), a Kickpanel(leftside.see page20-41)
Centerpillar lower trim panel (left side,see page 2041) Frontsidetrim (leftside,seepage20-41) Rearseat(leftside,seepage20-63) >: Clip locations B>,1 A>,6
Cargoareafloor and cargostoragebin (seepage 2043) a Reartrim panel{seepage20-42) Rearsidetrim panel(leftside,see page20-421 a Rearsidetrim (leftside,see page20-41)
c>,1
@lRlg FUELFILLOOORLATCH (seepage20-96)
FUELFILLDOOROPENER {seepage 20-96)
Installationis the reverseof the removalprocedure. NOTE: . lf necessary, replaceany damagedclips. r Makesurefuel fill door openercableis routedand connectedproperly. . Makesurethe fuel fill dooropens properly.
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Hood ReleaseHandleReplacement
HoodLatchReplacement
NOTE:Takecarenot to bendthe openercable.
NOTE:Takecarenot to bendthe openercable.
Removethe left kickpanel(seepages20-41).
Removethe front grille (seepage20-77).
>: Eoltlocations.2
>: Boltlocations,3
6x1.0mm 9.8 N.m {1.0kgl.m, 7.2 tbl.tll
6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 tbt.ftl
HOODOPENER CABLE {seepage20-93)
HOOOLATCH
Installationis the reverseof the removalprocedure.
Installationis the reverseof the removalprocedure.
NOTE; . Greaseeachlocationofthe hoodlatchas indicated by the arrows. . Makesurethe openercableis connectedproperly. . Makesurethe hood locksproperly. . Adjust the hood latchalignment(seepage20-76).
NOTE:Makesurethe hood opensproperly.
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20-95
Openers FuelFillDoorOpenerReplacement
Fuel Fill Door Latch Reolacement
NOTE:Takecarenot to bendthe openercable.
NOTE:Takecarenot to bendthe openercable.
Removethe leftfront sidetrim (seepage20-41).
Removethe rear speakercover and rear speakerfrom the left rearsidetrim panel(seepage20-42).
>: Boltlocstions.2 >: Boh locdions, 2
5x1.0mm 9.8N.m (1.0kgf.m, 7.2 tbt.ftl
6x1.0mm 9.8 N.m (1.0 kgf.m, 7.2 tbf.ft)
FUELFILLDOORLATCH
FUELFILLDOOR OPENERCABLE (seepage 20-94) FUELFILLDOOR After installing, checkfor a flushfit with the body.
DOOROPENER FUEL CAELE (seePage20,94) LATCH Removethe fuel fill door latch by turningit 90' FUEL FILL
Installation is the reverseof the removalprocedure. NOTE: . Makesurethe openercableis connectedproperly. . Makesurethe fuel fill door opensproperly,
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20-9 6
Installationis the reverseof the removalprocedure. NOTE:Make sure the fuel fill door opens properly and lockssecurely.
Wiper/Washer ComponentLocationIndex
WIPERARMS WINOSHIELD and LINKAGE page20-98 Replacement, Adiustment,Page20-103
WASHERRESERVOIN page20 99 Replacement,
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REARWINDOWWIPER ARM and MOTOR page20 99 Replacement, Adiustment,page20 103
TUBE WASHER page20-100 Replacement,
20-97
Wiper/Washer WindshieldWiperArmsand LinkageReplacement CAUTION: Put on gloves to protoct your hands.
3.
NOTE:Takecarenot to scratchthe hood and body.
Disconnectthe connector,remove the bolts, then removethe windshieldwiper linkageassembly. >: Bohlocations,3
1.
Removethe windshieldwiper arms.
2.
Removethe clips,then removethe cowl cover.
6x1.0mm 9.8 N.m (1.0kglm, 7.2 tbt.fr)
>: Cliplocations A>.9 a. Pryout the annerclip. INNERCLIP
b. Removethe clip.
/G SHOP TOWEL
"rr/ &
(Cowlcoverside)
4.
S e p a r a t et h e w i n d s h i e l dw i p e r l i n k a g ea n d w i n d shieldwiper motor.
B>.8 NOTE:Scribea line acrossthe link and windshield wiper linkageto show the originaladjustment.
ql
>: Bohlocations, 3 6x1.0mm 8 N.m 10.8kgf.m, 5.8 lbf.ftl
WINDSHIELD WIPERARMS
NUTS '10x 1.25mm 18 N.m 11.8kgf.m. 13 tbf.ftl
s}@ 1ffi, /Y{
' L|NK / WINDSHIELD WIPERLIN(AGE
5.
COVER
2 0- 9 8
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NUT 10 x 1.25mm 18 N.m 11.8kgf.m, 13 tbf.ftl SPRING WASHER
WIPERMOTOR
Installationis the reverseof the removalprocedure. NOTE: . Makesurethe connectoris connectedproperly. . lf necessary. replaceany damagedclips. . I n s t a l lt h e w i n d s h i e l dw i p e r a r m s a s d e s c r i b e d on page20-103. . Checkthe windshieldwiper motor operation. . Greasethe moving parts.
RearWindowWiperArm and Motor Replacement
WasherReservoirReplacement GAUTION: Put on glovesto protect your hands.
CAUTION:Put on gloves to protect your hands. 1.
Remove: . Frontgrille (seepage20-771 . Front bumper (see page 20-721 . Frontwheel{leftside,seesection18) . Frontwheelwellprotector(leftside,see page2089) . Innerfender(leftside,see page20-89) . Headlight(leftside,seesection23)
2.
D i s c o n n e ctth e w a s h e rt u b e s a n d w a s h e r m o t o r connectors. >: Boltlocations, 3
NOTE;Takecarenot to damagethe rear hatchglass. 1.
Removethe rearwindow wiper arm. a: Nut loc.tion!, 3 6x1.0mm 9.8 N.m 11.0kgt'm, 7.2 tbf.ftl
REARWIPER
COVER
>: Scaowlocationa,2
@rrc REARWINDOW WIPERMOIOR
6x1.0mm 9,8 N.m 11.0kgt.m, 7.2 tbt.ftl SPECIALNUT 18 x 1.0mm 9 N.m 10.9kgt m, 5.r tbt.ftl
Routethe washertubes to the washerteservoir
WASHER RESERVOIR WINOSHIELO WASHERMOTON CONNECTORS REAR WIPERARM
NUT 6x 1.0mm 9.8 N.m {1.0 kgt.m, ?.2 tbfftl
HARNESS
cLrP
\ - S(ilq l' wrsHER
Removethe rearwiper lowercover.
s{J
D i s c o n n e ctth e c o n n e c t o r t, h e n r e m o v et h e r e a r window wiper motor.
3.
Removethe bolts, then remove the washer reservotr,
Installationis the reverseof the removalprocedure.
4.
Installationis the reverseof the removalprocedure.
NOTE: . Makesurethe connectoris connectedproperly. . Installthe rea. window wiper arm as described on page20-103. . Checkthe rearwindow wiper motor operation. . Greasethe movingparts.
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/ t
C-(fu
NOTE: a M a k e s u r e t h e w a s h e r m o t o r c o n n e c t o r sa n d washertubes are connectedproperly. . Checkthe washermotor operation.
20-99
Wiper/Washer WindshieldWasherTubeReplacement '97
NOTE: . Takecarenot to scratchthe relatedpartsand body. . When removingthe clips,use a clip remover.
'fr{------63
ax--\J
Removethe followingparts. . Leftfront wheelwellprotector(seepage20-89) . Left innerfender(seepage20-89) >: Clip locations A >,2
,.&--
\7 B>,1
c>,1
D>,1
WINDSHIELO WASHERNOZZLES
Y-JOINT
\ Boutethe w6shertubes to the washerreservoir
lnstallation is the reverseof the removalprocedure. NOTE: . Takecare not to pinchthe washertubes. . lf necessary, replaceany damagedclips. . Afterinstalling, (seepage20-103). adjustthe aim ofthe washernozzles
20-100
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model:
RearWindow WasherTubeReplacement NOTE: . Takecarenot to scratchthe relatedpartsand body. . When removingthe clips,usea clip remover. Removethe followingpartsfrom the left side of the vehicle,then pull the carpetbackas necessary(seepage20-45) . . . . . . a
Reartrim paneland rearsidetrim panel(seepage2042J . Rearsidetrim (seepage20-41) . Rear hatch glass support strut (body side, see page 20-7Al . Ouarterpillartrim panel(seepage20-421 o Cargoarealight (seesection23) . Headliner(rearedge,seepage20-44) .
Frontwheelwellprotector(seepage20-89) Innertender(seepage20-89) Kickpanel(seepage20-4't) Centerpillarlowertrim panel(seepage20-41) Frontsidetrim (seepage20-41) Rearseat(seepage20-63) Cargoareafloor and cargostoragebin (seepage2043)
>: Clip,harnesscu3hionlocation3 c>,3 A > ,1 B > ,1
D>,12
GROMMET
el4 @s_l GROMMET
Routethe washert!be underthe wire harness WINDSHIELD WASHEBTUBE Routethe washertubes to the washerreservoir
wasnerno2zre.
WASHEB RESERVOIR
wrNoow
TUBE WASHER
REARWINDOW WASHERMOTOR
(cont'd)
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20-101
Wiper/Washer RearWindow WasherTubeReplacement(cont'dl
REARWINDOW WASHERNOZZLE
GSOMMET
\
t
"'..--a i;r.
B
REARWINDOW WASHERTUBE
Routethe washertube undorthe wire harness,
Installationis the reverseof the removalDrocedure. NOTE; . Takecarenot to pinchthe washertubes. . lf necessary, replaceany damagedclips. . After installing,adjustthe aim of the washernozzle(seepage20-103).
20-102
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WiperArms and WasherNozzlesAdiustmenl RearWindow wipor/Washer:
Wind3hieldWipor/Washer: 1,
Adiust the wiper arms so that their park positions matchthe illustration.
\
Distance '_\ from center ltne ru"rrr."i. 2 7 m m ( 1 . 1i n . )
Viow from flont io roar
from black ceramicedge 88 mm (3.5in.)
GLASS
Vi6w trom roar to lront REAR
sPo[.-ER
C.nlar lino L
2.
\
Insert a tack into the washer nozzles.and adjust them so that they aim at positionsA, A', B, and B' shown in the illustration. Distance from center line
^,J;-ll\
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Alignto the rearwindow defoggergrid line.
from black ceramicedge
A and A'
3,$ mm (13.5in.) 287mm (11.3in.)
B and B'
122mm (4.80in.) 352mm (13.9in.)
20-103
Sub-frame
Sub-frameTo.que Sequence: CAUTION: After loo3eningthe sub-framemounting bolts, be sure to replacethem with now ones.
REANCROSS BEAM
10 r 1.25mm 49 N.m 15.0kg{.m, 12 x 1.25mm 36 tbt.ftl 74 N.m (7.5kgtm. 54 tbf.ft)
SNFFENER
BOLTS 1 l x 1 . 5m m 89 N.m 19,1kgt m, 66 tbt ftl Replace.
20-104
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FrameRepairChart
Top view: U n i t :m m ( i n . ) 0: Innerdiameter
{4.021 t1.19} lm 302
tr.rr!9$I
POtt{T
POINT'
POINT hl
SECTIONDD
20-106
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2&2 t111.11 I
POINTn
258,1{10r.7}
32A7 1129.11
(cont'd)
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20-107
FrameRepairChart (cont'd) Sideview: U n i t :m m ( i n . ) 0: Innerdiamete.
POINTd3 o15 {0.591For TrensmissionMount
z
d15 10.591 For Trrnsmi3don Mount POINTd1 t13 10.5'llFor Transmb3ion Mount POINTel 613 10.51)For Transmirsion Mouni
130
POINTh1
t13 {0,511For Engin6 Mount M10 x Pl.25 t13 10.51)For Uppcr Arm
.25 POINT ,1710.67) Fof Re.r Beam
t5011.97| Locrt. Hol.
o16 10.631 LocateHole o12 (0.,171 For Right Front Stop POINTc1 612 {0.47}For Left Front Stoo b2 t12 {0.47}For Right Front Stop POINTc2 r12 {0.47)For Left Front StoD o11 (0.{31For EngineMount
20-108
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Damper Lower Bushing Point
POINT
t17 10.671 Fo. R..r
r'17 10.671 For Rcar Bo.m
POlNTx.y /
'sad
I
POINTm3, m4 FuelTank Strap Poinr 2700.5(106.32)
SECTIONBB
RearDamoer Center Upper Arm
M12 x P1.25 POINTn I
FOINT
\ql ol
.df
o2010.8|Locate Hole
rg (0.3)Fuel T Strap Center For RearCros3Beam LocateHole
For ReerCross Beam
271,1(10,6.9) POINTw
POINT 3, s1
ForTrailingAim o14 {0.551 POINT v
Bear Damper Lower Bushing Point
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20-109
Heaterand Air Conditioning Heater
...........21
NOTE:Section21 ("Heater")is includedin section22.
......'..'.. Air Conditioning
'.'22'1
SYSTEM(SRS} RESTRAINT SUPPLEMENTAL airbagin the dashboard This model has an SRSwhich includesa driver'sairbagin the steeringwheel hub, a passenger's abovethe glove box ('97,00 models).and seat belt tensionersin the seat belt retractors('98- 00 models).Information necessaryto safelyservicethe SRSis includedin this ServiceManual.ltems markedwith an asterisk(*) on the contents or replacingtheseitemswill requirespecial pageinclude.or are locatednear,SRScomponents.Servicing,disassembling precautionsand tools,and shouldonly be done by an authorizedHondadealer.
a
@ . To avoid rendering the SRS inoperative, which could lead to personal iniury or death in the event of 8 severe frontal collision, all SRSservicework must be performed by an authotized Honda dealer. lmproper service procedures, including incorrect removal and installation of the SRS, could lead to personal iniury causedby unintentional deployment of the airbags ('97 - 00 models),and seat belt tensioners 138 - 00 models). Do not bump the SRS unit. Otherwise, the system may fail in case of a collision, or the airbags may deploy when the ignitionswitch is ON {lll. SRS eleqtricalwiring harnessesare identified by yellow color coding. Relatedcomponents are located in the steering column, front console,dashboard,dashboardlower panel, and in the dashboard above the glove box. Do not use electricaltest equipment on thes€ cilcuils.
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Air Conditioning Heater Control Panel Reofacement ,.,...,,.,..,.,.,,22-46 Blower Unit Replacement .................. 22-46 Overhaul...........,,,., .......-.22-17 Evaporalor ReDlacement ...,.,.,..,......,22-4A Overhaul................ .........22-19 A/C Filter Replacement ..................22-50 *HeaterUnit ReDfacement ..................22-50 Overhaul..,.,..,.,...,.. .........22-52 TemperatureControl Adiustment ....................22-53 A/C ServiceTips and Precauiions............-....-.... 22-54 A/C SystemTorqueSpecifications .................... 22-55 A/C System Service Performance Test ......,...22-56 PressureTestChart .-.....22-5a Recovery..............,. ...-.-...22-59 Evacuation -...........-........22-60 Charging................ .......-.22-61 LeakTest ........................22-61 Compressor Repfacement ..........-.......22-62 flfustratedIndex .....,.......22-64 Cfutchfnspection .........,.22-65 CfutchOverhaul ............22-66 ThermafProtectorRep|acement................... 22-68 RefiefValveReplacement.............................. 22-68 A/C ComoressorBelt Adiustment .................... 22-69 Condenser Repfacement .,.....,,.,..,.,..22-70 'Read SRSprecautionsbetore working in this area.
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SpecialTools
Rel. No.
.o
I
Tool Number
Oty
Description
0 7 J G G- 0 0 1 0 1 0 A 07sAz - 001000A 07947- 6340300 07965- 6920500
1 2 1 1
BeltTensionGauge BackprobeSet DriverAttachment @ Hub AssemblyGuideAttachment @ * Includedin the BeltTensionGaugeSet,T/N 07TGG- 001000A 6,
t
o
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22-2
I
PageRelerence 22-69 22-33,36,37 22-66 22-61
ComponentLocation lndex
EVAPORATOR Replacement,page 22-48 Overhaul,page22-49
SERVICE VALVE ILOW-PRESSURE SIDE}
A/C PRESSURE SWTTCH When the refrigorantpressureis below 200 kPa12.0kglc.r|r, 28 psi) or abov€ 3,200kPa(32 kgflcmr,455 psi),the AJCpressure switch opensthe circuit to the Ay'Cswitch and stops the air conditioningto protectthe compressor.
, [\,
-il
CONDENSER Replacement,page 22-70
SERVICEVALVE IHIGH-PRESSURE SIDEI Replacement,page 22-62 Clutch Inspection,page 22-65 ClutchOverhaul,pago22-66 Thermal ProtectorReplacement,page 22-68 ReliefValve Replacem€nt.page 22-68
(cont'd)
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ComponentLocation lndex (cont'dl SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,and proceduresin the SRS section(24)beforeperformingrepairsor service.
BLOWERUNIT page22-46 Replacement, Ovethaul,page22 47
ruoronl /alowen page \Test,
22-16 /
RECIRCULATION CONTROLMOTOR page22 42 Replacement,
EVAPORATOR Feplacement, page22-48 Overhaul,page22,49
lest, pag.e22 42
HEATER UNIT page2250 Replacement, page2252 Overhaul,
A/C FILIER Replacement.page 22-50 RECIRCULATION CONTROLSWITCH
VALVECABLE Adjustment,page 22-53
a/c swtTcH REARWINDOW DEFOGGER SwlTCH See section23
MODE MOTOR page22-41 Replacement, Test,page 22-41
MODECONTROL DIAL HEATERCONTROL PANEL Replacement,page 22 46
CONTROL
swtTcH
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22-4
SLOWERMOTORRELAY, RADIATORFAN RELAY. CONDENSER FAN REI-AY, COMPRESSOR CLUTCHRELAY (Locatedin the undeFhoodfuse/relay box) Test. page 22-45 CONDENSER FAN 2P CONNECTOB RADIATORFAN 2P CONNECTOR
A/C PRESSURE SWITCH 2P CONNECTOR
COMPARTMENT WIREHARNESS
1PCONNECTOR
{cont'd)
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22-5
Component Location Index(cont'dl and proceduresin the SRS SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions, section(24)beforeperformingrepairsor service.
BECIRCULATION CONTROLMOTOR 4P CONNECTOR TEMPERATURE SENSOR EVAPORATOR Tesl, page 22-44
POWERTRANSISTOR 3P CONNECTOR
AIR MIX CONTROLMOTOR page22-43 Replacement, lest, page 22-13
BLOWERMOTOB 2P CONNECTOR
BLOWERMOTORHIGHRELAY Test, page 22-45 HEATERSUB.HARNESS
7P CONNECTOR
DASHBOARDWIREHARNESS HEATERCONTROLPANEL 8P AND 2OPCONNECYORS
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22-6
Description
The air conditionersystemremovesheatfrom the passengercompartmentby circulatingrefrigerantthroughthe system as shown below. High'temperature/ h i g h - p r e s s u rgea s Suction and compression
High-temperature/ h i g h - p r e s s u r lei q u i d
r r a p so e o n s , and removes motsture
Radiationof heat
IlcoMpREssoR
necetve
coruoerusenl*
Lessmoisturized low-pressurevapor
High-temperature/ h i g h - p r e s srue l i qu i d
More liquidified row-pressurevapor Absorption of heat
EVAPoRAToR (-l
EXPANSToN vAL
EVAPORAYOR
SUCTIONLINE tLow-PRESSURES|OEt
LIOUIDLINE
CONDENSER DISCHARGE LINE IHIGH.PRESSURE SIDEI
This vehicleusesHFC-I34a(R-l34a)refrigerantwhich does not containchlorofluorocarbons. Pay attentionto the following serviceitems: . . . . . .
Do not mix refrigerantsCFC-12(R-12)and HFC-l34a(R-134a). They are not compatible. (PAG)refrigerantoil (SP-10)designedfor the R-134acompressor. Use only the recommendedpolyalkyleneglycol Intermixingthe recommended(PAG)refrigerantoil with any other refrigerantoil will resultin compressorfailure. Afl Ay'Csystemparts(compressor, dischargeline.suctionline,evaporator,condenser.receiver/dryer, expansionvalve, O-ringsfor joints)haveto be properfor refrigerantR-134a.Do not confusewith R-12parts. Usea halogengas leakdetectordesignedfor refrigerantR-134a. R-12and R-134arefrigerantservicingequipmentare not interchangeable. Use only a recovery/recycling/charging station that is U.L.iistedand is certifiedto meetthe requirements of SAEJ2210to serviceR-134a air conditioning system. Always recover the refrigerant R-134awith an approved recovery/recycling/charging station before disconnectingany lVC fitting.
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22-7
CircuitDiagram BOX FUSE/RELAY HOOD UNDEB
IGNITON SWITCH
+ wHTBLK
**f
/6'^'\
,o+trrffl-
UNDER.DASH FUSEiRELAY BOX
F;t"^i I
eLK/YEI f
\_-./
COMPRESSOF CLUTCH RELAY
RED
I, m
BLK
BLU'ryVHT
I d I CoMPRESSOR I I I CLUTCH
LIl
I
G401 G402
BLK/RED
GRN
WHT
IL^"^,Y**t,| I,^,^,", I CONDENSER
T*.'1 Y l l l
MOTOR
r t l
BLK
BLK
BLK
l l l -
G201 www.emanualpro.com
22-8
-
G101
-
G202
,JC PRESSURE SWITCN 1 2 /:\ -{.-!}Btu/yvHT Btu/RED
\,-/
POWER TRANSISTOR
4
ORNMHT
EVAPONATOR TEMPERATURE SENSOR
cnNj@_snN
Fg"{
GRY
PNK/BLK
s5v AMD P
NED/8LU REO/YEL
"'"fi3'.Hfi|$l#i9D> DASH LTGHTS _/4 EE|GHTNESS < -! l_ CONTROLLER REAR
RED
s coM A I RM I X CONTROL MOTOB
HOT
BRN YEL/RED
VENT
GRN/YEL
B/L
8LU/8LK
H
YEL
YEL/BLU
H/D
I/lODE CONT8OL l\r10T0R M
DEF
8RN/WHT
(l fllf$!S,* RELAY
aLurrL
GRNI/VHT GRN/RED 8LK
O:8P coNNEcToR n :20Pc0NN€CToR HEATER CONTROL PANEI-
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c401 c402
22-9
Troubleshooting SymptomGhart function (see next system,reterto selt-diagnosjs For electricalmalfunctionswhich are indicatedby the self-diagnostic page). a symptom. Notetheseitemsbeforetroubleshooting . Checkthe enginecoolantlevel,and allow the engineto warm up beforetroubleshooting. . Anv abnormalitymust be correctedbeforecontinuingthe test. . Becauseof the precisemeasurementsneeded,use a digital multimeterwith an output of 1 mA or less at the 20 kO rangewhen testing. procedurescheck: . Beforeperformingany troubleshooting - FusesNo. 47 17.5AJ,No. 55 (40A), No. 56 (20A), No. 57 (20A) in the under-hoodfuse/relaybox, and No. 17 {7.5A) in fuse/relaybox. the under-dash ._ GroundsNo. G101,G201,G202,G401,G4O2 - Cleanliness and tightnessof all connectors Symptom
Sse pags
Mode controlmotor does not run, or one or more modesare inoperative. controldoor doesnot changebetweenFreshand Recirculate. Recirculation Radiatorfan does not run at all (but condenserfan runswith the AVCon).
22-24
Condenserfan does not run at all {but radiatorfan runswith the Ay'Con). Bothfans (radiatorand condenser)do not run for enginecooling.but they both run with the A,/C on.
22-29
Both fans do not run with the Ay'Con
22-33
Compressorclutchdoes not engage. AJCsvstemdoes not come on (bothfans and compressor).
22-34
Both heaterand A/Cdo not work,
22-39
22-10
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22-37
Self-diagnosis Function The heatercontrolpanelhasa self-diagnosis function. Runningthe Self-diagnosisFunction '97 mod€l: Turn the ignitionswitchON {ll),then set the mode controldial to the Vent position,and the recirculation controtswitchto Recirculate indicatorlightcomeson).Pressand holdthe recirculation {recirculation controlswitchto Fresh(recirculation indicatorlight goes off).Continueto hold the switch;the recirculation indicatorlight will come on for two seconds.then it will blink the DiagnosticTroubleCode(DTC)to indicatea iaulty component.lf no DTC'Sare found,the indicatorliqht will not blinkatterthe initialtwo secondlight. '98 - 00 models: Set the mode controldial to the Vent position,and turn the ignitionswitchON (ll).Withinsix secondsafterturningthe ignition switchon, pressthe recirculation controlswitchthe requirednumberof times dependingon the recirculation indicator lightstatus: . l f t h e i n d i c a t o r l i g h t i s O N , p r e s s t h e r e c i r c u l a t i o n c osnw t riot cl hf i v et i m e s . . l f t h e i n d i c a t o r l i g h t i s O F F , p r e s s t h e r e c i r c u l a t i o n c osnwt irtoclhs i xI | m e s . The recirculation indicatorlight will come on for two seconds,then blinkthe DiagnosticTroubleCode(DTC)to indicatea faultycomponent.lf no DTC'Sarefound,the indicatorlightwill not blinkafterthe initialtwo secondliqht. DTCIndicaiion Pattern{SeeDTC3}: Rocirculation indicator light on Recirculrtion indicator lighi off '97 model:
,r*
P.essand hold th6 recircul.tion control switch '98 - 00 modek: Within six second3 atter the ignition switch b turned ON (lll. Prassthe rocirculationcontrol switch the required number ol times dependingon the r6circulation indicator light striu3
1.5 aaa
/ 0.3 aac RECIRCULANON INDICATORLIGHT
MODECONTROLOIAL Diagnostic trouble code {DTCI 'l
2
t
R6circulation indicator light
Component with problsm
Possiblo causc
See page
22-12
O n eb l i n k
Air mix control molor
Openor shortcircuit,obstructed door, faultymotor
Two blinks
Elower motor
Open or short circuit,faultv motor
Three blinks
Evaporator temperature sensor
Opon or short circuit,faulty sensor
22-14,16 22-20
In caseof multipleproblems,the recirculation indicatorlight indicateonly one DTCthat is the leastnumberof blinks. Resetiing the Solf.diagnosisFunqtion Turningthe ignitionswitchOFFwill cancelthe self-diagnosis function.After servicework, run the self-diaqnosis function onceagainto checkthat there is no other Droblem.
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Troubleshooting Air Mix ControlMotor Recirculation indicatorlight indicatesDiagnosticTroubleCode(DTC)1:A problemin the air mix controlmotor circuit. The air mix controlmotor regulatesthe mixtureof cool/hotair accordingto outputsfrom the heatercontrolpanel. Selt-diagnosiscircuit check indicates a Droblem in the air mix control motor circuil.
Chockthe air mix control moior: 1. Disconnect the air mix control motor 5P connector, 2, Testthe air mix controlmotor (seepage22-43).
ls the air mix controlmotorOK?
Checkthe air mix control linkago and doors: 1 . R e m o v et h e a i r m i x c o n t r o l motor (seepage22'43). 2. Checkthe air mix controllink age and doors for smooth
Do the air mix controllinkageand doorsmovesmoothly?
Reolacelheair mix conlrol motor.
HEATERCONTROLPANEL2OPCONNECTOR
PNK/BLK CheckIor a short in the wires: 1 - R e m o v et h e h e a t e rc o n t r o l panel(seepage22-46). 2. Checktor continuitybetween body ground and the heater control panel 20P connector terminalsNo. 1, 6, 9, 17 and 18 individually.
RED/BLU
Wiresideof femaleterminals Ropairany short in the wire(s) betwoon th. heater co.rtrol panel and the air mix conlrol motor.
To page22-13
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Ftom page 22.12
HEATERCONTROLPANEL2OPCONNECTOR
Checktor a short to poweri C h e c kt h e s a m e t e r m i n a l s f o r voltage. REO/8LU
RED/YEL
Wire sideol femaleterminals
Repairshon lo power in the wi.e between the heater control panel and the air mix control motor, (Thisdamagesthe heater control Danel.l
Checktor an open in the wires: Checkfor continuity between foll o w i n g t e r m i n a l so f t h e h e a t e r control panel20P connectorand the air mix controlmotor 5P connector, zOPi 5P: N o .1 No.3 No.6 _ N o .4 No.g _ No.2 N o .1 7 _ No.5 N o .1 8 _ N o .1
RED/YEL
Repair any open in the wire{s) betweon the heatercontrol panel and air mix control motor. Check toa loos€ wir63 or poor connectionsrl the heater control panel 20P connector and st the air mix control motor 5P connsctor. lJ the connections aro good, substitute a known-good hoater control panel, and rechock.I the symptom/indication goes away, ..pl.ce the original heater control panel.
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AIR MIX CONTROLMOTOR 5P CONNECTOR Wire sideof femaleterminals
Troubleshooting BlowerMotor Speed indicatorlight indicatesDiagnosticTroubleCode(DTC)2: A problemin the blowermotor circuit Recirculation The speedof the blowermotor is controlledby signalssentfrom the heatercontrolpanel Blower motol only runs on high spood position; h does not run in any othe. speodpositions.
NOTE: lf the blower motor does run at all,referto page22-16.
3P CONNECTOR POWERTRANSISTOR Self-diagnosis circuitcheck indic a t e sa p r o b l e mi n t h e b l o w e r motor circuit,
1 2 ) 3 BLK
f
Chacklor.n open in the wire: 1. Disconnectthe power transistor 3P connector. 2. Checkfor continuitybetween the No.3 terminaa l nd body gro(1nd.
ls therecontinuity?
Wire side of femaleterminals
Chock for.n op.n in thc wiro botween ihe powa. transistor rnd body ground, It tho wir. is OK, check for poor ground at G,O1 .nd G4o2.
JUMPER WIRE
Chsckfor an opon in the wire: '1. Connectthe No. 1 and No. 3 t€rminals of the power trans i s t o r 3 P c o n n e c t o rw i t h a jumperware. 2. Turn the ignitionswitch ON {ll).
Repairop6n in the wiro betwoon tho Dower transi3tol and the blowor motor. HEATERCONIROLPANEL2OPCONNECTOR Wire sideoI fgmalet€rminals Checktor an open in tho wire: 1. Turnthe ignitionswitchOFF. 2. Disconnect the iumperwire. 3 . R e m o v et h e h e a t e rc o n t r o l panel (seepage 22-46). 4. Check for continuity botween the No. 20 terminal of the heatercontrolpanel20Pconnectorand the No.2 terminal o f t h e p o w e r t r a n s i s t o r3 P connectof,
1
2
,/1,/
't1 12 1 3
1ia
6
22-14
10
o LT GBN/BLK
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I
LI GRN/BLK
R€pairopon in tho wire betwoen th6 oowor ttan3i3tor and th6 hoatar control oanel.
10 page22-15
8
't5 1 6 1 1 1 8 1 9 20
From page22-14
Chockfor a short in the wire: Checktor continuity between the No. 20 terminal of the heatercon' trol panel20Pconnectorand body ground,
HEATERCONTROLPANEL2OPCONNECTOR
2 11
,/1,/l/
6
8
9
10
12 1 3 1 a 1 5 1 6 1 7 1 8 1 9 20 LT GRN/BLK
o R.p.ir short in the wire betwoen th. herter control Denel snd the oowor tranSastor. Checkto. an open in the wire: 1. Turnthe ignitionswilchON (ll). 2. Measurethe voltage between t h e N o . I t e r m i n a lo f t h e heatercontrol panel 8P connectorand body ground.
Wire sideof femaleterminals
HEATERCONTROLPANEL8P CONNECTOR 1 4
6
7
8 BLU/8LK
Wire sideof femaleterminals
ls there batteryvoltage?
Repairopan in the wire betwaen tho heatsr cont.ol o.nel and the blower motor.
Chockth6 power iransistor: 1. Turnthe ignitionswitchOFF. 2. Reconnectthe heatercontrol panel8P and 20Pconnectors. 3. Test the power transistor (see page 22 44).
ls the power transistorOK?
Chec* for loo3e wires or Door oonneclions at the heater control panel 8P and 20P connoctorsand at lhe power tran3istor 3P connector. lf lhe connectiorc are good, substituta , known-good hoater contrcl pan6l, and r€check.ll the symptom/indication goes away. replecgth6 originalheater control oanel.
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22-15
Troubleshooting BlowerMotor Recirculation indicatorlight indicatesDiagnosticTroubleCode(DTC)2: A problemin the blowermotor circuit. The speedof the blowermotor is controlledby signalssentfrom the heatercontrolpanel, Blower motor do.3 not run at all.
circuitcheck indiSelt-diagnosis c a t e sa p r o b l e m i n t h e b l o w e r motor circuit,
check rhe No. 55 (40 A) {use in the under-hoodfuse/relaybox, and the No. 17 (7.5A) fuse in the under-dashfuse/relaybox.
Replaceth6 fuse(s),and rechalck.
BLOWERMOTOR 2P CONNECTOR Check tho blowe. motor input and output cilcuh: 1. Connectthe No. 2 terminalof the blower motor 2P connector to body ground with a jumperwrre. 2. Turnthe ignitionswitchON (ll).
Doesthe blowermotor run?
Chockthe blower moto.: 1 . D i s c o n n e ctth e j u m p e r w i r e and the blowermotor 2P connector. 2. Measurethe voltage between the No. l terminal and body ground.
Checktho blower motor rolay: 1. Turnthe ignitionswitchOFF. 2 . R o m o v et h e b l o w e r m o t o r relayfrom the under-hood fuse/relaybox, and test it (see page 22 45l'.
fo page 22-19
22-16
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JUMPEF w|RE fo page 22-11
Wire side of lemale terminals
Frompage22-16
Check lhe blower motor high telay: 1. Turn the ignitionswitchOFF, and disconnecthe jumper 2 . R e m o v et h e b l o w e r m o t o r h i g h r e l a y ,a n d t e s t i t { s e e page22-45).
BLOWERMOTORHIGHBELAYitP CONNECTOR
BLU/BLK rF r .--1 1 2 ) l | _ #
Checkfor rn opon in the wire: l. Connectthe No. 1 terminalof the blower motor high relay 4P connectorto body ground with a iumperwire. 2. Turn the ignitionswitchON (ll).
. r u u eI e l"3 1 i wrRE I
Wire side of female terminals Doesthe blowermotor run?
R6pairopcn in the wire botwoen the blower motor and the blower motoi high relry.
Checktor an opon in the wire: '1. Turn the ignitionswitch OFF, and disconnect he iumper 2. Turn the ignitionswitchON {ll). 3. Meas0rethe voltage between t h e N o . 2 t e r m i n a lo f t h e blower motor high relay 4P connectorand body ground.
ls there batteryvoltage?
Repairopon in the wiro betweon the No. 17 fuse and tho blowel motor high relay.
Checktor an open in the wire: '1. Turnthe ignitionswitchOFF. 2. Checklor continuity between t h e N o . 3 t e r m i n a lo t t h e b l o w e r m o t o r h i g h r e l a y4 P connectorand body ground. Check for an open in the wire between the blowar motor high rel.y and body ground.lf the wiro i3 OK, check fo. poor ground at G{Ol .nd Gt|()2,
To page22-18
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(cont'd)
Troubleshooting BlowerMotor (cont'd) Ftom page 22-17
BI-OWERMOTORI{IGHRELAY4P CONNECTOR Wire sideof femaleterminals Checkfor an open in the wiro: 1 . F e m o v e t h e h e a t e rc o n t r o l panel(seepage22-46). 2. Checklor continuitybetween t h e N o . 8 t e r m i n a lo I t h e heatercontrol panel 8P connectorand the No. 1 terminal of the blower motor high relay4P connector.
Ropairop6n in th€ wira between tho heater control panol and tho blowgr motor high relay.
Checklor an op6n in the wire: Checklor continuity between the No. 8 terminaloI the heatercon trol panel20Pconnectorand the N o . 4 t e r m i n a lo f t h e b l o w e r motor high relay4Pconnector.
ls therecontinuhy?
Check fo. looso wiles or oool connoctionsat the haateacontrol Danel8P .nd 20Pconnectorsand at the blower motor high relay 4P connoctor. ll the conn€ctions are good, substitutg a knowngood h.at.r control panol, and r.check. lf the symptom/indicetion goes away, replacethg original heater contrcl panel.
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HEATERCONTROLPANEL8P CONNECTOR Wiresideof femaleterminsls
I{EATERCONTROLPANEL2OPCONNECTOR Wirc sideot femaleterminals
Repairopen in the wire botweon the heater control Daneland the blowel motor high r6lay.
Frcm page 22-16
Rcpbcc tho blower motor rolay. BLOWERMOTORRELAY4P SOCKET Ch.ck th. under-hoodtu.o/rolay box: Measur6the voltage betweenthe No. 3 terminalofthe blowermotor relay4P socketand body ground.
Chacktor an open in the wilo: 1. Turnthe ignitionswitchON (ll). 2. Measurethe voltage between the No. 4 terminal of the blower motor relav ,[P socket and body ground.
ls thore batteryvoltage?
Ropairopon in the wirs botwoon th. No. 17 fu3o and th. blow6r motol lolay.
Chacktor an opon in tho wilo: 1. Turnthe ignitionswitchOFF. 2. Checkfor continuity between the No. 2 terminal ot the blower motor relay 4P socket and body ground. Chock tor !n opan in the wile bstween tha blowar motor ralaY .nd body ground. It tho wilc is OK, chock fol poor ground at G/Ol and G402. Ropair opon in th. BLU/WHT wira batwaan lho blowor motol rohy and tho blowe. motor.
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22-19
Troubleshooting EvaporatorTemperatureSensor Recirculationindicatorlight indicatesDiagnosticTroublecode (OTC)3: A problemin the evaporatortemperaturesensorcircuit. The evaporatortemperaturesensor is a temperaturedependentresistor{thermistor}.The resistanceof the thermistor decreases as the evaporatoroutletair temperatureincreases. Self-diagnosiscircuit check indi cates a problem in the avaporator tempeleture ssnsor circuit,
EVAPORATOR TEMPEMTURESENSOR
Terminalsideof mal€terminals
Ch€ck the ev.porato. temperature sensor: 1. Disconnecthe evaporator temperaturesensor 2P conRESISTANCE ko
2. Measure the resistance betweenthe No. 1 and No. 2 t o r m i n a l so f t h e e v a p o r a t o r temperature sensor.
86'F
30"c ls the resistance withinthe speci, ficationsshownon the 9raph.
HEATERCONTROLPANEL2OPCONNECTOR
Checklor a short in the wire: l R e m o v et h e h e a t e r c o n t r o l panel(seepage22-46). 2. Checktor continuitybetween the No.2 terminao l l the heatercontrolpanel20Pcon, nectorand body ground.
Wiresideof fema16 terminals
Repai. short in the wir6 betwa€n lhe hoater control Danoland the evaporatoatampereturc senSoa.
fo page22.21
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From page22-20 HEATERCONTROLPANEL2OPCONNECTOR Wire sideol femaleterminals Chocktor an oDenin th€ wire: Checkfor continuity betlveenthe No. 2 terminalof the heatercontrol oanel 20P connector and the No.2 terminaloI the evaporator temperaturesensor2P connoctor.
1
8
10
11 1 2 1 3 1 a 1 5 1 6 't7 1 8 1 9 20
GIIN Fopair open in the wiro between tho heato. control penel and the evaporatortempetatule sensor.
TEMPERATURE EVAPORATOB SENSOR 2P CONNECTOR Wire sideoI temaleterminals
1
'tl
Checkfor rn opsn in tha wiJe: Checkfor continuity between the No. 9 terminalof the heatercon trol oanel 20P connector and the No. 'l terminalot the evaporator temperaturesensor2P connector,
o +
li-L:t Ropairopen in tho wire betwegn the heater control oanel and the evaporatortgmpcrature sen3or.
Chgck fol loose wiros or pool connectronsat the hoator control oan6l 20P connector and at the eveporator temperatura Sensol 2P connector. It the connections are good, substitute a knowngood he.tel contlol panel, and rech€ck. ll thg symptom/indication 90o3rwey, roplscethe original heatercontrol oanel.
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,/ l,/
2 8 9 t0 6 1 2 1 3 l a t 1 5 1 6 '17 1 8 't9 20
Troubleshooting Mode ControlMotor Mode control motol does not run. or ono or more modesare inoD€aa-
Checkthe No. 17 {7.5A) Iuse in the under-dashfuse/relaybox.
Replacethe tus€, snd iecheck. MODECONTROLMOTOR7P CONNECTOR Chocktor an open in th€ wi.6: 1. Disconnectthe mode control motor 7P connector. 2. Turn the ignitionswitch ON (ll). 3. Measurethe voltagebetween the No. l terminal and body ground.
3
1
I
5
BLK/YEL
Wiresideof femaleterminals
Repairopon in the wire betwoon tho No. 17 luse and tho mode control motor. Checkthe mode control motor: 1. Turnthe ignitionswitchOFF. 2. Test the mode control motor . Gee page 22 41')
ls lhe modecontrolmotor OK?
Chock th€ mode cont.ol link.ge and doors: 1 . R e m o v et h e m o d e c o n t r o l motor (seepage22-41). 2. Checkthe modecontrollinkage and doors for smooth movement,
Do the mode control linkage and doors move smoothly?
Replece the inod6 control motor.
Chockfor s shon in the wir€s: 1 . R e m o v et h e h e a t e rc o n t r o l panel(seepage22'46). 2. Checkfor continuitybetween the No. 12,13,14,15,16and 19 terminalsol the heater control panel20Pconnectorand body groundindividuaily.
HEATERCONTROLPANEL2OPCONNECTOR
2 1 1 12
l,/1,/
NO To page22-23
I
[E!r!
Repairany short in the wire(sl between the mode control rnotoa and the h6ater control Danel.
Ii
Wiresideof femaleterminals
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10
YEL/RED BLU
ls therecontinuity?
8
1 3 t a 1 5 1 6 1 7 r 8 1 3 20 BRN/WHT
From page22-22 HEATERCONTROLPANEL2OPCONNECTOR
1
Chgckfor a short to power: Checkth6 same wires lor voltage.
' V VL g l
2
't1 1 2
8
r s l r r l r s l 1r7e1 8
9
BRN/WHT
:L/BLU
Ropairlhort to powor in the wiio betw6an tho mode comrol motor end thc hoat.r cont.ol pan.l. (ThisdamagF tha h€ator Gontrol pancl.l
10
1 9 20
8LU/BLX
Wire sideot femaleterminals
2
Chackfor an opon in tha wiles: Checklor continuity between the followingterminalsoI the mode control motor 7P connectorand the heatercontrolpanol20Pconnector. 7P. 20Pt N o .1 2- N o .3 No. '13- No. 4 N o .1 4 - N o . 5 N o .1 5- N o .6 No. t6 - No. 2 N o .1 9- N o .7
,/1,/l/
I
I
10
1 1 1 2 1 3 t 1 4 t 1 51 5 1 1 1 8 1 9 20
YEL/BLU
BRN/WHT
BLU/BL Kt I I GRi|/YELI I I YEL/REDI t
YEL/BLUI
-
q
;f;T;T; YEL BLU/BLK GRN/ItEL
BRN/WHT
YI:L/FED MODECONTROI-MOTOR7P CONNECTOR Wire sideol temaleterminals R.pair any opon in tho wilols) betwaen th6 modg cortrol motor and th. heatar control p.nsl.
Chock fo. loose wiret or pool connections at the heat6r control pancl 20P connector and tt the modo control motor 7P connoctor. lf tho connactions sre good, substitute a known-good hortcr control pan6l, and tech.ck. lf the symptom/indication goes awayt roplacotho original hcater @nttol p3nel.
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22-23
Troubleshooting Recirculation GontrolMotor Rocirculation control door do6s noi chango botw€en Fresh and Reci.culate.
Checkthe No. 17{7.5A)tuse in the under-dashf use/relaybox.
Roplacethe fu36,and rechock.
REORCULATION CONTROL MOTOR ,rPCONNESTOR
q?
Checkfor .n open in the wire: 1. Disconnectthe recirculation control motor 4P connector. 2. Turn the ignitionswitchON (ll). 3. Measurethe voltage betlveen the No. l terminal and body ground.
-
T---
V-l
l 1 l, r l / l 1 l I BI.IUYEL
(v)
+
Repairop6n in the wire bdtween the No. 17 fuse and thc recirculetion control motor.
Wiresideof femaleterminals
Check the rocirculation control moior: 1. Turnthe ignitionswitchOFF. 2. Test the recirculationcontrol motor (seepage22-42).
YES
Chock ths r.circulation control linkag. end doori 1. Removethe recirculation control motor (see page 22,42). 2. Checkthe recirculationcontrol linkageand door for smooth
To page22-25 Do the recirculation controllink age and door move smoothly?
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Boprir the recirculrtion control linkag. or dooJ,
Ftom page22-24 HEATERCONTROLPANEL8P CONNECTOR
Checktol a short in the wit6: 1 . R e m o v et h e h e a t e rc o n t r o l panel{seepage22-46) 2. Checkfor continuitybetween of the No.2 andNo.3terminals the heatercontrolpanel8Pcon nectorand body ground individually. Wire sideof femaleterminals Reoaii short in tfte wir€{s) b€irv€€n the redrc{lstion conttol motor and ihe hedter control panel.
Checkfor a shon to power: Checkthe samewireslor voltage.
ls thereany voltage?
Repairshort to power in the wite between the rocirculationcontrol motor and lh€ heator control panel. (This demsges the heater conlrolpanel.l
Ch€cktor an open in the wires: Checkfor continuity betweenthe followingterminalsol the recircu' lation control motor 4P connector and the heatercontrol panel 8P
GRN/REO ---1 T
' l F I2 1 3 i r l 5 1 6 I ;T;
4P: 8P: N o . 2- N o . 4 No.3- No.2
Ropairopen in the wile(sl between the recirculalioncontrol motor and the heeter cortrol Pan€|.
Check for loose wires or pool connections at the heat€r control Danel8P connoctor and .t the rocirculation control motor 4P connector.lf lhe connec{ionsare good, substitule a known-good hester control oanel, and rochock. lI the symptom/indication goes away, .eplace the otiginal heater control pan€|.
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1
ffi
I V I 4 I
GRN/WHT CONTROLMOTOR RECIRCULATION ,lP CONNECTOR wire sideot femaleterminals
22-25
Troubleshooting RadiatorFan Radiator tan doos not run at sll (but condonserfsn runs with the A/C onl.
Checkrhe No.57 (20Alfuse in the underhood fuse/relaybox, and t h e N o . 1 7 1 7 . 5A ) l u s e i n t h e 0nder-dashfuserelay box.
R.pl.c. th. fur€|.l, .nd r.chack.
Remove the radiator fan r6lay, and test it {seepage22-45).
R.pllco tha r.diator frn rehy.
MDIATOR FAN RELAY4P SOCKET Check the und.r-hood fus./r.l.y box: Measurethe voltage betweenthe No. 2 terminalol the .adiatortan relay 4P socketand body ground.
Chockthe radiatortan: Connectthe No. 1 and No.2 t€r minals of the radiatorfan relay 4P socketwith a iumperwire.
Doesth6 radiatorfan run?
fo page22-28
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fo page22-21
Ftom page22-26
RADIATORFAN REI-AY4P SOCKET Ch6ckfor an open in the wire: 1. Disconnect the jumperwire. the radiatorfan 2P 2. Disconnect
BLK/RED
3. Checkfor continuitybeNveen the No. l terminalo{the radiator fan relay 4P socketand the N o . 2 t e r m i n a lo f t h e r a d i a ' tor fan 2P connector-
RADIATORFAN 2P CONNECTOR Wire sideof lemaleterminals
Repai. open in the wira between the radiatorfan .olay ,nd the radi' atorfan.
Checklor an open in the wi.e: Checkfor continuity betweenthe No. 1 terminaloI the radiatorfan 2P connectorand body ground.
ls therecontinuity?
Check lor an open in the wir. b€turosn the radi.tor fan and body ground. lf ihe wire b OK, check fol poor ground .t G2()l.
Replacethe radiator tan motor.
(cont'd)
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Troubleshooting Radiator Fan (cont'dl From page 22-26
RADIATORFAN RELAY4P SOCKET Chockfor an open in the wire: '1. Disconnect jurnper the wire. 2. Turn the ignitionswitchON (ll). 3. lleasure the voltage between the No.4terrninalof the radiat o r f a n r e l a y 4 P s o c k e ta n d bodyground.
1 2
a BLK/YEL
ls there batteryvoltage?
Rep.ir open in the GRN wire botw€en lhe radiator tan relay and the PCM/ECM.
22-28
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R€pairopen in th6 wire botwoon the No. 17 fuso and the radiatol fan .elsy.
Fan Condenser Condenserlan does not run at all lbut radiator fan runs with the A/C on).
Checkthe No. 56 (20A) fuse in the under hoodfuse/relaybox, and the No. 17 {7.5A) fuse in the underdashfuse/relaybox.
Replacethe luse(s),and .echeck.
Removethe condenserfan relay, and test it (seepage22-45).
Replacethe condenserfan r€lay.
FAN RELAY4P SOCKET CONDENSER
Checkthe under-hoodluso/relay box: Measurethe voltage betweenthe No.2terminalof the condenserfan relay4Psocketand body ground.
Checkthe condensff fan: Connectthe No. 1 and No. 2 ter minals of the condenserlan rclay 4Psocketwith a jumperwire.
Doesthe condenserfan run?
page22-30
To page22 31
(cont'd)
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22-29
Troubleshooting CondenserFan{cont'd)
CONDENSER FAN RELAY4P SOCKET
Chockfor an open in the wire: '1. Disconnect the iumperwire. 2. Disconnect the condenserfan 2P connector. 3. Checkfor continuitybetween the No. 1 terminalof the con, denserfan relay 4P socketand the No. 2 terminalof the condenserfan 2P connector.
ls therecontinuity?
r---------t wHT
lr_f__l 1
2 |
fT;.]
|
|I
/Or \j/
Ropairopen in the wire betwoen th€ condenserfan rslay and the condensertan.
G
I
CONDENSER FAN 2P CONNECTOR Wire sideol temaletorminals Chechtor an open in the wire: Checkfor continuitybetweenthe No. I terminal of the condenser fan 2P connector and body ground.
-r+-,. 1 2 TBtK Check for an open in thg wire between the condenser fan and body ground. lf the wiro is OK. checktor poor ground .t G202.
Replacetho condensertan motor.
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22-30
@ !
Ftorn page 22-29 FAN RELAY4P SOCKET CONDENSER
Chockfor an open in the wiro: 1. Disconnect the iumperwire. 2. Turn the ignitionswitchON (ll). 3. Measurethe voltage between the No. 4 terminaloI the condenserfan relay 4P socketand body ground.
Repairopcn in tho wire betwoon the No. 17 tuse and the condenseafan relay,
R e p a i ro p e n i n t h e G R N w i r o b6tw6en the cond.nser lan relay and rhe PcM/EcM,
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22-31
Radiator Fan Switch Both tans (radiatorand condenser) do not run fo. enginecooling,but they both run with the A/C on.
Checklor rn open in the wire: 1 . D i s c o n n e ctth e r a d i a t o rf a n switch2P connector. 2. Turnthe ignitionswitchON lll). 3, Measurethe voltage betlveen the No.2 terminaa l nd body ground.
RADIATOBFAN SWITCH2P CONNECTOR
1
'.r GRN
ls there battery voltage?
Repairopen in the wire between the radiator tan relay, the condensei lan .elay and the radiaior tan swhch.
Chockfor an open in the wire: 1. Turn the ignitionswitchOFF. 2. Checkfor continuitybetween the No. 1 terminalof the radiator fan switch 2P connector and body ground.
ls therecontinuity?
ls the coolingsystemOK?
Replscethe radialor fan switch.
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Check for an open in the wire between the .adialor fan switch and body glound. I ths wire is OF; choc*tor poor g.ound at G'101.
Wiresideof femaleterminals
Both Fans
Checkthe No. 17 (7.5 A) tuse in the under-dash fuse/relay box.
Reolacethe tuse. and recheck.
RADIATORFAN RELAY'P SOCKET
1
Checkfor an op€n in the wire: 1. Removethe radiatorfan relay. 2. TLrrnthe ignitionswitchON (ll). 3. Measurethe voltagebetween the No.4 terminaloftheradia t o r f a n r e l a y 4 P s o c k e ta n d bodyground.
2 1
BLK/YEL
Repairopen in the wire between lhe No. 17 luse and the radiator tan relay. '9? model:
PCMCONNECTOR A I32PI 1
12
Checkfor an open in the wire: 1. Make sure the A/C switch is OFF. 2. Using a *BackprobeSet {T/N 0 7 S A Z- 0 0 1 0 0 0 A )m , easure the voltagebetweenthe No. 27 I20l terminalol the PCM/ECM connectorA (32P)and body groundwith the PCM/ECMconnectorsconnected. '98- 00 models [ ]:
2
4
6
t5 t6 17 18 r9
10 22
23
11 21
GRN
Wire sideoI femaleterminals
PCM/ECMCONNECTOR A (32PI '98 - 0Omod6ls:
Repairopen in the wire b€tween the.adiator fan ralav, the condenser tan rolay and the PCM/ ECM.
Checktor loosewires or poor connodions at the PCM/ECMconnoctor A (32P1.lf the connectionsarc good, substitute a known-good PCM/ECM,and recheck. It the symptom/indicalion goes away, r.plrce the originalPCM/ECM.
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Wire sideof femaleterminals
* How to use the BackprobeSets Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multi meter.Usingthe wire insulationas a guide for the contouredtip of the backprobeadapter, gentlyslidethe tip into the connectorfrom the wire side until it comesin contactwith the ter minalend ofthe ware{seesectionl1).
22-33
Troubleshooting
Checkthe No. 56 (20 A) fuse in the underhood fuse/relaybox, and the No. 17 (7.5A) fuse in the under dashluso/rglaybox.
Replacethe fuso(sl,and r6check.
R e m o v et h e c o m p r e s s ocr l u t c h relay,and test it (seepage 22 45).
Checkthe under-hoodfuse/relay DOX:
Measurethe voltage betweenthe No. 2 terminalof the compressor clutch relay 4P socketand body ground,
Chacklhe complessorclutch: Connectthe No. 1 and No. 2 terminalsofthe comoressorclutchrelav 4Psocketwith a jumper wire.
Doesthe comprossorclutchclick?
To page22-36
22-34
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To page22-35
Ftom page 22-34 COMPRESSOR CLUTCHRELAY ilP SOCKET Checkfor an open in the wire: 1. Disconnect the jumperwire. 2 . D i s c o n n e ctth e c o m p r e s s o r clutch 1Pconnoctor. 3. Checkfor continuity between the No. 1 terminalof the compressorclutch relay 4P socket and the terminalol the compressorclutch1Pconnector.
I
tr-=--l
I
I
I.TT @ i
$"f 1
I \
I
__---.1
1___J.RED COMPRESSOR CLUYCHlP CONNECTOR Wire sideof lemaleterminals Repairopen in the wire between the comp.e3sor clutch relay and the comprsssorclutch.
I
+
RED
-_-l
Inspect tha compreslor clutch clearanco,the thormal protector, and ths comDrg$or clutch tiold coil lsee page 22-65).
I
I
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(cont'd)
Troubleshooting Compressor(cont'dl Frcm page22-34
COMPRESSOR CLUTCHRELAY 4P SOCKET
Ch6ckfor an open in the wire: 1. Disconnect the jumperwire. 2. Turnthe ignitionswitchON (ll). 3, Measurethe voltage between the No. 4 terminalot the com' pressorclutchrelay4P socket and body ground.
1
2 3
4
BLK/YEL Repairop.n in the wire between the No. l7 fu3e and the compressor clutch ielay.
Checkfor an opon in the wire: 1. Turn the ignitionswitch OFF, then reinstallthe compressor clutchrelay. 2. Make sure the A"/Cswitch is O F F ,t h e n t u r n t h e i g n i t i o n switchON (ll). 3. Using a *BackprobeSet (T/N 07SAZ - 001000A),measure the voltage betweenthe No. 17 terminal ol the PCM/ECM connectorA (32P)and body g r o u n d w i t h t h e P CM / E C M connected, connectors
A I32P) PCMCONNECTOB
'97 model:
1
12
2 15 1 6 1 7
6 '18 1 S
I
10
22
23
11 21
BLK/RED
Wiresideof femaleterminals
A {32P} PCM/ECMCONNECTOR 38 - 00 models:
Wire sideof {em6leterminals Repairopen in lhe wire betwoon the compressor clutch r6lay and the PCM/ECM.
Check tor loose wires or Door connections at the PCM,/ECM connecto. A {32P1.lf the connections are good, sub3titute a k n o w n - g o o d P C M / E C M ,a n d rocheck. lf the symptom/indication goas away, replac€the original PCM/ECM.
22-36
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* How to use the BackDrobeSets Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multimeter.Usingthe wire insulationas a guide for the contouredtip ot the backprobeadapter, gentlyslidethe tip into the connectortrom the wire sideuntil it comesin contactwith the teF minalendo{the wire {seesectionl1).
A/C System A/C aystem does not come on {both fans and comDrossor). A/C PRESSURE SWITCH2P CONNECTOR Ch6cklor .n open in the wire: 1. Disconnectthe A,/Cpressure switch2P connector. 2. Turnthe ignitionswitchON (ll). 3. Measurethe voltagebetween t h e N o . 2 t e r m i n a la n d b o d y ground.
ls thereapprox.5 volts?
fo page 22-38 C (31PI PCMCONNECTOR
check tho PcM/EcM: U s i n g a * B a c k p r o b eS e t ( T / N 07SAZ 0010004).measurethe v o l t a g eb e t w e e nt h e N o . 5 t 2 7 l terminalof the PCM/ECM connec, t o r C ( 3 1 P )[ A 1 3 2 P )al n d b o d y ground with the PCM/ECMconnectorsconnected, '98 - 00 models I l:
'97 modol:
Wire sideof femaleterminals
PCM/ECMCONNECTOR A I32P' 38 - 00 modeb:
Wire sideof femaleterminals
ls thereapprox.5volts?
Check tor loo3e wires or Door connections at the PCM/ECM connoctorC l3lPl lA (32Pll.It the connections arg good, 3ubdtitut€ a known-good PCM/ECM,and recheck. ll the 3ymptom/indication go.. eway, r€placo thG original PCM/ECM, '98 -00 models [ ]:
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Rop.ir open in th6 wire botweon the A/C Dr*sure switch and the PCM/ECM.
* How to use the BackprobeSets Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multimeter.Usingthe wire insulationas a guide for the contouredtip ol the backprobeadapter, gentlyslidethe tip into the connectorfrom the wire side until it comesin contactwith the ter. minalondolthe wire (seesection11).
(cont'd)
22-37
Troubleshooting A/G System {cont'd) Frompage22-37
SWITCH A/C PRESSURE
Checkth€ A/C pressureswitch: 1. Turnthe ignitionswitchOFF. 2. Checklor continuitybgtween t h e N o .1 a n dN o . 2 t e r m i n a l s ofthe A,/Cpressureswitch.
Checkfor properAy'Csystempressure.
Roplecetha A/C pr€ssureswitch.
HEATERCONTROLPANEL2OPCONNECTOR Chocklor an opgn in thg wire: 1. Feconnectthe A/C pressure switch 2P connector, 2 . R e m o v et h e h e a t e rc o n t r o l panel(seepage22-46). 3. Turn the ignitionswitch ON llli. 4. Measurethe voltage between t h e N o . 1 0 t e r m i n a lo f t h e heatercontrolpanel20P connectorand body ground.
ls there approx. 5 volts?
Check lor loos6 wiras or pool connectionsat the heater control Danel 20P connoctor and at the A/C pr.ssule switch 2P connsctor. lf the connectionsere good, substitute a known-good heatar co trol pangl, end recheck.lf the symptom/indication goes away, replacethe original heaterconlrol panel.
22-38'
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Wire sideol femaleterminals
Repairopen in the wir. botwcen the A/C pres3ur€switch and the heater control oanel.
Both heater and A/C do not work.
Checkthe No. 17(7.5A)fusein the under-dashfuse/relaybox, and the No. 47 (7.5A) fuse in the underhoodluse/relaybox.
nophcc ih. fur.l.l, .nd r.check.
HEATERCONTROLPANEL8P CONNECTOR
Checktor rn open in the wiro: 1 . R e m o v et h e h e a t e rc o n t r o l panellseepage22 46). 2. Turnthe ignitionswitchON (ll). 3. Measurethe voltage between the No. 1 terminal of the heatercontrol panel 8P connectorand body ground.
ls thero batteryvoltage?
Wiresideot femaleterminals
R.pair opan in lha wlra batw.cn the No. 1? fuaa and tha h.ltcr control panal.
Chgckfor an opan in th€ wirg: 1. Turnthe ignitionswitchOFF. 2. Measurethe voltage between t h e N o . l l t e r m i n a lo f t h o heatercontrolpanel20Pconnoctorand body ground.
ls there battery voltags?
I
A,/1,/
5
8
9
WHT/BLU Repsil opon in tha wi.a batwcan th. No. 47 tur. and tho hoitor contlol panol.
Wiresideof femaleterminals
2
{
5
7
3 8
BLK Check for an opon in tho wira b6{woon tho hoatar control p.nol and body ground. It the wir. i3 OK, chsck for poor ground rt GlOl lnd Glo2.
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2
10
1 t 1 2 1 3 1 a 1 5 1 5 1 7 1 8 1 9 20
Checkfor an opon in the wire: Ch6cklor continuity betwoen the No. 7 terminalof the heatercontrol panel8P connectorand body ground.
Check for loose wire3 or oooa connection3at the haater control prnol 8P and 20P connoctors. It thc conncction3are good, substituta a known-good h€ater control prnol, and rechecft.lf the symptom/indic.lion go.3 ewry, repl.cg the original ha.ter contlol oancl.
HEATERCONTROLPANEL2OPCONNECTOR
0
Troubleshooting HeaterControl PanelInput/OutputSignals HEATERCONTROLPANELCONNECTORS 2OPCONNECTOR
8P CONNECTOR
Wire sideof femaleterminals
8P CONNECTOR Cavity
lrvire colol
'l
BLK/TEL
2
Cavity
Signal
I G 2( P O W E R )
Wire colol
INPUT
RED
GRN/RED RECIRCULATE
INPUT
RED/BLK
GRN/VVHT F R E S H
INPUT
1
CUTPUT
8
BLUI/EL
REARWINDOW RELAY DEFOGGER
Signal
DASHLIGHTSERIGHTNESSCONTROLLER LIGHT COMBINATION SWITCH(ViaNo. 30 (7.5A) fuse)
CUTPUT INPUT
GROUND
OUTPUT
BLU/BLK BLOWERFEEDBACK
INPUT
BLK
20PCONNECTOR Cavity
Cavity
Signal
Wire color
1
GRY
+5V AIR MIX POTENTIAL
2
GRN
TEMPERA. EVAPORATOR OUTPUT T U R ES E N S O R
PNI(BLK
6
AIR MIX POTENTIAL
OUTPUT
INPUT
7 8
BLOWERMOTORHIGH
ORNrur'HT RELAY BRN
10
22-40
SENSOR GROUND
SWITCH BLU,ryVHTA"/CPRESSURE
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INPUT INPUT INPUT
'll
12
Signal
Wire color
WHT/BLU BACKPU (POWER)
YEL
MODEHEAT/DEF
INPUT INPUT
13
BLU/BLK MODEHEAT
INPUT
14
GRN/YEL MODEHEAT/VENT
INPUT
I C
YEURED M O D EV E N T
INPUT
to
YEUBLU MODEDEF
INPUT
17
RED/BLU A I RM I X C O O L
OUTPUI
18
RED/VEL
AIR MIX HOT
OUTPUI
'19
MOTORGROUND BRNA/VHT IVIODE
INPUT
20
BASE CUTPUT T GRN/BLKPOWERTRANSISTOR
Mode ControlMotor Replacement
Test
1.
1 . Disconnectthe 7P connectorfrom the mode control motor.
Disconnect the 7P connectorfrom the mode control motor. Removethe rod from the arm of the mode control motor, Remove the self-tapping screws and the mode controlmotor. 7P CONNECTOR
Connectbattery power to the No. 1 terminal, and ground the No. 7 terminal.To avoid damagingthe mode control motor, do not reverse power and grouno.
MODECONTROLMOTOR
MODECONTROLMOTOR
2.
Installin the reveGeorderof removal.After installation, make sure the mode control motor runs smoothlv.
U s i n g a j u m p e r w i r e . c o n n e c tt h e N o . 7 t e r m i n a l i n d i v i d u a l ltyo t h e N o , 2 , 3 , 4 , 5 a n d 6 t e r m i n a l si n that order. Eachtime the connectionis made. the mode controlmotor shouldrun smoothlyand stop. lf the mode control motor does not run when jumping the first terminal,jump that terminalagain after j u m p i n g t h e o t h e r t e r m i n a l s .T h e m o d e c o n t r o l motor is OK it it runs when jumping the first terminal again. lf the mode control motor does not run in step 3, removeit, then checkthe mode control linkageand doorsfor smoothmovement.lf they move smoothly, reDlacethe mode control motor.
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RecirculationControl Motor Replacement
Test
1.
1 . Disconnectthe 4P connectorfrom the recirculation controlmotor.
Oisconnectthe 4P connectorand the wire harness clio from the recirculationcontrol motor. Remove the self-tappingscrewsand the recirculation control motor,
Connectbattery power to the No. 1 terminal, and groundthe No. 2 and No. 4 terminals;the recirculation control motor should run smoothly.To avoid damaging the recirculationcontrol motor. do not reversepower and ground.
{P CONNECTOR
RECIRCULANON CONTROLMOTOR
lnstall in the reverseorder of removal.After installacontrolmotor runs tion, make sure the recirculation smoothlv.
Disconnect the No. 2 or No. 4 terminalsfrom ground; control motor shouldstop at Fresh the recirculation Don't cvcle the recirculationcontrol or Recirculate. motor for a long time. 4.
22-42
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lf the recirculationcontrol motor does not run in step 2, remove it, then checkthe recirculationcontrol linkage and door for smooth movement.lf they move smoothly, replacethe recirculationcontrol motor.
Air Mix GontrolMotor Replacement
Test
1.
1.
Disconnectthe 5P connectorfrom the air mix control motor. Remove the self-tapping screws, the air mix controlmotor and the flangecollar.
Disconnectthe 5P connectorfrom the air mix control motor. Connect battery power to the No. I terminal of the air mix control moto., and ground the No, 5 terminal; the air mix control moto. should run, and stop at MAX HOT. lf it doesn't, reversethe connections; the air mix control motor should run, and stoo at MAX COOL.
5P CONNECTOR
lf the air mix controlmotor does not run, remove i t , t h e n c h e c kt h e a i r m i x c o n t r o l l i n k a g ea n d doors for smooth movement. lf they move smoothly,replacethe air mix control motor.
AIR MIX CONTROLMOTOR
6 AIR MIX CONTROL MOTOR
A
Installin the reverseorderof removal.After installation. makesure the air mix control motor runs smoothlv.
Measurethe resistance betweenthe No. 2 and No. 3 terminals.lt shouldbe approximately6 kOt 20%. 4.
Measurethe resistance betweenthe No. 2 and No, 4 terminals,lt shouldbe approximately 4.8kO:t 20%at MAX HOT and approximately '1.2kO t 20% at lilAx
cooL.
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22-43
EvaporatorTemperature Sensor
Power Transistor
Test
Test
Dip the sensorin ice water, and measurethe resistance with a digital multimeter.Then pour hot water on the sensor,and checklor changein resistance.
1 . Disconnectthe 3P connectorfrom the oower transt$or.
Compare the resistancereading between the No. | 8nd No. 2 terminals of the evaporatortemperaturesensor with the specificationsshown in the following graph; resistance shouldbe within the specifications.
Carefullyreleasethe locktab on the No. 2 terminalin the 3P connector,then removethe terminal and insulate it from body ground.
1 2 V1 . 2 - 3 . 1 W EVAPOBATOR TEMPERATURE SENSOB No. 2 ILT GRN/BLK)
Terminalsideol maleterminals
4
RESISTANCE
ko t0
50 10
68 20
86.F 30'c
No.I IBLU/BLK)
Connecta 1.2- 3.4 W bulb betweenthe No, 1 and the No,2 cavityon the 3P connectol Reconnect the 3Pconnectorto the powertransistor. Turn the ignitionswitch ON (ll). and checkthat the blowermotor runs. a lf the blower motor runs at half soeed the oower transistoris OK, replacethe heatercontrolpanel. . lf ths blower motor does not run at half soeed, reDlacathe Dowertransistor.
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22-44
Relays Test Thereshouldbe continuitybetweenthe No. 1 and No.3 terminalswhen power and ground are connectedto the No. 2 and No. 4 terminals,and thereshouldbe no continuity when power is disconnected.
,I In
I
3
Thereshould be continuitybetweenthe No. 1 and No. 2 terminalswhen power and ground are connectedto the No. 3 and No. 4 terminals,and there shouldbe no continuitv when oower is disconnected.
I
t) P
)
.I
I
tI r I€
o Blowermotor relay
a Rsdiatorfan relay
Condenserfan relay a Compressor clutchrelay
.
Blowermotor high relay
F)'"
,2-4.._.
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22-45
HeaterControlPanel
Blower Unit
Replacement
Replacement
'1. Removethe center panel togetherwith the heater controlpaneland the audio unit (seesection20).
1 . Bemovethe evaporator (see page 22-48),
Removethe self-tappingscrewsand the heatercontrol panelfrom the centerpanel.
Disconnectthe connectors from the blower motor, the blower motor high relay, the power transistor and the recirculationcontrol motor. Remove the w i r e h a r n e s sc l i o f r o m t h e r e c i r c u l a t i o nc o n t r o l motor,and releasethe wire harnessfrom the clamp on the blower unit. Removethe mountingbolts,the mountingnut and the blower unit. 6x1.0mm 9.8 N.m (r,0 kgf.m, 7.2 lbl.ftl
6x1.0mm 9.EN.m 11.0kgf.m,7.2lbtftl CENTERPANEL
lnstall in the reverseorder of removal. Make sure that there is no air leakage. 3.
lnstallin the reverseorderof removal.
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22-46
Overhaul Notetheseitemswhen overhaulingthe blower unit. . The recirculationcontfol motor. the power transistor,the blower motor high relay, and the blower motor can be replacedwithout removingthe blowerunit. . Betorereassembly, makesurethattherecirculation controldoorand linkagemove smoothlywithout binding. o After reassembly, makesurethe recirculation controlmotor runs smoothly(se€page22-42). o Makesurethat there is no air leakage. RECIBCULATION CONTBOLMOTOR page22-42 Replacement.
m POWEBTMNSISTOR Test. page 22'44
BLOWER Tost, page 22-45
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22-47
Evaporator Replacement 1 . Recoverthe refrigerantwith a recovery/recycling/ chargingstation(seepage22-59).
6.
Removethe battery. Removeeach bolt, then disconnectthe suctionand receiverlinesfrom the evaporator.Plug or cap the them to avoid linesimmediatelyafter disconnecting moistureand dust contamination,
Disconnectthe connectorfrom the evaooratortemoeraturesensor.and removethe wire harnessfrom the evaporator.Removethe self-tappingscrews,the mounting bolt and the mounting nut. Disconnect the drain hose,then removethe evaporator.
5xl,0mm 9.8 N.m {1.0kgf.m, 7.2 lbf.ftl
II
I
I
RECEIVERLINE
o
,
-l: "
.. \
EVAPORATOR 6x1.0mm 9.8 N.m (1.0kgtm,7.2lbf.ftl
6x1.0mm 9.8N'm(1.0kgfm, 7.2 tbl.ttl (see glove Removethe box section20). Removethe self-tappingscrewand the passenger's dashboardlower cover,then removethe bolts and the glove box frametogetherwith the kneebolster. KNEE
GLOVEBOX FRAME
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22-44
7.
Installin the reverseorder of removal,and note of theseitems. .
lf you're installinga new evaporator,add refrigerantoil (SP.10)(seepage22-541. Replacethe O-ringswith new ones at each fitt i n g , a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l before installingthem. Be su.e to use the right (R-134altoavoid leakage. O-ringsfor HFC-134a a Apply sealantto the grommets. a Makesurethat there is no air Ieakage. a Charge the system (see page 22-6'll, and test its performance(see page 22-56]-,
} -
Overhaul 1.
6.
Remove the filter lid. then pull out the A/C filter assembly.
the O-ringswith new onesat eachfitting, Replace and apply a thin coat of refrigerantoil before installingthem. Be sure to use the right O-rings (R-134a) to avoid leakage. for HFC-'134a . Installthe expansionvalve capillary tube with the capillarytube in contactwith the outlet line directly,and wrap it with electricaltape. . Reinstallthe evaporatortemperaturesensor to its originallocation. . Makesurethat there is no air leakage.
.
Pull out the evaporatortemperaturesensor from the evaporatorfins. R e m o v et h e s e l f - t a p p i n gs c r e w sa n d t h e c l a m p s from the housings. 4.
the evaporatorin the reverseorder of Reassemble Makenoteof theseitems. disassembly.
Carefullyseparatethe housings,then remove the evaporator. lf necessary,remove the expansion valve When looseningthe nuts of the expansionvalve,use a second wrench to hold the expansionvalve or the evaporator line.Otherwise,they can be damaged.
TAPE ELECTRICAL Replace. Makesure there is no foreign matter stuck between the capillarytube and outletline.
CAPILLARY TUAE
; EXPANSIONVALVE
TEMPERATURE SENSOR lest, page 22-41
,m \!{
Y
FILTERLID
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I-OWERHOUSING
A/C FILTERASSEMBLY
22-49
A/C Filter Replacement 1.
Removethe glove box (seesection20). Removethe glove box frame {see page 22-4A). Releasethe wire harnessfrom the clamps on the evaporator.Removethe filter lid, then pull out the ,VCfilter assemblyfrom the evaporatorhousing.
A/C FILTERASSEMELY
HeaterUnit Replacement SRS componentsare located in this area. Reviewthe SRS componentlocations,precautions,and procedures in the SRSsection{24)beforeperformingrepairsor ser-
1.
Disconnect the negativecablefrom the battery.
2.
Fromunderthe hood,openthe cableclamp,then disconnectthe heatervalve cable from the heatervalve arm. Turn the heatervalve arm to the fullv ooened oositionasshown.
HEATERVALVE ARM
R e m o v et h e A / C f i l t e r f r o m t h e f i l t e r h o u s i n g . Replacethe Ay'Cfilter accordingto the maintenance schedulein the owner'smanual. HEATER VALVECABLE
When the engine is cool, drain the engine coolant from the radiator(seesection10). Do not remove the rldiator cap when @ the engine is hot; the engine coolant is under pressure and could sevo.ely scald you.
Installin the reverseorder of removal.Make sure that there is no air leakage.
22-50
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4.
Disconnectthe heater hosesfrom the heater unit. Enginecoolantwill run out when the hosesare disconnected;drain in into a cleandrip pan. CAUTION:Enginocoolantwill damagep8int. Ouickly rinse any spill€d engine coolant Itom painted surfaces.
Removethe dashboard(seesection20). 7. ll.
HEATERHOSE IOUTLETSIDE)
Removethe evaporator(seepage22-48). Disconnectthe connectorsfrom the mode control motor and the air mix control motor, and removethe wire harnessclips and wire harnessfrom the heater unit. Remove the clip from the heater duct, then removethe mountingnutsand the heaterunit 6x1.0mm 9,8N.m (1.0kgt m,7.2lblft)
HEATER UNIT
CLAMPS
Remove the mounting nut from the heater unit. Takecare not to damageor bend the fuel lines,the brake lines.etc. q
Installin the reverseorderof removal.Make note of the followingitems. a Apply sealantto the grommets. a Do not interchangethe inlet and outlet heater
hoses.Makesurethat the clampsare secure. Refill the cooling system with engine coolant {seesection10). a Adiustthe heatervalvecable(seepage22-53). a Makesurethat there is no air leakage.
13 N.m 11.3kg{.m,9.4lbtftl
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22-51
HeaterUnit Overhaul 1.
Removethe self-tappingscrews and the heater core cover.
Pull out the heate.core. Be carefulnot to bend the inletand outlet pipesduring heatercore removal.
Pullout the grommetfrom the heatercore pipes.
Reassemble the heaterunit in the reverseorder of disassemblv.
Removethe self-tappingscrewand the pipe clamp.
HEATERCORECOVER
HEATERCORE
22-52
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TemperatureControl Adjustment l.
From under the hood, open the cable clamp, then disconnectthe heatervalve cable from the heater vatvearm. HEATERVALVE ARM
5.
From underthe hood.turn the heatervalve arm to t h e f u l l v c l o s e d p o s i t i o na s s h o w n , a n d h o l d i t . Attach the heater valve cable to the heater valve arm, and gently pull on the heatervalvecablehousing to takeup any slack,then installthe heate.valve cablehousinginto the cableclamp.
HEATERVALVE ARM
HEATERVALVECABLE
From under the dash, disconnectthe heatervalve cablehousingfrom the cableclamp.and disconnect the heatervalvecablefrom the air mix contlol arm
VALVECABLE HEATER
Setthe temperaturecontroldial on MAX COOLwith the ignitionswitchON (ll). Attachthe heatervalve cableto the air mix control arm as shown above. Hold the end of the heater valvecablehousingagainstthe stop,then snap the heatervalvecablehousinginto the cableclamp.
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22-53
A/C ServiceTips and Precautions
(R-134a) refrigerantand polyalkyleneglycol The air conditionersystemusesHFC-'134a {PAG)refrigerantoil*, which are not (R-12) refrigerantand mineraloil. Do not use R-12refrigerantor mineraloil in this system,and do compatiblewith CFC-12 not attempt to use R-12servicingequipmenudamageto the air conditionersystem or your servicingequipmentwill resutr. *KEIHINSP-10: . P/N 38897- Pl3 - A01AH:120m{ (4 fl.oz,il.2 lmp.oz) . P/N 38899- Pl3 - A01:40 mf 11113tl.oz,1.4 lmp.oz) Use only serviceequipmentthat is U.L.-listedand is certifiedto meet the requirementsof SAE J2210to removeR-134a from the air conditionersystem, CAUTION: Exposureto air conditioner refrigerant and lubricant vapor or misl can irritats eyes, nose and throat. Avoid breathingthe air conditionerrefrigerantand lubricantvaporor mist, lf accidentalsystemdischargeoccurs,ventilatework areabeforeresumingservice. R 134aserviceequipmentor vehicleair conditionersystemsshouldnot be pressuretestedor leaktestedwith compressed air. Some mixtures of air and R-13,1ahave been shown to be combustible at elevat€d pressuresand can result E@ in fire or explosion causing iniury or property damage. Never use complessed air to pressuretest R-l3,[a service equipment or vehicle air conditioner systems. Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand lubricantmanufacturers. 1. 2. 3. 4. 5. 6.
Alwaysdisconnectthe negativecablefrom the batterywheneverreplacingair conditioningparts. Keepmoistureand dust out of the system.When disconnecting any lines,plug or cap the fittings immediately;don't removethe capsor plugs untiljust beforeyou reconnecteachline. Beforeconnectingany hoseor line.applya few dropsof refrigerantoilto the O-ring, Whentighteningor looseninga fitting,usea secondwrenchto supportthe matchingfitting. When dischargingthe system,use a R l34a refrigerantrecovery/recycling/charging station;don't releaserefrigerant into the atmosphere. Add refrigerantoil afterreplacingthe followingparts. Notetheseitemswhen handlingrefrigerantoil: o To avoidcontamination, do not returnthe oil to the containeroncedispensed,and nevermix it with other refrigera n to i l s . . lmmediatelyafter usingthe oil, replacethe cap on the container,and sealit to avoid moistureabsorption. . Do not spill the refrigerantoil on the vehicle;it may damagethe painu if the refrigerantoil contactsthe paint,wash it off immediately. Condenser . 25 ml (5/6 tl.oz, 0.9 lmp.oz) Evaporator.,................................40 m/ 11113ll.oz,l.4lmp.ozl Lineor hose........... 10 ml (1/3fl.oz,0.4 lmp.oz) Receiver/Dryer....... 10 ml (1/3fl.oz,0.4 lmp.oz) Leakagerepair............................ 25 m/ (5/6ll.oz,0.9 lmp.oz) Compressor.......,..., For compressor replacement,subtract the volumg ol oil drained from the removed compressorfrom 130 m{ (4 113tl.oz, 1,6lmp.ozl, and drain the calculatsd volume of oif from the now comprossor:130 ml (,1113tl,oz, 1.6lmp'ozl - Volume of removed compressor= Volume to drain from new compressor. NOTE:Evenif no oil is drainedtrom the removedcompressor,don't drain more than 5 0 m t 1 12 1 3 l l , o z , 1 .l m 8 p . o zf)r o m t h e n e w c o m p r e s s o r .
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22-54
I
A/C SystemTorqueSpecifications EVAPORATOR
SUCTIONLINE
SUCTIONHOSE
RECEIVERLINE A RECEIVENLINE B
RECEIVER/ORYER
O Dischargehos€ to the compressor{6 x 1.0 mml
....9.8 N.m 11.0kgrf.m.7.2lbtftl
@ Condenserline to the condenser(6 x 1.0 mm) 9.8 N.m {1.0 kgf.m, 7.2 lbt.ft) @ Condensorline to the receiver/dryer{6 x 1.0 mm) ........ 9.8 N.m {1.0kgf.m.7.2lbf.ft} (6 ................... .... mm) ...... O Receiverline A to the receivor/dryer x 1.0 A receive. line B to th€ Receiver line @ O R€ceivertine C to the receivorline B 9.8 N'm (1.0kgf.m,7.2lbtftl @ Recoiverline C to the evaporator (6 x 1'0 mml O Sustion line to the evaporatot 16x 1.0 mml ......31 N.m (3.2kgl.m, 23 lbf.ft) @ Sustion line to the suction hose .....'...'9 8 N'm (1 0 kgt'm, 7'2 lbf'ftI @ Sucion hose to the qompressor(6 x 1.0 mm) .. 24 N.m l2.il kgf'm, 17 lbf'ft} @ Compressorto the compressorbracket {8 x 1.25mm) . il,t N'm (4.5kgt'm, 33 lbf'ft) ......... (10 1.25 mm) ................ x @ Compressorbracket to the cylindsr block ,14N.m (/r.5kgf'm,33 lbf'ft) (10 ..................... 1.25 mm) x pulley bracket to the compressor bracket @ ldler 24 N'm (2./tkgt'm, 17 lbf'ft) ......................... bracket to the compressor sdiusting boh Lock nut of the @ @|d|erpu||eytotheid|orpu||eybracket.....'..........................'.....'.....'........'....44N.m(4.5kg' 59 N'm (6.0kgt'm,/l:| lbf'ft1 @ compressorbracketto the left front mount (12x 1.25mml ................... ............................ www.emanualpro.com
22-55
A/G System Service Performance Test The performancetest will helDdetermineif the air conditionersystemis operatingwithin specifications.
Recovory/Recycling/chargingstation
Useonly serviceequipmentthat is U.L.-listed and is certified to meet the requirementsof SAEJ2210to remove (R-134a) HFC-134a from the air conditionersvstem. CAUTION: Exposure to air condiiioner r€trigerant and lubricant vapor or mist can irritate €yes, nose and throat. Avoid bre8thing the air conditioner retrige.ant and lubricant vapor or mist, lf accidentalsystem dischargeoccurs.ventilate work areabeforeresumingservice. R-134aserviceequipmento. vehicleair conditionersystems should not be pressuretested or leak tested with comDressed air. some mixtur€s ol air and R-134ahave becn @ shown to be combuslible at olsvated pressuresand can result in lire or explosion causing iniury or property damage. Never use compressed air to prgssure test R13i[a service equipment or vehicle air conditioner sys. tems. Additional health and safety information may be obtained from the refrigerant and lubricantmanufacturers. 1 . C o n n e c ta R - 1 3 4 ar e f r i g e r a n tr e c o v e r / r e c y c l i n g / chargingstationto the vehicle,as shown.following instructions, the equipmentmanufacturer's 2.
Insen a thermometerin the centerair vent. Determine the relativehumidityand airtemperature. Testconditions: . Avoid directsunlight. o Openhood. . open front doors. . Set the temperaturecontrol dial on MAX COOL, the mode controldial on VENTand the reci.culation controlswitchon RECIRCULATE. . Turn the A,/Cswitch on and the fan switch on MAX. . Runthe engineat 1,500rpm. . No driveror passengers in vehicle After running the air conditioningfor 10 minutes under the above test conditions,read the deliverv temperaturefrom the thermometerin the dashvent and the high and low systempressurefrom the Ay'C gauges.
22-56
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LOW.PRESSURE SIDE
5.
To comDletethe charts: . Markthe deliverytemperaturealongthe verticalline' . Markthe intaketemperature{ambientair temperature)alongthe bottom line' . Drawa line straightup from the air temperatureto the humidity' . Marka point 10%aboveand 10%belowthe humiditylevel' a Fromeachpoint,draw a horizontalline acrossthe deliverytemperature' . The delivervtemperatureshouldfall betweenthe two lines' . Completethe low-sidepressuretest and high-sidepressuretest in the sameway' outsidethe line may indicatethe needfor furtherinspection . Anv measurements
kPa {kst/cm') Ipsil 29r,0 t30t l,a0l
HUMIDITY LEVEI-
2500 (251 t3601 2000 l l20l I t28ol | I 1s00'l {15} |
DELIVERY r21or I PRESSURE
980 j rlol
t
kp. {ksf/cmz}"F lcsil Pcl ,l0oI 85 -l (4} | (301
t57lI
t
I
3oo-.J {31 I
"r1 I l25lI
200 t2) |
68 J (2otI
r14ol r13l I -lL
r28r I I -.1
100
TNTAKElli' I PRESSURE
]
I
80v. 80vo
HUMIOITY LEVEL
l
HUMIDITY LEVEL
I
I ss l
(15r I | 50 -l
,to, I
DELIVERY TEMPEBATURE.t
I :.] _
rsl -ll
fl 6g t2o)
j7 l25l
* (30)
95 (351
104 (ro)
fct
INTAKETEMPERATURE
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22-57
A/C System Service PressureTestChart NOTE: PerformanceTest is on page 22-56. Test results (high) Discharge pressure6bnormally hagh
Dischargepressure abnormallylow
Suction {low) pros, sureabnormally
Suction pressure abnormallyhigh
Slction and dis, charge pressutes abnormallyhigh
Suctionand dischargepressure abnormallylow
Refrigerant leaks
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Relatadsymptoms After stoppingcompressor,pressure dropsto about200 kPa12.0kgtlcm,, 28 psi)quickly,and then lalls gradualty.
Prcbablecaus€ Air in system
No bubblesin sightglasswhen condenseris cooledby water Reducedor no air flow through condenser
Excessiverefrigerantin system . Cloggedcondenseror radiator fins . Condenser or radiatorfan not wo.king properly
Remody Discharge, evacuate, and recharge with specifiedamount. Evacuation: seepage22-60 Charging: seepage22-61 Discharge, evacuate, and recharge with speciliedamount. Clean Checkvoltageand fan rpm. Checkfan direction.
Line to condensoris excossivelvhot.
Restrictedflow of relrigerantin sy$em
Festrictedlines
Excessive bubblesin sightglass; condenseris not hot. Highand low pressures are balanced soon after stopping compressor.Low sideis higherthan normal. Outlet ot expansionvalve is not frosted, low-pressuregauge indicates
Insufficientretrigerantin
Checkfor leak. Chargesystem. Replacethe comprossor.
. Faultycompressordischarge . Faultycompressorseal ' Faultyexpansionvalve . Moisture in system
Excessive bubblesin sightglass; condenseris not hot.
Insufficiontrelrigerantin
Expansionvalve is not frosted, and low-pressure lineis not cold.Lowpressuregaugeindicates vacuum. Dischargetemperatureis low, and the air llow trom vents is restricted.
' Frozenexpansionvalve lMoisture in system) . Faultyexpansionvalve Frozenevaporator
Expansionvalve is frosted. Feceiver/dryeroutlet is cool, and inlot rsw6rm (shouldbe warm during operation).
Cloggedexpansionvalve Cloggedreceiver/dryer
Low-pressurehose and checkjoint are coolerthan tho temperature around evaporator. Suction pressureis loworedwhen condenseris cooledby water. Highand low-pressure are equalized as soonas tho compressoris stopped, and both gaugestluctuatewhile running. Reducedair flow throughcondens€r,
. Expansionvalveopentoo long . Looseexpansioncapillary tube Excessiverefrigerantin system
No bubblesin sightglasswhen condenseris cooledby waler Low-pressure hoseand motalend areasare cooterlhan evaporator. Temperature aroundexpansionvalve rstoo low comparedwith that around
Faultygasket Faultyhigh-pressure valve Foreignpaniclestuckin high. Cloggedcondenseror radiatortins . Condenser or radiatorfan not workingproperly Excessiverefrigerantjn system Cloggedor kinkedlowpressurehose pans Cloggedhigh-pressure line
. Replace . Discharge,evacuate,and rechargewith specifiedamount. Repairthe leaks. Discharge, evacuate, and rechargewith specifiedamount. Chargeas r€quired. . Discharge,evacuate,and rechargewith specitiedamount. . Replaceth€ expansionvalve. Run the fan with compressoroff, then checkevaporatortempera, ture sensor. Cleanor replace. Replace
Repairor roplace.
Discharge, evacuate, and recharge wathspecifiedamount. Replace the compressor.
Clean Checkvoltageand fan rpm. CheckIan direction. Discharge, evacuate, and recharge with specifiedamount. Repairor replace. Repairor replace.
Compressor clutchis diny. Compressor boltls)are dirty.
Compressor shaftsealleaking Leakingaroundbolt(s)
Replace the compressor. Tighton bolt{s)or replace compressor.
gasketis wet with oil. Compressor
Gasketleaking
Replacethe compressor,
Recovery and is cerUseonly serviceequipmentthat is U.L.-listed tifiedto meetthe requirementsof SAEJ2210to remove (R-134a) from the air conditionersystem. HFC-134a
Station Recovery/Recycling/Charging
CAUTION: Exposure to air conditioner refrigerant and lubricant vapor or mist can irritate eyes, nose and throat. Avoid brqathing the air conditioner retrigerant and lubricant vapor or mist. systemdischargeoccurs,ventilatework area lf accidental beforeresumingservice. R-134aserviceequipmentor vehicleair conditionersystems should not be pressuretested or leak testedwith compressedarr. some mixtures of air and R-134ahave been @@ shown to be combustible at elevated plessures and can result in fire or explosioncausinginiury or property damage. Never use compressed air to pressure tect R-134a serviceequipment or vehicleair conditionersystems. Additionalhealthand safetyintormationmay be obtained and lubricantmanufacturers. from the refrigerant ' 1 . C o n n e c ta R - 1 3 4 ar e f r i g e r a n rt e c o v er y l r e c y c l i n g / chargingstationto the vehicle,as shown,following instructions the equipmentmanufacturer's 2.
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Measurethe amountof refrigerantoil removedtrom the A,/Csystem after the recoveryprocessis comoleted.Be sure to installthe same amount of new refrigerantoil backinto the AVCsystembeforecharginq.
22-59
A/C System Service Evacuation Use only serviceequipmentthat is U.L.-listed and is certified to meet the requirementsof SAE J2210to remove HFC-134a {R-134a)from the air conditionersystem. CAUTION: Exposure to air conditioner refrigerant and lubricant vapor or mist can irrhate eyes,noso and throat. Avoid breathing the air condhioner retrigerant and lubricant vapor or mist. lf accidentalsystem dischargeoccu.s. ventilate work areabeforeresumingservice. R 134aserviceequipmentor vehicleair conditionersystems should not be pressuretested or leaktested with compressedarr. some mixtures of air and R-134ahsvo been !@ shown to be combustible at elevatedpressuresand can result in tire or explosion causing iniury ot property damage. Never use compressed air to pressure test R134a service equipment or vehicle air conditioner svstems. Additionalhealthand safetyinformationmay be obtained from the refrigerant and lubricantmanufacturers. 1, When an A,/CSystemhas beenopenedto the atmosphere,such as during installationor repair,it must be evacuatedusing a R-l34a refrigerantrecovery/ recycling/charging station.{lf the system has been open for severaldays,the receiver/dryer should be replaced,and the system should be evacuatedfor severalhours.) Connect a R-134arefrigerant recovery/recyclin g/ chargingstationto the vehicle,as shown,following t h e e q u i p m e n t m a n u f a c t u r e r ' si n s t r u c t i o n s . Evacuatethe system, lf the low-pressuredoes not reach more than 93.3 kPa (700 mmHg,27.6 in.Hg)in 15 minutes,there is probablya leak in the system.partiallychargethe system,and checkfor leaks(seeLeakTest).
22-60
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Recovery/Recycling/Charging Station
Charging
LeakTest
and is cerUseonly serviceequipmentthat is U.L.-listed tified to meetthe requirementsof SAEJ2210to remove (R-134a) HFC-134a from the air conditionersystem.
and is cerUse only serviceequipmentthat is U.L.-listed tified to meetthe requirementsof SAE J2210to remove (R-134a) HFC-134a from the air conditionersystem.
CAUTION:Exposureto air conditionerrefrigerantand lubricant vapor or mist can irritate eyes, nose and throat. Avoid breathingth€ air conditionerrefrigerant and lubricant vapor or mist.
CAUTION: Exposure to air conditionor refrigerant and lubricantvapor or mist can irritate eyes,nose and throat. Avoid breathing the air conditioner retrigerantand lubricant vapor or mist.
lf accidentalsystem dischargeoccurs,ventilate work a r e a b e f o r er e s u m i n gs e r v i c e .A d d i t i o n a lh e a l t ha n d safetyinformationmay be obtainedfrom the relrigerant and lubricantmanufacturers.
lf accidentalsystem dischargeoccurs,ventilate work areabeforeresumingservice.
Connecta R-'134a refrigerantrecovery/recycling/charging stationto the vehicle,as shown.followingthe equipment manufacturer'sinstructions. Station R€covery/Recycling/Charging
R-134aserviceequipmentor vehicleajr conditionersystems should not be pressuretested or leak testedwith compressedarr. some mixturos of air and R-1348 have !@ been shown to be combustible at olovatod pres3uras and can result in fire or explosion causing iniury or property damage.Never use comprelisedair to pressure test R-13ilaservice equipment or vehicle air conditioner systems. Additionalhealthand safetyinformationmay be obtained from the refrigerantand lubricantmanufacturers. 1 . Connect a R-134arefrigerant recoverylrecycling/ chargingstationto the vehicle,as shown in the previous column,followingthe equipmentmanufacturer's instructions. 2.
Open the high-pressure valve to chargethe system t o t h e s p e c i f i e dc a p a c i t y ,t h e n c l o s e t h e s u p p l y valve,and removethe chargingsystemcouplers. S e l e c tt h e a p p r o p r i a t eu n i t o f m e a s u r ef o r y o u r chargingstation. Refrigerantcapacity:700 to 750 g 0.70to 0.75kg 1.5to 1.6lbs. 21.7 to 26.5 oz.
HIGH-PRESSURE SIDE Add the same amount of new refrigerantoil to system t h a t w a s r e m o v e d d u r i n g r e c o v e r y .U s e o n l y S P - ' 1 0 refrigerantoil.
Checkthe systemfor leaksusing a R-134arefrigerant leak detectorwith an accuracyof 14 g (0.5 ozl per year or better.
C h a r g et h e s y s t e m w i t h R e q u i r e da m o u n t o f R - 1 3 4 a refrigerant.Do not overchargethe system;the compressor will be damaged.
lf you find leaksthat requirethe systemto be opened (to repair or replacehoses,fittings, etc.), recoverthe system accordingto the RecoveryProcedureon page 22-59.
S e l e c tt h e a p p r o p r i a t eu n i t o f m e a s u r ef o r y o u r chargingstation.
ll-
Refrigerantcapacity:700 to 750 g 0.70to 0.?5k9 1.5to 1.6lbs. 21.7 to 26.5 oz.
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5.
After checkingand repairing leaks,the system must be evacuated(seeSystemEvacuationon page22-601.
22-61
Compressor Replacement 'L
lf the compressoris marginally operable.run the e n g i n e a t i d i e s p e e d ,a n d l e t t h e a i r c o n d i t i o n e r work for a few minutes.then shut the engineoff.
2.
Disconnect the negativecablefrom the battery.
5.
Removeeach bolt, then disconnectthe suctionand dischargelines from the compressor.Plug or cap the lines immediatelyafter disconnectingthem to avoid moistureand dust contamination, 6x1.0mm 9.8 N.m 11.0kgf.m,7.2 lbf.ft)
Recoverthe refrigerantwith a recovery/recycling/ chargingstation(seepage22-59). Disconnectthe condenserfan connector.Remove the compressorclutch connectorand the wire harness clip from the condenserfan shroud,then disconnectthe compressorclutch connector.Remove the mountingbolts and the condenserfan shroud,
CONDENSER FAN CONNECTOR
6x1.0mm 7 N.m 10.7kg{.m,5 lbl.ftl
LINE
LINE DISCHARGE
6.
Removethe power steeringpump belt (seesection 17t.
7.
Loosenthe pivot bolt of the idler pulleybracketand the adiusting bolt, then remove the Ay'Ccompressor b e l t f r o m t h e p u l l e y s .l f n e c e s s a r y r, e m o v e t h e mountingbolts from the left front mount,then remove the A,/Ccompressorbelt through the gap betweenthe bodv and the left front mount. PIVOTBOLT 10 x 1.25mm AIUUSTING 4,t N.m (4.5 kgf.m, 33 tbf.ftl
10x 1.25mm /t4 N.m (4.5kgl.m,33 lbtftl
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t€FT FRONT MOUltlT
COMPRESSOR BELI
8.
Removethe mountingboltsand the compressor.
1 0 . C h e c kt h e i d l e r p u l l e yb e a r i n gf o r p l a y a n d d r a g , and replaceit with a new one if it's noisy or has excessiveplay or drag. IDLERPULLEY
kgtm,33lbfftl +r N.m14.5 E x 1.25mm l7 lbl.ft) 2aN.m(2.,1kgf.m, BBACKET q
lf necessary,remove the compressor bracket as follows. .
.
Remove the nut and the washer from the left front mount. When tighteningthe nut to the left front mount,makesurethe washeris set properly on the leftfront mount as shown.
1 1 . lnstallin the reverseorderof removal.Make note of the followingitems, .
Removethe mountingbolts and the compressor 12 x 1.25mm bracket. 59 N.m (6.0 kgt'm,
.
. .
.
.
. 10x 1,25mm art N.m (4.5 kgf'm, 33 lbfftl
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PIVOTBOLT 10x 1.25mm ir4 N.m{4.5kgt m, 33 lbl'ft}
.
drainall the lf you'reinstallinga new compressor, reJrigerantoil from the removed compressor,and m e a s u r ei t s v o l u m e . S u b t r a c tt h e v o l u m e o f drainedoil trom 130 m/ 14 U3 fl'o2,4.6lmp'oz); the result is the amount of oil you should drain lrom the new compressor(throughthe suctionfittrngl. Replacethe O-ringswith new ones at each fitt i n g , a n d a p p l y a t h i n c o a t o { r e f r i g e r a n to i l before installingthem. Be sure to use the right (R-134a) to avoid leakage. O-ringsfor HFC-134a (SP-10) for R-134aKEIHINspiUse refrigerantoil ral type compressorsonly. To avoid contamination,do not returnthe oil to the containeronce dispensed,and never mix it with other refrigerantoils. lmmediatelyafter using the oil, replacethe cap on the container.and seal it to avoid moisture aDsorprlon. Do not spill the refrigerantoil on the vehicle;it may damagethe paint; if the retrigerantoil contacts the Daint,wash it off immediately. Adjust the Ay'Ccompr'essorb€lt (see psge 22-69) and the power steeringpump belt {see section 17t. and test its Chargethe system (seepage 22-611, performance(seepage 22-56]-.
Gompressor lllustratedIndex
CENTER NUT Replace. ARMATUREPLATE Inspection,page 22-65
sHtM{s) Replace. SNAPRINGB Replace.
ROTORPULLEY Inspection.page 22-65
SNAPRINGA Replace.
FIELDCOIL Inspection,page 22-65
THERMALPROTECTOR Replace. Inspection,page 22-55 Replacement, page22-68
---------------coMPRESSOR (Donotdisassemble.)
O.RING Roplace. RELIEFVALVE Replacement,page 22-68 RELIEFVALVECOVER ('97modelonly.)
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22-64
ClutchInspection Checkthe plated parts of the armature plate for color changes,peelingor other damage.lf there is damage,replacethe clutchset.
.
Releasethe field coil connectorfrom the holder,then disconnectit. Checkthe thermal protectorfor continuity, lf there is no continuity, replacethe thermal prorecror.
Checkthe rotor pulley bearing play and drag by rotating the rotor pulley by hand. Replacethe clutch set with a new one if it is noisy or has excessiveplay/drag.
ROTOR
Measurethe clearancebetweenthe rotor pulley and the armature plate all the way around. lf the clearanceis not within specifiedlimits,the armatureplate must be removed and shims added or removed as required,following the procedureon page 22-66. Cloarance:0.5 t 0.15 mm {0.020t 0.q)6 in)
NOTE:The thermal protectorwill have no continuity above 251.6to 262.4"F1122to 128"C).When the temperaturedrops below 240.8to 219.8"F(116to 104'C), the thermalprotectorwill havecontinuity. Checkresistance of the field coil. Field Coil Resistance:3.2 i 0.15 ohms at 68"F {20'C) lf resistanceis not within specifications, replacethe field coil.
NOTE:The shims are availablein four thicknesses: 0.1 mm. 0.2 mm. 0.4 mm and 0.5 mm ABMATUBE
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22-65
Compressor GlutchOverhaul 1.
Removethe centernut while holdingthe armature platewith the tool. CENTERNUT 17.6N.m ('1.8kgf.m, 13lbfft) A,/CCLUTCHHOLOER Reolace. \ lCommerciallY.vailable) Robinair:P/N 1020,0 Ked-Mooro: P/N J37872 i
2.
Removethe armatureplateby pullingit up by hand. ARMATUREPLATE
sHtMls) Replace.
za:s (i@,
22-66
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3.
Removethe snap ring B with snap ring pliers. Be careful not to d8mage the rotor pulley and compressor.
SNAPRINGB R6place.
Remove the rotor pulley from the shaft with the tools.Be surethe clawsot the pullerare on the back of the rotor pulley,not on the belt area;otherwise the rotor pulleycan be damaged.
l5.
Removethe bolt and holder,and screw and clamp. then disconnectthe field coil connector.Remove the snap ring A with snap ring pliers,then remove the field coil. Be carefulnot to damagethe field coil and comoressor.
6.
Positionthe rotor pulleysquarelyover the field coil. Pressthe rotor pulley onto the compressor boss with the specialtool. lf the rotor pulley does not press on straight, remove it, and check the rotor pulleyand compressorbossfor burrsor damage. CAUTION: Maximum pre3s load: 39,200 kPa (400kgf/cm,, 5,690psi)
+ Press
FIELDCOIL CLAMP
HUB ASSEMBLY GUIDEATTACHMENT 07966 - 6920500 ROTOR PULLEY
HOLDER
GROUND TERMINAL 7,a N.m 10.75kgt'm, 5 tbt ftl
7.
Reassemblethe comDressorclutch in the reverse order of disassembly.Make note of the following rrems. Installthe field coil with the wire side facing down, and alignthe bosson the tield coilwith the holein the compressor. C l e a nt h e r o t o r p u l l e ya n d c o m p r e s s o sr l i d i n g surfaceswith non-oetroleum solvent. a lnstallnew snap ringsA and B. a Make sure the snap rings are fully seatedin the groove. Make sure that the rotor pulley turns smoothly afterit's reassembled. Routeand clamp the wires properlyor they can be damagedby the rotor pulley.
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Compressor ThermalProtectorReplacement 1.
Removethe bolt,the groundterminaland the holder. Disconnectthe field coil connector.then remove the thermalDrotector.
ReliefValveReplacement l.
Recoverthe refrigerant with a Recovery/Recycling/ ChargingSystem(seepage22-59). Removethe reliefvalvecover ('97 model),the relief valve and the O-ring.Plug the openingto keepforeign matterfrom enteringthe systemand the compressoroil from runningout.
7.4 N.m (0.75kgrf.m,5lbfftl GROUND TERMINAL
O.RING Replace.
RELIEF VALVE 9.8 N.m {1.0hgf.m, 7.2 rbr.ftl
Cleanthe matingsurfaces. ReDlace the thermal protectorwith a new one, and apply siliconesealantto the bottom of the thermal orotector,
Replace the O-ringwith a new one at the reliefvalve, a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l b e f o r e installingit. Removethe plug. and installand tighten the relief valve. Put the cover on the relief valve so that the arrow d i r e c t sd o w n w a r d s a s s h o w n i n t h e i l l u s t r a t i o n above('97 model). 7.
SILICONESEALANT
3.
lnstallin the reverseorderof removal.
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22-68
Chargethe system (see page 22-61),and test its performance(seepage 22-561r.
A/C CompressorBelt Adjustment Detlection Method 1.
Apply a force of 98 N (10 kgf, 22 lbfl, and measure the deflectionbetweenthe A,/CcomDressorand the crankshaftpulley. A/C CompressorEelt UsedBeh:7.5- 10.5mm (0.30- 0.41inl New Belt: 5.0 - 7.0 mm (0.20- 0.28 in) Notetheseitemswhen adjustingbelttension: . lf there are cracksor any damageevidenton the belt,replaceit with a new one. . "Used belt" means a belt which has been used for five minutesor more. . "New belt" means a belt which has been used for lessthan five minutes.
Loosenthe pivot bolt of the idler pulleybracketand the locknutofthe adjustingbolt. Turn the adjustingbolt to get properbelttension, Retightenthe pivot bolt of the idler pulley bracketand the locknutofthe adiustingbolt.
Tension Gauge Method 1.
Attachthe specialtool to the Ay'Ccompressorbelt as shown below,and measurethe tensionof the belt. A/C ComoressorBelt Used Belt; 390 - 540 N (40 - 55 kgf, 88 - 120 lbtl New Belt: 740 - 880 N (75 - 90 kgf, 170- 200 lbt) Notetheseitemswhen adjustingbelttension: . F o l l o wt h e m a n u f a c t u r e r 'isn s t r u c t i o n fso r t h e belttensiongauge. . lf there are cracksor any damageevidenton the belt,replaceit with a new one. . "Used belt" means a belt which has been used for five minutesor more. . "New belt" means a belt which has been used for lessthan five minutes.
BELTTENSIONGAUGE 07JGG- 00't010A
Loosenthe pivot bolt of the idler pulley bracketand the locknutofthe adjustingbolt. Turn the adjustingbolt to get properbelttension.
Recheckthe deflectionof the A,/Ccompressorbelt, Retightenthe pivot bolt of the idler pulley bracketand the locknutofthe adjustingbolt. Recheck the tensionof the A,/Ccompressorbelt.
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22-69
Gondenser Replacement 't. Recoverthe refrigerantwith a recovery/recycling/
6.
chargingststion(seepage22-59) Removethe front grille (seesection20).
Removethe mounting bolts,then removethe condenserby lifting it up as shown. Be carefulnot to d a m a g e t h e r a d i a t o r a n d c o n d e n s e rf i n s w h e n removingthe condenser.
Removethe coolant reservoii,but do not disconnect the reservoirhose Jrom the coolant reservoir and the radiator. Removethe bolts and the suction line bracketas s h o w n . R e m o v et h e b o l t s a n d t h e u p p e r m o u n t brscketsfrom the radiator. 6xl.0mm 9,8 N.m 11.0kgf'm' 7.2lbf'ft)
1,0mm
MOUNT UPPER BRACKETS Remove each bolt, then disconnectthe discharge and condenserlines from the condenser,Plug or them cap the lines immediatelyafter disconnecting to avoid moistureand dust contamination. 6x1.0mm 9.8 N.m 11,0kgf.m,7.2 lbfttl
t\,
6x1.0mm
7.
Installin the reverseorderof removal.Make note of the followingitems. . o
l/
a it--:
. .
i..
.
LINE DISCHARGE
CONDENS€RLINE
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22-70
lf you'reinstallinga new condenser,add refrigerant oil (sP-10)(see page 22-54].. Replacethe O-ringswith new ones at each fitt i n g , a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l before installingthem. Be sure to use the right (R-134a) to avoid leakage. O-ringsfor HFC-134a Be careful not to damagethe radiatorand condenserfins when installingthe condenser. Be sure to install the lower mount cushionsof condensersecurelyinto the holes, Chargethe system(seepage 22-61),and test its performance(seepage22-56).
Body Electrical SpeciafToofs ,...,..,.............-.23-2 Troubleshooting Tips and Precautions......,.,..........,.................. 23-3 Five-stepTroubleshooting........,.,.,...,,.,......... 23-5 Wire ColorCodes ...,....,.. 23-5 Relay and Control Unit Locations EngineCompartment..,.,......,......................... 23-6 Dashboard ,.,.,..............-.23-7 Door....................... .........23-10 Index to Cilcuits and Sysiems AccessorySocket.. ,....,.,..,.,. 23-95 *Airbags................ .,....,.Sestion24 Air Conditioning ,.,.,.... Section22 Alternator ................... Section4 Anti-lockBrakeSystem{ABSI ................... Section19 'A/T GearPositionIndicator....................... Section1,1 AutomaticTransmission System ...........,.. Section14 B a t t e r y. . . . . . . . . . . . . . . . . . . ..............23-50 BlowerControls .,...,.,, Section22 ChargingSystem .......Seqtionil Clock-'98 Model ................ 23-98 Connectorldentification and Wire Harness R o u t i n g. . . . . . . . . . . . . . . . . . . . . . . . .2. .3 . 1 1 CruiseControl ............ Ssction4 DashLightsBrightnessContlo||er..................... 23-90 FanConlrols ...,......,.... Section10 FuelPump ,..,.,...,....,.... Section11 Fuses...................... .,,.,.,.,.,,.,23-40 *Gauges CircuitDiagram ......-....-..23-58 FuelGauge .....,.,..... Section11 Speedometer ..,..........,... 23-56 GroundDistribution ,....,.,...23-46 HatchGlsssODenor.........................,.,.,.,.,..,.,.,.,,. 23-121 HeaterControls .-........ Soction21 *Horns.,...,..,.,.,....... ................23"104 *fgnitionSwitch ,,.,.,..,.,.,,.,.,.,23-51 lgnitionKey Light System-'97 Mod6l .............. 23.88
+ BODY
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SpecialTools
Ret. No.
o
Description
Tool Numbel OTLAJ PT3O2OA
23-2
I
PageReference 23-62,63
TestHarness
o
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Oty
Troubleshooting Tips and Precautions Before Troubleshooting . Checkapplicablefuses in the appropriatefuse/relay box. . Checkthe batteryfor damage,state of charge,and clean.and tight connections. . Checkthe alternatorbelttension.
N e v e r t r y t o d i s c o n n e c ct o n n e c t o r sb y p u l l i n g o n their wires;pull on the connectorhalvesinstead. Alwavsreinstallolasticcovers.
CAUTION: . Do not quick-chargea battery unless the battery ground cable has been disconnected,otherwise you will damage the alternator diodes. . Do not attempt to crank thc engins wilh the battery ground cable loosely connected or you will severely damagethe wiring. Handling Connestors . Makesurethe connectorsare cleanand haveno loose wire terminals, . N4ake sure multiplecavityconnectorsare packedwith grease(exceptwater-tightconnectors). . All connectorshavepush-downreleasetype locks.
Beforeconnectingconnectors,make sure the terminalsare in placeand not bent.
LOCKINGTAB
. S o m e c o n n e c t o r sh a v e a c l i p o n t h e i r s i d e u s e d t o attach them to a mount bracketon the body or on anothercomponent.This clip hasa pull type lock. Some mounted connectorscannot be disconnected unlessyou first releasethe lock and removethe connectorfrom its mount bracket.
Checkfor looseretainersand rubberseals.
RETAINER
T h e b a c k s o f s o m e c o n n e c t o r sa r e o a c k e d w i t h grease.Add greaseif necessary. lf the greaseis con taminated.reolaceit.
LOCKING PAWLON OTHER Pullto HALFOF disengage CONNECTOR
BRACKET
{cont'd}
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23-3
Troubleshooting Tips and Precautions(cont'dl Insen the connectorall the way and make sure it is securelyIocked. Positionwires so that the open end of the coverfaces down.
V
Slip pliers under the clip base and through the hole at an angle,then squeezethe expansiontabs to releasethe clrD.
After installingharnessclips, make sure the harness doesn'tinterferewith any moving pans. Keep wire harnessesaway from exhaustpipes and other hot parts, trom sharp edges of bracketsand holes.and from exoos€dscrewsand bolts.
Seatgrommetsin their groovesproperly.
NOT GOOD
A
Face openend
Handling Wires and Harnesges . Securewires and wire harnessesto the frame with wire ties at the designatedlocations. their respective . Removeclipscarefully;don't damagetheir locks.
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.
lr
-M/
lr*
T€sting and Repairs . Do not usewires or harnesses with brokeninsulation. Replacethem or repairthem by wrappingthe break with electricaltape. . A f t e r i n s t a l l i n gp a r t s ,m a k e s u r e t h a t n o w i r e s a r e pinchedunderthem. . W h e n u s i n g e l e c t r i c a tl e s t e q u i p m e n t ,f o l l o w t h e manufacturer'sinstructionsand those describedin t h i sm a n u a l . . lf possible,insert the probe of the tester from the wire side (exceptwaterproofconnector).
.
Usea probewith a taperedtip.
Referto the instructionsin the HondaTerminalKit for i d e n t i f i c a t i o an n d r e p l a c e m e not f c o n n e c t o rt e r m i nals.
Five-stepTroubleshooting 1.
VerifyThe Complaint Turn on all the componentsin the problemcircuitto verify the customercomplaint.Note the symptoms. Do not begin disassemblyor testinguntil you have narroweddown the problemarea. AnalyzeThe Schematic L o o k u p t h e s c h e m a t i fco r t h e p r o b l e mc i r c u i t . Determinehow the circuit is supposedto work by t r a c i n gt h e c u r r e n tp a t h sf r o m t h e p o w e r f e e d throughthe circuitcomponentsto ground.lf several circuitsfail at the sametime, the fuse or ground is a likelycause, Basedon the symptomsand your understandingof the circuitoperation,identifyone or more possible causesof the problem.
3.
4.
lsolateThe ProblemBy TestingThe Circuit Make circuitteststo checkthe diagnosisyou made in step 2. Keepjn mind that a logical,simple procedure is the key to efficienttroubleshooting. Test for the most likely cause of failure first. Try to make testsat pointsthat are easilyaccessible, FixThe Problem Once the specificproblem is identified,make the repair.Be sure to use propertools and safe procedures. MakeSureThe CircuitWorks Turn on all componentsin the repairedcircuitin all modes to make sure you've fixed the entire problem. lf the problem was a blown fuse, be sure to test all of the circuitson the fuse.lvlakesure no new problemsturn up and the originalproblemdoes nol recur.
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Wire ColorCodes T h e f o l l o w i n ga b b r e v i a t i o nasr e u s e d t o i d e n t i f yw i r e colorsin the circuitschematics: W H T . . . . . . . . . . . . . . . . . . . .W . . .h. i. t. e. . . Y E L , . . . . . . . . . . . . . . . . . . . .Y. .e. .l .l o . .w ... B L K . . . . . . . . . . , . . . . . . . . . .B. .l.a. .c.k. . . B L U . . . . . . . . . . . . . . . . . . . . .B. .l.u. .e. . . . GRN.............................Green R E D. . . . . . . . . . . . . . . . . . . . .R. .e. .d. . . . . ORN.............................Oran9e P N K . . . . . , . . . . . . . . . . . . . . .P. .i n . .k. . . . . B R N. . . . . . . . . . . . . . . . . . . . .B. .r.o. .w. .n. . G R Y. . . . . . . . . . . . . . . . . . . . .G . .r. a. .y. . . . P U R. . . . . . . . . , . . . . . . . . . . .P. .u. .r .p. l. e. . L T B L U. . . . . . . . . . . . . . . . . .L, i.g. .h. .tB. l u e L T G R N . . . . . . . . . . . . . . . . .L. .i .g.h. .tG . reen T h e w i r e i n s u l a t i o nh a s o n e c o l o r o r o n e c o l o r w i t h anothercolor stripe.The secondcolor is the stripe.
WHT/BLK
Relayand ControlUnit Locations EngineCompartment ELECTRICAL LOADDETECTOR IELDI
UNIT
UNDER.HOOD FUSE/RELAY BOX
t:
tr tr ; tr BLOWER MOTOR RELAY
A/C COMPRESSOR CLUTCHRELAY
UNDER.HOOD ABS FUSE/RELAY BOX
''r@
D
l--\ r rr r
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23-6
RADIATOR FAN EELAY
Dashboard
PGM.FIMAIN RELAY
MOTORHIGHRELAY BLOWER lwir. colorc:BLK/YEL, I ORN/WHT,.ndBLKI LBLU/BLK,
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23-7
Relayand GontrolUnit Locations Dashboard(cont'd)
HEATERCONTROLPANEL
RELAY REARWINDOWDEFOGGER
-rj,r1 Iu
/-\,r1 lJ-JlJ
r*t
WINDOWRELAY
CONTROLUNIT INTEGRATEO
23-8
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TURNSIGNAL/HAZARDRELAY
DAYTIMEBUNNINGLIGHTS CONTROLUNIT (Canrda){'98 - (X)modok) IGNITIONKEYLIGHT CONTROLUNIT l€7 model)
OAYTIMERUNNINGLIGHTS CONTROLUNIT lcanad!l l'97 modell
CRUISECONTNOLUNIT
HORNBELAY137 modell
Iwiro color3:WHT/GRN, I GRY,andBLU/REDI IWHT/GBN,
STARTERCUT RELAY{'98 - 00 modelsl IWir6 color3:BLK/WHT,BLK^ UHT,I STARTEnCUTRELAYl€7 mod€ll I lGRY,.nd BLx/nED lwire colors:BLK/WHT,BLK/WHY,l I IGRY,and BLK/RED HORNFELAYl'98 - 00 modcb) lwire coloF: WHT/GRN, l LWHT/GRN,GRY,and BLU/REDI
{cont'd)
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23-9
Relayand ControlUnit Locations Dashboard(cont'd)and Door
REARACCESSORY SOCKETRELAY I Wire colors:YEL/GRN, J IWHT/BLK.BLK,.nd YEL/BLUl
REVERSE RELAY {A/TI I WirecolonrYEI-/RED, I IYEL/RED,YEL,.nd GRN/BLKI
REARWINDOWWIPER CONTROLUNIT 137 mod.ll INTERLOCX CONTROLUNIT
KEYIISS/POWER DOORL(rcK CONTROL UNIT
23-10
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Gonnectorldentificationand Wire HarnessRouting
How to ldentity Connectors: "C" for connectors. The numberis precededby the letter numbershavebeenassignedto all connectors, ldentification "G" for groundterminalsor "T" for non-groundterminals. Location Harness
EngineCompartmsnt
Startercable
T 1 ,T 2 a n d@
Batterygroundcable
G 1 a n dO
Enginegroundcable
T3
groundcable Transmission
T4 G3
Enginewire harness
C 1 0 1t h r o u g hC 1 3 7 T 1 0 1a n dT 1 0 2 G101
Enginecompartmentwareharness
C201throughC218 G201and G202
Under-hoodABS fuse/relaybox wire harness
t5ano9
Main wire harness
C301throughC309 C351throughC361
Dashboardwire harness
Dashboard
C401throughC447 G401and G402 C501throughC524(C525) G501
Leftsidewire harness
C551throughC581 G551,G552and G553
Rightsidewire harness
C601throughC605
lnteriorwire harness
C701throughC703
Rearbumperwire harness
C641throughC643
Heatersub-harness
C731throughC740 C721through C722
Secondaryheatedoxygensensor sub-harness Combinationswitchsub-harness
C751throughC760
Driver'sdoor wire harness
C661throughC667
door wire harness Frontpassenger's
C6Tl throughC676
Left reardoor wire harness
C681throughC684
Rightreardoor wire harness
C69'lthroughC694
Rearwire harness
C611throughC520
Tailgatewire harness
C631throughC634 G631
SRSmain harness
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Others lFloor, Door, 8oof, Tailgate)
C801throughC808 G801
High mount brakelight sub-harness
C651throughC653
Fueltank oressuresensorsub-harness
C645throughC647
Connectorldentificationand Wire HarnessRouting
Starter Cables Connoctoror Terminal
Number of Cavities
T1
Location
Connectsto
r2
Rightside of enginecompartment Rightside of enginecompartment
Under-hoodfuse/relaybox Starter motor
o
Battery
Batterypositiveterminal
Notes
Battery Ground Cable Connoctoror Terminal
Numberof Cavities
GI
Location
Conneqtslo
Rightfront shocktower
Bodyground,via batteryground cable
Battery
Batterynegativeterminal
Notes
EngineGroundCable Connectoror Terminal
Numb6r ol Cavities
T3
Location
Connectsto
Leftsideof engine
Powersteeringpump bracket
Leftside of enginecompartment
Bodyground.via engineground caote
Notes
TransmissionGround Cable Connsstor o. Terminal
Number of Cavities
T4
Location
Connectsto
Rightside of enginecompartment
Transmission
Rightside of front frame
Body ground,via transmission groundcable
Notes
Under-hoodABS Fuse/RelayBox Wire Harnsss Conn6storor Terminal
Numberof Cavities
Location
Connoctsto
tc
Rightside of enginecompartment
Under-hoodABS tuse/relavbox
@
Battery
88tterypositiveterminal
23-12
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Notos
STARTERCABLE ABS FUSE/RELAY UNDER-HOOD BOX WIREHARNESS @
EATTERY GROUND CABLE
ENGINEGROUND CABLE TRANSMISSIONGROUND CABLE
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23-13
Connectorldentificationand Wire HarnessRouting
EnginoWire Harness Connecto; or Terminal
c101 c102 c103 c104 c105 c105 c106 c 107 c 108
Number of Cavities 10 6
1
2
c 109 c]10 c1l'l c112 c113 c ' t1 4 cl16 cl16 c117 c118 c119 c120 c121 c't22 c't23 c't25 cl26 cl27 cr28 cl29 c130 c131 c132 c 133 c134 c134 c135 c 136
Location
Conneqtsto
Leftside of enginecompartment Leftside of enginecompartment Middleof engine Middleof engine Leftsideof enginecompartment Leftsideof enginecompartment Middleof engine Middleof engine Middleof engine
Main wire harness(C304) - 98 models Mainwire harness(C305):'97 No. 1 fuel injector Crankshaftspeedfluctuation(CKF)sensor Alternator Alternator Engineoil pressureswitch No.2 fuel injector Evaporative emission(EVAP)purge controlsolenoidvalve No. 3 fuel injector No. 4 fuel injector Primaryheatedoxygensensor (PrimaryHO2S)(sensor1) Radiatorfan switch Coolanttemperaturesendingunit Enginecoolanttemperature(ECT)sensor Mainshaftspeedsensor Lock-upcontrolsolenoidvalve Back-uplight switch Shift controlsolenoidvalve Linearsolenoidvalve Countershaftspeedsesnsor Startersolenoid Distributor Junctionconnector PCM ECIWPCM ECM/PCM ECM/PCM Main wire harness(C,|:}1) IVT gear positionswitch Vehiclespeedsensor(VSS) Throttleposition(TP)sensor MAP sensor ldleair control(lAC)valve lntakeair temperature(lAT)sensor Junctionconnector Junctionconnector
Middleof engine Middleof engine M i d d l eo f e n g i n e
1
2
1 10 20
31 16 22 l0
l0 '14
Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Rightsideof engine Middleof engine Behindright kickpanel Underright side of dash Underright side of dash Underright side of dash Underright sideof dash Underright sideof dash Rightsideof engine Rightsideof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine
14 1
Leftsideof en0inecompanment Alternator Rightsideof enginecompartment Under-hoodfuse/relaybox
G101
Middle of engine
23-14
A/r USA Canada
Alr AlT
M/'r Afi
'97 mooel
'97 model '98 - 00 mooets
Leftsideof enginecompartment Powersteeringpressure(PSP)switch Middleof engine Junctionconnector Middleof engine Knocksensor(KS)
T101 r102
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Notos
Engineground,via enginewire harness
'99 - 00 models
c1733 clsl gra,
c103 c137 T101
c104
c112 ENGINEWIREHARNESS
cl13
cl' l1
23-15
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lrffiltEfinl,
Gonnectorldentificationand Wire HarnessRouting
EngineCompartment Wire Harness Connectorol Terminal
Number of Cavities
c20'l c202 c203 c204 c205 c206 c207 c208 c209 c210
14
c212 c213 c2't4 c215 c216
2 2
1 'l
2
c217 c21A c218 G201 G202
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23-16
10
Location
Connectsto
Leftside of enginecompartment Main wire harness(C307) Leftside of enginecompartment Cruiseactuator Behindfront bumper Rearwindow washermotor Behindright headlight Leftfront turn signal/sidemarkerlights Behindfront bumper Windshieldwashermotor Behindright headlight Leftfront parkinglight Leftsideof enginecompartment Condenserfan motor Leftsideof enginecompartment Frontfog lights Leftsideof enginecompartment IVC compressorclutch Behindleft headlight Left headlight Leftsideof enginecompartment IVC pressureswitch Behindfront bumper Left horn Behindfront bumper Righthorn Rightside of enginecompartment Radiatorfan motor Behindright headlight Rightheadlight Behindright headlight Rightfront turn signal/sidemarker lights B e h i n dr i g h th e a d l i g h t Rightfront parkinglight Rightsideof enginecompartment Main wire harness1C357) Rightsideof enginecompadment Main wire harness(C357) Rightsideof enginecompanment Bodyground,via enginecompartment wire harness Leftside of enginecompartment Bodyground,via enginecompartment wire harness
Notes
Optional
'97 - 98 models '99 - 00 mooets
ENGINECOMPARTMENT WIREHARNESS
c212
c211
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23-17
Gonnectorldentificationand Wire HarnessRouting Main Wire HarnesslEngine compartmont left and right branches) Connectot ol Terminal
Number ot Cavities
c301
5
c303 c304 c305
2 10
c306 c307 c308 c309
c356 c357
c358 c359 c360 LJO
I
G35l
23-18
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Conneqtsto
Leftside of enginecompartment Leftsideof enginecompartment Leftside of enginecompartment Leftside of enginecompanment Leftside of enginecompartment
Windshieldwiper motor Daytimerunninglightsresistor Test techometerconnector Enginewire harness(C10]) Enginewire harness(C102):'97 - 98 models Left front ABS wheel sensor Enginecompartmentwire harness(C201) Brakefluid level switch {-) Brakefluid levelswitch(+) Under-hoodfuse/relaybox (C908) Under-hoodfuse/relaybox (C906) Under-hoodfuse/relaybox (C905) Under-hoodfuse/relaybox (C907) ABS modulatorunit ABS pump motor Enginecompartmentwire harness(C218)
8
Leftside of enginecompartment Leftside of enginecompartment Leftsideof enginecompartment Leftside of enginecompartment Rightsideof enginecompartment Rightsideof enginecompartment Rightsideof enginecompartment Rightsideof enginecompartment Rightsideof enginecompartment Rightsideof enginecompartment Rightsideof enginecompartment
10
Rightside of enginecompartment
'14 1 1 t1
c352 c354
Location
3 10
2
Rightsideof enginecompartment Rightsideof enginecompartment Rightsideof enginecompartment Rightsideof enginecompartment Rightside of enginecompartment
Not€s
Canada
ABS
USA ABS ABS '97 - 98 models Enginecompartmentwire harness(C218) '99 - 00 mooets Rightfront ABS wheelsensor ABS Under-hoodABS fuse/retaybox (C931) ABS Under-hoodABS fuse/relaybox (C9321 ABS '98 Evaporative emission(EVAP)contro 00 canistervent shutvalve mooets Bodyground,via main wire harness ABS
UNDEB.HOOD FUSE/RELAY BOX
MAIN WIREHARNESS branch) G351
MAIN WIREHARNESS {left branch}
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23-19
Connectorldentificationand Wire HarnessRouting Main Wire Harn€ss(left side of dash and floor branchesl{cont,dl
c401 c402 c403 c404 c404 c405 c406 c407 c408 c409 c410 c410 c411 c412 c413
5 20 20 24 't4 8 5 3
12
Behindleft kickpanel Behindleft kickpanel Behindleft kickpanel Behindleft kickpanel Behindleft kickpanel
Startercut relay Horn relay Leftsidewire harness(C558) Leftsidewire harness(C559) Leftsidewire harness(C559)
Underleft side of dash Underleft side of dash Underleft sideof dash Underleft side of dash Underleft side of dash Underleft side of dash Underleft sideof dash
Cruisecontrolunit Daytimerunninglightscontrolunit Daytimerunninglightscontrolunit lgnitionkey light controlunit Interiorwire harness{C701) Cablereel Cablereel
Underleft side of dash Underleft side of dash Underleft sideof dash
c413
Underleft side of dash
c414 c415 c416 c416 c417 c418 c419 c420
Underleft side of dash Underleft side of dash Underleft side of dash Underleft sideof dash Underleft side of dash Underleft side of dash Underleft sideof dash Underleft side of dash
10 '1 18 20 '18 10
c420 c421 c422 c423 c424 c425 c42A c426
15 1 4 8 5 5
Underleft side of dash Underleft sideof dash Underleft side of dash Undermiddleof dash Undermiddleof dash Undermiddleof dash Undermiddleof dash Undermiddleof dash
c437 c438
22
Underleft side of dash Underleft side of dash
c438 c439 c440 c441 c442
Underleft side of dash Underleft side of dash Underleft sideof dash Underleft sideof dash Underleft side of dash Underleft side of dash Underleft side of dash Underleft sideof dash Underleft side of dash Underleft side of dash Underleft side of dash
23-20
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'97 model '98 - 00 mooets Canada Canada '97 model '97 model '98 00 models
lgnitionkey switch lgnitionkey switch '97 Combinationswitchsub-harness {C753) 98 models Combinationswitchsub-harness (C753) '99 - 00 moqets SRSmain harness(C803) Dashboardwire harness(C503) Dashboardwire harness(C501) Dashboardwire harness{C501) Under-dash fuse/relaybox (C922) Under-dash fuse/relaybox (C920) '97 model Under-dash fuse/relaybox (C919) '98 - 00 lntegratedcontrolunit mooets Integratedcontrolunit Optional Frontfog lightsswitch Brakeswitch Interlockcontrolunit Reverserelay Rearaccessorysocketrelay Rearaccessorysocketrelay Rearheatedoxygensensorsubharness(C722) Optional Securitycontrolunit Optional Securitystarter cut relay (for security alarmsystem) Junctionconnector(for interlocksystem) Optional Securitywire harness Optional '97 model Securitywire harness Rearwindow wiper controlunit Combinationswitchsub-harness(C760) '97 - 98 mooels Combinationswitch sub-harness(C760) '99 - 00 models Securltyindicator Optional Securityvalet switch Optional Clutchinterlockswitch Mfi Clutchswitch(forcruisecontrol) Mlr Bodyground,via main wire harness
MAIN WIREHARNESS
c115 cla6 c+to "n,
dn' cntt
I --r F -'L-1al 1l}a] a
UNDER-DASH FUSE/BELAYBOX
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-n-rrr---rrr
-:/l -
Connectorldentificationand Wire HarnessRouting
Main Wire Harness{Right side of dash and floor branchesl{cont,dl Connector or Tsrminal
Number ol Cavities
c427
25
Frontpassenger's door
c428 c429 c430 c431 c432 c433 c434 c435 c436 c436
6
Behindright kickpanel Behindright kickpanel Behindright kickpanel Behindright kickpanel Underright side of dash Under.ight side of dash Undermiddleof dash U n d e rm i d d l eo f d a s h Undermiddleof dash Undermiddleof dash
Frontpassenger's door wire harness (c671) Rightsidewire harness{C601) ABS controlunit ABS controlunit Enginewire harness(C127) PGM-Flmain relay JUnotronconnector Tailgateopen relay Headlightsf lasherrelay (C731) Heatersub-harness (C731) Heatersub-harness
c447
Behindright kickpanel
ECM/PCM
G402
Underright side of dash
Body ground,via main wire harness
23-22
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26 22 7 20
5 7
Location
Connectsto
Notes
ABS ABS
Optional Optional '97 model '98 00 models '98 00 mooets
MAIN WIREHARNESS
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23-23
Connectorldentificationand Wire HarnessRouting DashboardWire Harness Connectorol Terminal
Numb€r of Cavities
c501 c501 c502 c503 c504 c505
10 1 20
c506 c507 c508 c509 c510 c511 c512 c514
14
Main wire harness(C416) Main wire harness(C416) Under-dashfuse/relaybox 1C912) Main wire harness(C415) Hatchglassopenerswitch Left side wire harness(C556)
16
Above under-dashfuse/relaybox
Leftsidewire harness(C556)
Left side of steering wheel Left side of steering wheel Underleft side of dash Behindgauges Behindgauges Behindgauges Behindgauges Behindgauges Rightside of gauges Behindmiddleof dash Behindmiddleof dash Behindmiddleof dash Undermiddleof dash Undermiddleof dash Behindmiddleof dash Behindmiddleof dash Behindmiddleof dash Behindmiddleof dash Behindmiddleof dash
Dashlightsbrightnesscont.oller Cruisemain switch Junctionconnector Gaugeassembly Gaugeassembly Gaugeassembly Gaugeassembly Gaugeassembly Hazardwarningswitch Audio unit Heatercontrol panel Heatercontrol panel Datalink connector Servicecheckconnector Front accessorysocketconnector Ashtraylight Heatersub-harness(C733) Heatersub-harness {C740} Heatersub-harness(C740)
Behindgauges Uppermiddleof dash
Gaugeassembly Clock
Behindmiddleof dash
Bodyground,via dashboardwire harness
6 20 13 5 t6 14 10
20 16 2 24 2 1
c524
G501
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23-24
Conngctsto
Above under-dashfuse/relaybox Above under-dashfuse/relaybox Above under-dashfusehelaybox Above under-dashfuse/relaybox Behinddashboardlower panel Above under-dashfuse/relaybox
to
c518 c519 c520 c521
Location
5
Notes
Mir
'97 - 98 models '99 - 00 models
A/r
'97model '98- 00 mooets '98- 00 models
DASHBOARD wlRE HART{ESS
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23-25
Connectorldentificationand Wire HarnessRouting
Left Side Wire Harness ConnectoroI Terminal
Number of Cavities
c551 c552
8 16 10 14 'I
Locaiion
Connectsto
14
Behindunder-dash fuse/relay box Behindunder-dash fuse/relay box Left side of steeringwheel Left side of steeringwheel Left side of steeringwheel Above under-dashfuse/relaybox
fuse/relaybox (C921) Under-dash fuse/relaybox (C923) Under-dash Powermirror switch Powerwindow masterswitch Powerwindow masterswitch Dashboardwire harness{C505)
16
Above under-dashfuse/relaybox
Dashboardwire harness1C505)
c558 c559 c559
20 20 24
Driver'sdoor Behindleftkickpanel Behindleftkickpanel Behindleftkickpanel
Driver'sdoor wire harness(C661) Main wire harness(C403) Main wire harness(C404) Main wire harness(C404)
c560
) 1 5
Left side offloor Leftquanerpanel Fueltank On left half of rearcrossbeam On left half of rearcrossbeam
Driver's seat belt switch Left rear door switch F u e lu n i t Left rearABS wheelsensor Left rearABS wheelsensor
1 1
Leftquarter panel Leftquarter panel Leftquarter panel Leftquarter panel Leftquarter panel Leftquarter panel On left half of rearcrossbeam Rightquarterpanel Rightquarterpanel Leftquarter pillar Leftside of floor Left B-piller Left B-piller Behindleftkickpanel
c554 c556
Not6s
'97 - 98 mooets '99 - 00 models '97 model '98 - 00 models
c562 c563 c563
'97 model '98 - 00 models
c564 c565 c566
c578
Underleftsideof dash
Rearaccessorysocketconnector{+} Rearaccessorysocketconnector (-) Rearbumperwire harness1C641) Trailerlightingconnector Tailgatedoor latchswitch Left rear speaker RightrearABS wheelsensor Rearwire harness(C611) Rightrea. door switch Lefttaillight Parkingbrakeswitch Leftreardoor wire harness(C681) Driver's door switch Selectunlockrelay(for securityalarm system) Junctionconnector(for power door locks) SRSmain harness(C807)
c579
LeftB-piller
Driver'sseat belttensioner
c580
Fueltank
c581
Leftside of steeringwheel
Fueltank pressuresensorsub-harness (c645) Power window master switch
G551
Behindleftkickpanel Left side ot floor Leftquarterpiller
Bodyground,via left sidewire harness Bodyground,via left sidewire harness Body ground,via left sidewire harness
c568 c569 c570 c572 c573 c574 c575 c576
6 1 2 14 1 1 6 1
6
G553
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23-26
Behindleftkickpanel
Optional
'98 - 00 mooets '98 - 00 models '98 - 00 mooets '99 - 00 mooets
c553 c5:6 c5J5
C561 C565 C566 LEFTSIDEWIREHARNESS
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23-27
Gonnectorldentificationand Wire HarnessRouting
Right Side Wire Harness Connec{oror Tsrminal
Numberof Cavities
c601 c602 c603 c604
6 '1
Location
Conneststo
2
Behindright kickpanel RightB-piller Rightreardoor Undermiddleof dash
Main wire harness(C428) door switch Frontpassenger's Rightreardoor wire harness(C691) SRSmain harness{C808)
2
R i g h tB - p i l l e r
seatbelttensioner Frontpassenger's
Notes
'98 - 00 mooets '98 - 00 models
Rear Bumper Wire Harness Connectorol Terminal
c641 c642 c643
Number ot Cavities 4 2 2
Location Leftquarterpanel Behindrearbumper Behindrearbumper
FuelTank PressureSensor Sub-harnessConnectoror Terminal
Number ot Cavities
c645 c646 c647
?
2
Connoctsto
Notes
Leftsidewire harness(C566) Leftrearside markerlight Rightrearside markerlight
'98 Model Location
Fueltank Leftside of fuel tank Leftside of fuel tank
Connectsto
Not63
Leftsidewire harness(C580) Fueltank pressuresensor emission(EVAP)bypass Evaporative solenoidvalve
High Mount Brake Light Sub-harnoss Conneslor or Terminal
Number of Cavities
c651 c652 c653
2
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23-28
1 1
Location Top of hatchglass Top of hatchglass Top of hatchglass
Connec-tsto High mount brakelight Rearwire harness(C617) Rearwire harness(C618)
Notes
HIGHMOUNT BRAKELIGHT SUB-HARNESS
RIGHTSIDEWIBEHARNESS
FU€LTANK PRESSURE SENSORSUB.HARNESS
REARBUMPERWIREHANNESS
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23-29
Gonnectorldentificationand Wire HarnessRouting
RearWiro Harness Connectoror Terminal
Number of Cavities
Location
Connectsto
c61l c612 c613 c614
14 2
c617
1
r anel R i g h tq u a r t e p r anel R i g h tq u a r t e p r anel R i g h tq u a r t e p R i g h tq u a n e rp i l l e r Rightside of hatchglass Middleof hatchglass Top of hatchglass
c618
'I
Top of hatchglass
c619 c620
1
Leftside of hatchglass Roofarea
Leftsidewire harness(C57'l) Rightrearspeaker Tailgatewire harness(C631) Rightaillight Rearwindow defogger(+) Rearwindow wiper motor High mount brakelight sub-harness (c652) Hjgh mount brakelight sub-harness {c653) Rearwindow defogger(-) R e a rc e i l i n gl i g h t
r iller R i g h tq u a r t e p
Bodyground,via rearwire harness
6 1
G611
Notes
Tailgate wire Harness Connestoror Terminal
c633 c634
23-30
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Numberof Cavities
2 2 1
Location
Connectsto
Rightquarterpanel Middleof tailgatedoor Leftsideof tailgatedoor Middleof tailgatedoor
Rearwire harness(C613) Hatchglassopenersolenoid Licenseplatelight Hatchglasslatchswitch
I/iddle of tailgatedoor
Body ground,via tailgatewire harness
Noles
TAILGATEWIREHARNESS
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23-31
Connectorldentificationand Wire HarnessRouting
Drivsr's Door Wire Harness Connectoror Terminal
Number of Cavities 25 4
c664 at
c667
18
Location Driver'sdoor Driver'sdoor Driver's door Driver's door Driver's door Driver's door Driver's door
Connoctsto
Notes
Leftsidewire harness{C557) Left front speaker Driver'spowerwindow motor Driver's door lock actuator Driver's door lock switch Driver's power mirror actuator Keyless/power door lockcontroluni
Front Pa$enger's Door Wire Harnsss Connectoror T6rminal
c671 c612
Number ot Cavities 2^
c674 c675 I
Location Frontpassenger's door Frontpassenger's door Frontpassenger's door Frontpassenger's door Frontpassenger's door Frontpassenger's door
Connectsto Main wire harness(C4271 Rightfront door speaker Front passenger'spower window motor Frontpassenger's door lockactuator Front passenger'spower window switch Front passenger'spower mirror actuator
DBIVEB'SDOORWIRE HARNESS
6tt
23-32
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inliiioint""
Notes
o,-
Left Rear Door Wile Harness Conneclor or T€rminal
c681 c6a2 c683 c684
Numbor of Cavities 2 5
Location Left rear door Leftreardoor Left rear door Left rear door
Connectsto
Notos
Leftsidewire harness{C575) Leftrearoowerwindow motor Left rear door lock actuator Left rear oower window switch
Right Real Door Wire Harness Connectoror Terminal
c691 c692 c694
Number of Cavitios
Locstion Rightreardoor Rightreardoor Rightreardoor Rightreardoor
LEFTREARDOOR WIRE HARNESS
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Conneststo Rightsidewire harness(C603) Rightrearpowerwindow motor Rightreardoor lockactuator Rightrearpowerwindow switch
Notos
Connectorldentificationand Wire HarnessRouting
lntglior Wire Harness Connectoror Terminal
Numb€r of Cavities
Location Underleft sideof dash Roofarea Roofarea
c701 c702 c703
Connoct3lo
Notes
Main wire harness(C409) Frontceilinglight Spotlights
SocondaryHeatedOxygen Sensor Sub-harfl€ss Connoqto. ol Tarminal
Numbor ot Cavities
Location
c721
Undermiddleof dash
c722
Undermiddleof dash
23-34
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Connectsto Secondaryheatedoxygensensor {SecondaryH02S)(Sensor2) Main wire harness(C426)
Notos
OXYGENSENSOR
SUE.HARNESS www.emanualpro.com
23-35
Connectorldentificationand Wire HarnessRouting
Hoat6rSub-harness Connectoror Tgrminal
Numbsrot Cavities
c73'] c731
5 7
Undermiddleof dash Undermiddleof dash
Main wire harness{C436) Main wire harness(C436)
c732 c733 c734 c735 c736 c737 c738 c739 c740
7 24
Behindmiddleof dash Behindmiddleof dash Behindglove box Behindglove box Behindglove box Behindglove box Behindglove box Behindglove box Behindmiddleof dash
Modecontrolmotor Dashboardwire harness(C522) Air mix controlmotor Evaporatortemperaturesensor Blowermotor high relay Blower motor Powertransistor controlmotor Recirculation Dashboardwire harness(C523)
c740
1
Behindmiddleof dash
Dashboardwire harness(C523)
Localion
Connectsto
Notes '97 model '98 - 00 modsls
'97 model '98- 00 mooels
Combination Switch Sub-harness Conneqtor ol Terminal
c751 c753
c754 c755 c756 c757 c758
Number of Cavities
Location
6 7 12
Above under-dashfuse/relaybox Above under-dashfuse/relaybox Underleft side of dash
fuse/relaybox (C914) Under-dash fuse/relaybox {C915) Under-dash Main wire harness(C413)
10
Underleft sideof dash
Main wire harness(C413)
2
Behindsteeringcolumn Behindsteeringcolumn Behindsteeringcolumn Behindsteeringcolumn Behindsteeringcolumn Behindsteeringcolumn Underleft side of dash
Shift locksolenoid Parkingpin switch Combinationlight switch Combinationlight switch Wiper/washerswitch Wiper/washerswitch Main wire harness(C442)
Underleft side of dash
Main wire harness(C442)
7 6 8
c760 c760
23-36
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5
Conneststo
Notos
'97 - 98 mod6ls '99 - 00 models
'97 - 98 models '99 - 00 models
Ol-
i
I
f-
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Connectorldentificationand Wire HarnessRouting
SRS Main Haln93s
Conn€Gtoro1 Terminal
Numbor of Cavities
c801
t
Location
Connectsto fuse/relaybox (C911) Under-dash
Leftside of under-dash fuse/relaybox Top of under-dashfuse/relay box Underleft sideof dash Underleft sideof dash Behindglove box Middleof floor Underleft sideof dash
Main wire harness{C414) Cablereel Frontpassenger's airbag SRSunit Leftsidewire harness(C578)
c808
Undermiddleof dash
Rightsidewire harness(C604)
G801
Middleof floor
Bodyground,via SRSmain harness
c802 c803 c804 c805 c806 c807
23-38
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18
Notes
Memoryerasesignal{MES)connector
'98 - 00 mooets '98 - 00 mooets
SRSMAINHARNESS
D\
n ll-
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/
23-39
Fuses Under-hoodFuse/RelayBox ALTERNATOR lTo engine wire harness{T102)l
BATTERY lTo slarter cableslTlll
DEn r-'l
tr tr tr
IJ
11
IJ
r'1 51 LI
r-'l 56 IJ
r-'l 57
LJ
cro1
lTo blower motor releyl
lTo condens€rtan .slayl
c903 lTo radiator ten relavl
.: Not used
NOTE:View from the backsideof the under-hoodfuse/relaybox.
c306 fTo main wiro hamose(C352ll
c305 lTo mainwiie harnes lc353ll
lTo main wirc harness1C354)l
23-40
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lTo main wire harnesslC351ll
Under-dashFuse/RelayBox c912 wire harness{C502ll lTo dashboard c914 lTo
c911 lToSRSmainharness{C801)l
switchsub-harness {C751ll
c915 switchsub-harness lTo combinatioo 1C752)l
r'=G@6
G
T"r r-1 T't r't r-l r-r r't r;l Fl T1 r-l r-l 23
21
25
21
26
28
29
30
31
33
32
rr Ll tJ tJ LJ Ll lJ LJ t-J LJ u Ll
- r-l n rT n Tl r-l ri n Fl r-'l r-l 12 13
1a
16
t5
11 1a 19
20
21 22
L-] [J LI LI I.J I.J tJ tJ TJ LI LI IJ - Fn Fl F1 r-'l T1 r;l r-l r-t r;l |-] r-l |
a; Canada
2
3
1
5
6
7
a
9
1
0
r
c9r6 [Topowe.windowrelay]
l
LI I.J LI LJ tJ LJ IJ LI I.J IJ IJ tJ
i -': C927loption {ACCll C928lOption (lG2)l 141:
lTo rear window defoggerrelayl
NOTEr View from the backside of the under-dash tuse/relay box.
c924 lTo integraledconttolunitl
c922 1C417)l lTomainwireharness
(css1)l
c919 lTo mainwire herness1C419)l
c920 lTo main wire harness1C418)l
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Fuses Under-hoodABS Fuse/RelayBox
lTo under-hoodABS fus6/r6lay box wire harnessl
c931
c933
lTo main wire harness1C359)l
lTo ABS pump moto. relayl
c932
lTo main wire harness(C360)l
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23-42
PowerDistribution Index(numericalsequence) Fuse-to-Gomponent(sl Under-hood Fuse/RolayBox: Capacity
wiro Color
43
'100A 40A 7 . 5A
WHT/BLK WHT/RED
44
1 5A
WHT/BLK
46 47
40A 7 . 5A
WHT/BLU WHT/BLU
48
30A
WHT
204 204
WHT/GRN WHT/GRN
52
1 5A
WHT/GRN
53 54
10A 40A
WHT/BLK WHT/RED
50
40A 204
BLU/WHT WHT RED BLK/RED
Fuse 41
49 50
20A
Circuit(s)Prot€cted A lgnitionswitch(BAT) lntegratedcontrolunit Ceilinglights Spotlights PGM-Flmain relay Not used No. 7, 8, 10,11fuse in the under-dashfuse/relaybox A u d i ou n i t Clock{'98- 00 models) Datalinkconnector('98- 00 models) ECM(VBU){'98- 00 models:M/T) Heatercontrolpanel PCM (VBU)(A./T) Combinationlight switch(via under-dashfuse/relaybox) No. 20,33 fuse in the under-dashfuss/relaybox Not used Rearwindow defogger(viarelay) Door lockcontrolunit Hatchglassopenersolenoid Keylessdoor lockcontrolunit ('98- 00 models) Horn relay Horns(via relay) via brakeswitch: ABS controlunit Brakelights Cruisecontrolunit ECM ('98 - 00 models: M/T) Highmount brakeiight PCM(4./T) Trailerlightingconnector relay(viaswitch) Turn signal/hazard Optionconnector(+B) No. 6 fuse in the under-dashfuse/relaybox Blowermotor (viarelay) Condenserfan motor (viarelay) Ay'Ccompressorclutch (via relay) Radiatorfan motor (viarelay)
Under-hoodABS Fuss/nehy Box: Fusg
Capacity
61
40A 204 7 . 5A
Wire Color
Circuitls) Protoct
WHT WHT/GRN BRN/YEL
ABS pump motor {via relay} ABS controlunit ABS controlunit
{cont'd)
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23-43
PowerDistribution Fuse-to-Component(sl Index(numericalsequencel(cont'dl Under-dashFuse/RelayBox:
Fuse
Capacity
Wire Color
1
3
1 0A
"^
1 0A
RED/B LU
5
1 0A
RED/GRN
6 7 I 9 10 11
1 0A 20A 204 15A 204 204
WHT/BLK RED/VVHT YEUBLK RED GRN/BLK BLU/BLK
12 13
7 . 5A '15A
14
7 . 5A
YEVBLK YEUGRN RED BLK/YEL
7 . 5A
BLK/VVHT
7 . 5A 7 . 5A
BLVBLU
17
BLKA/EL
18 19
7.54 7.54
YEUBLK YEVRED
l0A 1 0A
BLKAr'YHT RED/VHT RED/YE L
20 22
23-44
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Circuit{s)Protected Not used Not used Rearwindow washermotor (viaswitch) Rearwindow wiper controlunit ('97 model) Rearwindow wiper motor Daytimerunningrightsresister{Canada) R i g h th e a d l i g h{tH i g hb e a m } Daytimerunningrights resister(Canada) High beam indjcatorlight Left headlight(Highbeam) Rearaccessorysocket(viarelay) Left rearpowerwindow motor (viaswitch) Rightrear powerwindow motor (viaswitch) Distributor(ignitioncontrolmodule) powerwindow motor (viaswitch) Frontpassenger's Driver'spowerwindow motor {viaswitch) Powerwindow masterswitch(powerwindow controlunit) Turn signal/hazard relay(viaswitch) PGM-FImain relay SRSunit (VA) Cruisecontrolunit (viaswitch) Cruisemain switchindicatorlight Alternator Chargingsystemlight E L Du n i t( U S A ) EVAPbypasssolenoidvalve('98- 00 models) EVAPcontrolcanistervent shutvalve('98- 00 models) EVAPpurgecontrolsolenoidvalve PrimaryHO2S SecondaryH02S VSS ABS controlunit Optionconnector(lG2) Ay'Ccompressorclutch relay Blowermotor high relay Blowermotor relay Condenserfan relay Heatercontrolpanel Left power mirroractuators(viaswitch) Mode controlmotor Radiatorfan relay Recirculation controlmotor Rightpower mirror actuators(viaswitch) Daytimerunninglightscontrolunit (Canada) Back-uplights Reverserelay (A"/T) Daytimerunninglightscontrolunit (Canada) R i g h th e a d l i g h(tL o wb e a m ) Left headlight(Low beam)
under-dash Fuse/RelayBox: Fuse
Capacity
wir6 Color PNK
25
1 0A 7 . 5A 7 . 5A
;
204 GRN/BLK
10A 28
YEUGRN
10A
YEURED 29 30
7.5A
a, olrL"
7 . 5A
BLU,ryVHT
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7 . 5A
RED/GRN
7 . 5A
WHT/GRN
Circuit(sl Protocted SRSunit (VB) Powerwindow relay IntegratedControlUnit ABS indicatorlight A/T gear positionindicatorlight Clock('98- 00 models) Cruiseindicatorlight Gaugeassembly Interlockcontrolunit (A,/T) Keylessdoor lockcontrolunit ('98- 00 models) Powerdoor lockcontrolunit Shift locksolenoid(lVT) SRSindicatorlight Integratedcontrolunit ('98- 00 models) Integratedcontrolunit (viawindshieldwiper switch) Windshieldwashermotor (viaswitch) Windshieldwiper motor Front accessorysocket Rearaccessorysocket relay Optionconnector(ACC) Audio unit Not used Optionconnector(dashlights) Integratedcontrolunit Ashtraylight A,/Tgear positionindicatorlight Audio univclock('97model) Audio unit ('98- 00 models) Clock('98- 00 models) Cruiseindicatorlight Cruisemain switchlight Dashlightsbrightnesscontrolunit Gaugelights Hazardwarningswitchlight Heatercontrolpanel Powerwindow masterswitchlight ('99- 00 models) Integratedcontrolunit ECM('98- 00 models:M/T) PCM (4./T) PGM-Flmain relay Leftfront pa.kinglight Leftfront side markerlight Left rearside markerlight Lefttaillight Licenseplatelight Rightfront parkinglight Rightfront side markerlight Rightrearside markerlight Rightaillight Trailerlightingconnector lgnitionkey light lgnitionkey light controlunit ('97model) Interlockcontrolunit (via ignitionswitch) Key interlocksolenoid
23-45
GroundDistribution Ground-to-Component(sl Index Ground
Wire Color
G2 G3 G1 0 ' l
BLIVRED BRN BLK BLK
BRN/BLK
G201
BLK
G202
BLK
G351
BLK
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23-46
Component or Circuits Grounded Battery ValveCover Transmissionhousing A,/Tgear position switch ECM(PG1,PG2)('98- 00 models:M/T) PCM(PG1,PG2l(Avrr) PGM-FImain relay Powersteeringpressure(PSP)switch Radiatorfan switch VSS Datalinkconnector ECM(1G1,LG2)('98- 00 models:M/T) PCM(LGI, LG2)(IVT) Shielding: between ECM ('98 - 00 models: M/T) or PCM (Ay'T)and CKFsensor betweenECM{'98- 00 modets:M/T}or pCM (Ay'T) and CKpsensor between ECM ('98 - 00 models: M/T) or PCM (rVT)and CYPsensor betweenECM ('98 - 00 models: M/T) or PCM (Ay'T)and TDC sensor between ECM {'98 - 00 models: M/T) or PCM (ly'T)and countershaftspeed sensor (Ay'T) between ECM ('98 - 00 models: M/T) or PCM{A,,/T) and mainshaftsp€ed sensor {!VT) between ECM ('98 - 00 models: M/T) or PCM(A,/T)and primary HO2S between ECM ('98 - 00 models: M/T) or PCM(Ay'T)and secondaryHO2S H o r n( H i g h ) Horn {Low} Radiatorfan motor R i g h th e a d l i g h t Rightfront parkinglight Rightfront side markerlight Rightfront turn signallight Condenserfan motor Cruiseactuator Leftfront parkinglight Leftfront side markerlight Leftfront turn signallight Leftheadlight Rearwindow washermotor Windshieldwashermotor ABS pump motor
Ground
Wir€ Color
G401
BLK
G402
BLK
Component or Circuits Grounded ABS indicatorcircuit ABS controlunit Ashtraylight A/T gear positionindicatordimmingcircuit Brakefluid levelswitch Clock('98- 00 models) Clutchinrerlockswitch(M/T) Clutchswitch(Mff) Cruisemain switch Cruiseindicatorcircuit Cruisecontrolunit Dashlightsbrightnesscontroller Dataiink connector Daytimerunningrightscontrolunit (Canada) Front accessarysocket Gaugeand indicators Heatercontrolpanel lgnitionkey light controlunit ('97model) lgnitionkey switch Integratedcontrolunit Interlockcontrol unit (Ay'T) Parkingpin switch{A,/T) Powerwindow relay socketrelay Rearaccessary Bearwindow defoggerrelay Rearwindow wiper controlunit ('97model) Servicecheckconnector Spotlights SRSindicatorcircuit relay Turn signal/hazard Windshieldwiper motor Windshieldwiper/washerswitch - plus everythinggroundedthrough G402 ABS controlunit Blowermotor relay Blowermotor high relay E L Du n i t( U S A ) Powertransistor - plus everythinggroundedthroughG401
{cont'd)
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23-47
GroundDistribution Ground-to-Component(sl Index(cont'dl Ground
Wire Color
G501
BLK BLK
G552
BLK
BLK
BLK
BLK G801
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23-48
BLK
Component or Circuits Grounded Audio unit Driver'sdoor lockactuator(doorlockknob switch) Driver'sdoor lockswitch Driver'spowerwindow motor Keylessdoor lockcontrolunit ('98- 00 models) Powerdoor lockcontrolunit Powermirror switch Powerwindow masterswitch Driver's seat belt switch F u e lg a u g es e n d i n gu n i t Fuelpump (FP) Leftrearside markerlight Lefttaillight Rearaccessary socket Rightrearside markerlight Trailerlightingconnector High mount brakelight Rearwindow defogger Rearwindow wiper motor Rjghtaillight - plus eveMhing groundedthroughG631 Hatchglassopenersolenoid Licenseplatelight - plus eveMhing groundedthroughG6l1 SRSunit
Box Fuse/Relay Under-dash Removal/lnstallation 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 SRS componentlocations,precautions,and procedures in the SRSsection(241beforeperformingrepairsor service.
I
Installation: 1.
C o n n e c t h e c o n n e c t o r st o t h e u n d e r - d a s hf u s e / relay box (seesection24 for the SRSmain harness connector),then install the under-dashlusehelay box in the reverseorderof removal.
2.
lnstallthe knee bolsterand the driver'sdashboard lower cover(seesection20).
3.
Connectthe batterypositivecable,then connectthe negativecable.
4.
Enterthe anti-theftcodefor the radio,then enterthe customer'sradiostationpresets(with anti-thettfeature).
5.
Confirmthat all systemswork properly
Removal: 1.
Makesureyou havethe anti-theftcode for the radio, then write down the frequenciesfor the radio'spreset buttons(with anti-theftfeature).
2.
Disconnectthe batterynegativecable,then disconnectthe positivecable,and wait at leastthree minutes.
3.
4.
Removethe driver'sdashboardlower cover and the kneebolster(seesection20). Removethe two mountingnuts,and pull the underdashfuse/relaybox out from underthe dash
D i s c o n n e ctth e c o n n e c t o r sf r o m t h e u n d e r - d a s h fuse/relaybox (seesection24 for the SRSmain harnessconnector),and take out the under-dashfuse/ relayoox.
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23-49
Battery Test
@M . Battery fluid (eleqtrolyte)contains sulturic acid. lt may couse sevore . .
burns if it gets on your skin or in your eyes. Wear protective clothing and a fac6 shield. - lf elestrolyte gets on your skin o. clothos, rinse it otf with wator imm€diately. - lf €leqtrolyte gets in your eyes.tlush it out by splashing water in your syes for at least 15 minutes; call a physician immediately. A battery gives off hydrogon gas. lf ignited, the hydrogen will €xplode and could crack the battery case and splatt€r acid on you. Kgop sparks.flamss, and cigarettesaway from the batt€ry, Overchargingwill raise the tomperatute of the electrolyte.This may torcs electrolyto to spray out of the battEry vents, Follow the charger manutacturer'sinstructions, and chargethe battery at a proper ral€,
Use eithera JCI or BearARBSTtester,and follow the manufacturer's procedures.lf you don't have one of tnesecomputerizedtesters,follow this conventionaltest procedure: To get accurateresults,the temperatureofthe electrolytemust be between70.F(21.c)and loo"F (38"c).
lf the caseis crackedor the terminalsare roose. replacethe batterv.
CheckIndicatorEYEColor lf the indicatorshows low electrolyte, add distilled water if possible. EYEIndicatesOK
Test LoadCapacity(#1) . Apply 300amp load for 15 secondsto removesurface charge. . Allow 15 secondsrecoveryperiod. . Apply test load (seeTest LoadChart). . Recordvoltageat the end of 15 seconos. Voltagestaysabove9.6 volts;batteryis OK.
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23- 5 0
(},
Chargeon High Setting(40amps) Chargeuntil EYEshowschargeis OK,plus an additional30 minutesto assureJullcharge. to bypass NOTE:lf the batterychargeis very low, it may be necessary the charger'spolarityprotectioncircuitry. lf the EYEdoes not show chargeis OK within three hours,the batteryis no-good;replaceit. Writedown how long the batterywas charged.
Test Load Capacity(#2) . . . .
Apply 300amp load for 15 secondsto removesurfacecharge. Allow 15 Secondsrecoveryperiod, Applytest load (seeTest LoadChart). Recordvoltageat the end ot 15 seconds.
Voltagestaysabove9.6volts; battery is OK.
Voltagedropsbelow9.6volts; batteryis no-good,
J-
TESTLOAD CHART Usethe test load or use 1/2the cold crankingamps (CCA)printedon the labelon the top of the battery.lf neitheris indicated.usethe informationbelow:
BATTERY CODE 55
COLDCRANKING AMPS (CCA)
TESTLOAD {amps)
410
200
BATTERYCODE
i 5582{LtS)-MF
J
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23-51
PowerRelays RelayTest NOTE:See page23-86for turn signal/hazard relay input IESI.
Normally-opontype: '1.
. .
Blowermotor relay Rearwindow defoggerrelay type 1:
Checkfor continuitybetweenthe terminats. . Thereshouldbe continuitybetweenthe No. I and No. 3 terminalswhen power and groundare connectedto the No. 2 and No. 4 terminals. . Thereshouldbe no continuitybetweenthe No. 1 and No. 3 terminalswhen power is disconnected.
Terminal
\
t"""r f*r
t*i__\
l
H
3
Disconnected Connected
o type 2i
a Blowermotor high relay a Rearaccessory socketrelay(M/T) a l
2
\
Itrrz-Hl llHrrUll Y:F,
' , 3
ffi 23-52
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a l
Normally-opentype:
Normally-opentype: 1.
Checkfor continuitybetweenthe terminals. . Thereshouldbe continuitybetweenthe No. 1 and No. 2 terminalswhen power and groundare con nectedto the No.3 and No. 4 terminals . Thereshouldbe no continuitvbetweenthe No. 1 and No. 2 terminalswhen power is disconnected.
Terminal
\
t.*", ^"-
t*f
1
1.
tl**^-*
o
Powerwindow relay Radiatorfan relay Condenserfan relay A,/Ccompressorclutchrelay Reverserelay (A/f) Horn relay Rearaccessorysocketrelay {A,/T) a Startercut relay
\K, www.emanualpro.com
-_\
Disconnected
Drsconnected
a a a a a
Terminal
\
2
\
Connected
Checkfor continuitybetweenthe terminals. . Thereshouldbe continuitybetweenthe No. 4 and No.3 terminalswhen power and groundare connectedto the No. 1 and No. 2 terminals. . Thereshouldbe no continuitybetweenthe No. 4 and No. 3 terminalswhen power is disconnected.
o
Connected
.
ABS pump motor relay
3
o- ---o
lgnition Switch Test
ElectricalSwitch Replacement
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{24}beforeperformingrepairsor ser vtce. L l M a k es u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e radio'spresetbuttons(wilh anti-theftfeature). 2. Disconnect the batterynegativecable. 3. Removethe driver'sdashboardlower coverand the kneebolster{seesection20). 4. Disconnectthe 5P connectorfrom the under-dash fuse/relaybox and the 3P connectorfrom the main wtre narness,
SRS componentsare located in this area. Review the SRScomponentlocations,precautions,and procedures in the SRSsection{24)beforeperformingrepairsor service.
3P CONNECTOR
1.
M a k e s u r e y o u h a v e t h e a n t i - t h e t tc o d e f o r t h e r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e radio'spresetbuttons(with anti-theftfeature).
2.
Disconnect the batterynegativecable.
3.
Removethe driver'sdashboardlower coverand the kneebolster(seesection20).
4.
Disconnectthe 5P connectorfrom the under,dash tuse/relaybox and the 3P connectorf.om the main wire harness{seeleft column). R e m o v et h e s t e e r i n gc o l u m n c o v e r s( s e es e c t i o n '17 t. Insertthe ignitionkey,and turn it to "0".
7.
Removethe two screws and the electricalswitch from the steeringlock,
5P CONNECTOR
Wiresideof temaleterminals Checktor continuitybetweenthe terminalsin each switchpositionaccordingto the table. rernrnal I
\ ros[ron
\
I3l
5
3
(ACC) {BAT} flG1) 0G2i
I1l
swrTcH
lsrl
LOCKCYLINDER
0 (LocK)
r(Accl
o- -o
fl (oN)
G
III(START)
o-
_o -.o
{ I | 3Pconnector
7.
lf the continuitychecksdo not agreewith the table, replacethe electricalswitch. After reconnectingthe battery,enter the anti-theft code for the radio,then enter the customer'sradio stationpresets(with anti-theftfeature).
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23-54
lnstallin the reverseorderof removal. 9.
After reconnectingthe battery,enter the anti-theft code for the radio,then enter the customer'sradio stationpresets(with antj-theftfeature).
GaugeAssembly ComponentLocationIndex and proceduresin the SRS SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions, section{24}beforeperformingrepairsor service. I x 1.25mm 24 N.m {2.4 VEHICLESPEEDSENSOF{VSS' page23-62 Troubleshooting,
GAUGEASSEMBLY Gauge/lndicator/Terminal LocationIndex,page 23-56 page23-57 BulbLocations, Removal,page23-61 FUELGAUGESENDINGUNIT Seesection1l
J-
PARKINGBRAKESWITCH
GAUGE COOLANTTEMPERATURE SENDINGUNIT
BRAKEFLUIDLEVELSWITCH SWITCH ENGINEOIL PRESSURE
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GaugeAssembly Gauge/lndicator/TerminalLocationIndex "A" CONNECTOR {A/T GEABPOSITIONINDICATOR) a1___-__-____>816
cl--------->cl3
JilililIJililil1 JililtHililL ..
"€""^
,
o
o
t)1- --->t)5
u e
E1- - -->E5
"DCONNECTOR {ABS INDICATOR)
"E" CONNECTOR {CBUISEINDICATOR'
SPEEDOMETER: Indicates 60 km/hat 637 rpm or 60 mph at 1,026rpm ofthe vehiclespeedsensor(VSS).
oo/
TACHOMETER: lndicates100rpm at 200pulsesper minute of the ignitioncontrol module(lCM).
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23- 5 6
\oo
o u
Fl---->F5
"F" CONNECTOR {SRSINDICATOR}
l-
Bulb Locations
TAILGATEINDICATOR LIGHT(,I.4W) CHARGING SYSTEMLIGHT(1.4WI GAUGELIGHT{1.4WI
SEATBELT REMINDERLIGHT{1.' W'
GAUGELIGHTI1,4WI
BRAKESYSTEM LTGHT 11.4Wl HIGHBEAM INDICATORLIGHT { 1 . 4W l
LOW ENGINEOIL PRESSURE INDICATORLIGHT{1./rW} MALFUNCTION INOICATOR LAMP {MIL) BULBI1.4WI
LOW FUELINOICATOB LIGHT13WI
LEFTTURN SIGNAL INDICATORLIGHT{1,4W}
RIGHTTURNSIGNAL INDICATORLIGHTI1.' WI
GAUGELIGHT
t3wl
1,. f-=\
GAUGELIGHTS13WI A/T GEARPOSITION INDICATOR {1.12x 7} (Onthe printed GAUGELIGHT{3.' W} circuitboard) (1,4W) ABSINDICATOR lOn the printedcircuitboard)
F -
SRSINDICATOR('1./tW) (Onthe printedcircuitboard)
w) cRutsEtNDtcAToR 11.r2 (On the printed circuit board)
J
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23-57
GaugeAssembly CircuitDiagram U N O E R . I I O OFDU S E / R E L8AOYX BATTERY
@*"
UNOER_DASH FUSEiNELAY BOX
N o . 4 1( 1 0 0 A ) N o . 4 2( 4 0 A )
YEL E5
'''
l-
|
I
J
CRUISE CONTROL UNIT
ABS CONTROL UNIT
G401 G4A2
23-58
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I
-I
-I DASHLIGHTS BRIGHTNESS CONTROLLER
| 0l
8LK BLU/RED
RED
ALTERNATOR
ASSEMSLY GAUGE
J
SRSUNIT
(}-.
tI -, I I T rJr--------11-.----..1'\-J
BLK/YEL I BLUMHT
BLKMHTJ 'i-
| g
l t Y
YEL_ TURN SIGNAU HAZARD WARNING
swrTcH
No.si10A) .--......_ FUSE LEFT
RIGHT
Y Y Y
IGNITION CONTROL I/lODULE IcM)
f7
I 1.,
BLU
MALFUNCTION INDICATOR tA[rP([,{tL) {1.4W1
l.,
CRN/ORN
I
PCM
COOLANT TEII,4PERATURE SENDING UNIT BLK
T G401 G402
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G552
(cont'd)
23-59
GaugeAssembly CircuitDiagram(cont'd)
GAUGE ASSEMBLY PREVIOUS PAGE
SEAT BELT REMINDER LIGHT (1.4W)
BRAKE SYSTEM LIGHT l1.4Wl
a1 \
\ ./
\J
/
7
TAILGATE INDICATOR LIGHT {1.4W}
' \ \
B6
Gnru;neo
I
f7
|
BED'BLU
I INTEGRATED I coNTRoL I UN|T
I
i oo,,#, i
I I l
L__c_o!l!g_yI'__l rcanada) t\
|
-l
|
R U I \ N | N0GG H T S
I
I
l v
REAR CEILING LIGHT
It tI
r-
REDIBLU
A I Jl FLUIO I SRAKE I LEVET SWITCH . Floaldown) I fCLOSED . Floal up J lLoPEN BLK
ABS CONTROL UNIT
+ G401 G402
23-60
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BLK
T tlsA)-
G552
I Glass open I rCLOSED closed toPEN : Glass I
TAILGATE LATCH swtTcH rTailsate openI fCLoSED I0PEN iTailsateclosed.J
Removal '1. Remove the two screwsfrom the instrumentpanel. 2.
Removethe instrumentpanelcarefullyto avoiddamagingthe clips.
3.
Tilt the steeringwheeldown with the tilt adjustmentlever.
4,
Spreada protectivecloth over the steeringcolumn.
5.
Removethe four mountingscrewsfrom the gaugeassembly.
6.
Pullthegaugeassemblyout, and disconnectall connectorsfrom it.
7,
Removethe gaugeassembly.
GAUGEASSEMELY
INSTRUMENT PANEL
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23-61
VehicleSpeedSensor(VSSI Troubleshooting Beforetesting,inspectthe No. 15 (7.5A) fuse in the underdashfuse/relaybox. T6st tho BLK wirei 1. Disconnectthe 3P connector from the vehiclespeedsensor {VSS). 2. Connect the test harness {07LAJ- PT3020A)only to the enginewire harness. 3. Connectthe FEDtest harness clip to the positiveprobe of an ohmmeter, 4. Checkfor continuitybetween the REDtest harnessclip and body ground.
TESTHARNESS OTLAJ- PT3O2OA REDTESTHARNESS
PROTECTIVE TAPE
Repairopen in the BLK wire betwGonthe vSS .nd G101.
GRNTESTHARNESS CLIP T.st the BLK/YELwire: 1. Connectthe WHT test harness clip to the positive probe of a vohmeter,and connectthe RED test harnessclip to the negative probe. 2. Turnthe ignitionswitchON (ll).
TESTHARNESS OTLAJ- PT3O2OA REO CLIP
WHT TESTHARNESSCLIP
ls there batteryvoltage?
Rep.ir op.n in th. BLK/YELwire betwaen the VSS rnd the und6rdash fuse/.6lav box.
Test the BLU/WHTwi.s: C o n n e c t h e G R Nt e s t h a r n e s s c l i p t o t h e p o s i l i v ep r o b e o f a voltmeter.and connectthe RED test harnessclip to the negative probe.
ls thereabout5 V or more?
(To next page)
23-62
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TAPE
Repairopen in the BLU/WHTwiro bstweon the VSS and PCM.
HARNESS
o-.
(Frompreviouspage) WHT TESTHARNESS CLIP
T6st the VSS: 1. Turn the ignition switch OFF. 2 , C o n n e c tt h e o t h e r t e s t h a r nessconnectorto the VSS, 3. Raisethe front and rearof the vehiclea , n d s u p p o r tj t w i t h safety stands. 4. Put the transmissionin neut r a l w i t h t h e i g n i t i o ns w i t c h
TESTHARNESS OTLAJ_ PT3O2OA BEDTESTHARNESS
ct-tP
GRNTESTHARNESS
PROTECTIVE TAPE
oN r).
5. Slowly rotateone wheel with the otherwheelblocked.
Doesvoltage pulse from 0 to approx,5 V or more?
Spoodom6torT6st: 1, Disconnect the 16Pconnector " B " f r o m t h e g a u g ea s s e m 2. Toucha probeto the BLUMHT wire. and connect it to body groundthrougha voltmeter. 3. Slowly rotate one wheel with the otherwheel blocked.
Doesthe meter indicatepulsing voltage?
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'BGAUGEASSEMBLY16PCONNECTOR
Wire sideof femaletermin6ls
R.p.ir opon in the BLU/WHTwire betwe€n the VSS and the 3oeedomgter.
BLU/WHT
I (v) It
23-63
Integrated Gontrol Unit CircuitDiagram-'97
Model tGNITtON SWlCrl
UNDER.HOOD FUSEiRELAY8OX BATTEFY
cr*"
I N o . 4 {' ' 0 0 4 )
l__*l;;T
\0.d2'40A) |
+!v_T w_T ELK
H-uTr.r--i=r-
I
BLKryEL
WINDSHIELD WIPER/ WASHEF 9WTTCH , OFF/INT INT
V
V
lo
,,.h\ WINDSHIELD ( il) WASHEB
SWITCH
Y
tt
l l
t
l
t
G F NBi L K
l
I
l-I
a g
WHTiBLK
YEL
3 BEMINDEB LIGHT (r 4w)
V
WHT]BLKWINDSHIELD WASHER I MOTOB I
NTERMITTENT WIPERRELAYCIRCUlT
KEY.IN/SEAT BELT andLIGHTS-ON BEMINDER CIRCUIT
RED/BLU
BLUMHT
BLK
DRIVER'S SEAT BELT
V
swtTcH
r Unbuckled f CLOSED ) (OPEN :Buckled -.1
WINDSHIELD WIPER MOTOR (As)
BL(
I
-tr -l
G401
23-64
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G552
<
-
ELK/WHT
COMBINATON LIGHTSWITCH
S'TARTEB CUT RELAY
\-/
I
RED/GRN
A,/rGEAR POSrr 0NSWTTCH (CLOSED :lnpostion Eor N)
1,,,,," Yilei'r
GRN/RED
I
.l-
. BNAKEFLUIO LEVELSWITCH . P A R K I NE GR A K E
(usA) swrTcH
NTEGRATED CONTROLUNIT
A8
BULB BRAKE CHECKCIFCUT
KEY.IN]SEAT BELTandLIGHTS'ON R E M I N D ECRR C UT
B1o PowER I LOCK BLU/RED DOOR CONTFOL UNT I
I
Y
J F r,r'tro
RED BLUi
/rh v
no* llon.
155,1'* I a C L O S E DK e y l n s e d e d
4
LTGRN/RED
t
"l\ u/
\oPEN | 8LK
POWER DOOR LOCK CONTROL UNIT
Keyrcmoved
LTGRN/RED
d[) !s-l
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t
_L :
LT
l
LEFT REAB 00OR SWITCH : Door opel f CLOSED \oPEN Doo'closed
l
-._ -
G40r www.emanualpro.com
23-65
IntegratedControlUnit CircuitDiagram-'98 - 00 Models FUSE/BELAY UNOER,HOOD 8OX EATTERY
N0.41(100A)
@*"
N0.42(40A)
-....+ WHT/BLK
WHT
WHT/RED
IJNDERDASHFUSEiBELAYBOX
GRN/BLK
WINDSH ELDWPER/
REAS WINDOW /.Fn WINDSHIELDWIPER ( il) WASHEF MOTOR
lo
gsHERlIrTcH . OFF/NT
f7
tt t
t
INT
SWITCH
f7 l
Y
WHT/BLK
l
l
-9
l
I LTGRN
BLU/BLKYEUBLU
INTEGFATED coNTsoLUNIT I 85
WINDSHIELD WASHEF MOTOR
t,,
I 83
INTERIT,IITTENT WIPER RELAY CIRCUIT
8LK
G401 G402
23-6 6
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f7
NEAFWINDOWINTERMITTENT WIPERRELAY CIRCUIT
WHT/BLK
COMBlNATION LIGHTSWIlCH
\-7
I
REO/GFN
GRY
I
GRN
I rql)
Y4-orot POSTT1ON
(A/T) SWTTCH I I . (cLosEDInposrlion Eor NI I CLUTCN INTERLOCK I I swrTcH(M,T) :Clulch I /CLOSED Dedal\ \lullydeprsssed I |
-"'-},,,,," YEL
SEATEELT REMNDER LIGHT (1.4W)
Y l1eff E
II
g v**JT" 8LK
{
6
Gl01(A,T)
f;iillrvrr
' BFAKEFLUID LEVELSWITCH 'PARKINB GR A K E
(usA) swrTcH
A6
INTEGRATED CONTROL UNIT
A8
\-
i KEY]N/SEAT BELTandLIGHTS.ON REMINDER CLRCUIT
I : *,
q
RED/BLU /BLU RED/BLU
FEO/BLU
I
dF)
Y* lsE
DRIVER'S SEAT BELT
swrTcH 13fr rcLosED
,,,[:ltrh::ffIxl,,'.l'"
l*,*,J I
B L UB/ E D
A Y
I cvro\
I
A
Y*,u,., | Bft_oi|l
(3!?i". sl:$P)l lHfi.#' ) Hrtrff"% l(3 l (OPEN
BtK
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T
: G40t G402
l
I
KEYLESS/POWER DOOB LOCK CONTROL UNlT
V
GFN/nED+-] LTGRN/R€D
t
d['\ \s.i
EF's l*'n
LTGRN/RED
l
4P'\
IFF^I'
13fft"Doo'open) l39P* :Door oper) | fCLOSED. ooe.) | fCLO#D.Door . Door dos€d, \oPE\ I
l--
. 000'closed, \oPE\ |
l --
Door ciosed,
IntegratedGontrol Unit Input Test -'97 Model SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions, and proceduresin the SRS section{24)beforeperformingrepairsor service. '1. Removethe driver'sdashboardlowercoverand the kneebolster(seesection20). 2.
Disconnect the 'l0Pconnectorfrom the inteoratedcontrolunit.
3.
Removethe integratedcontrolunit from the under-dashfuse/relaybox.
4.
Inspectthe connectorand socketterminalsto be surethey are all makinggood contact. . lf the terminalsare bent,looseor corroded,repairthem as necessary, and recheckthe system. .lftheterminalslookOK,makethefollowinginputtestsattheconnectorandthefuse/relayboxsocket. - lf any test indicatesa problem,find and correctthe cause,then recheckthe system. - lf all the inputtestsproveOK,the controlunit must be faulty;replaceit.
INTEGRATEO CONTROLUNIT
rOPCONNECTOR
femaleterminals
23-6 8
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All Systems: Cavity
Test condition
Wire
414
Test: Desiredr€sult
Underall conditions
Checkfor continuityto ground: Thereshouldbe continuity.
Under all conditions
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
lgnitionswitchON (ll)
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
A9
A6
Possiblecauseif result is not obtained . P o o rg r o u n d( G 4 0 1G , 402) . An open in the wire . Blown No. 43 (7.5A) fuse in the under-hoodfuse/relaybox . An open in the wire . Blown No. 25 (7.5A)fuse in the underdashfuse/relaybox . An open in the wire
Intermittent Wipol System: Cavity
B1
Wire
Tost condition
lgnitionswitchON (ll), and windshieldwiper BLU/BLK switchat OFF/lNT
lgnitionswitchON (ll)
82
BLUrur'HT
Test: Desiredresult Checkfor voltageto ground: Thereshouldbe batteryvoltage.
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
Possiblecauss if result is not obtained Elown No. 26 (20A)fuse in the under-dashfuse/relaybox Faultywindshieldwiper switch Faultywindshieldwiper motor An open in the wire Blown No.26 (20A) fuse in the under-dashfuse/relaybox Faultywindshieldwiper motor
Anopeninthewire B3
B4
YEVBLU
lgnitionswitchON (ll), and windshieldwipe. switch at INT
lgnitionswitchON (ll), and windshieldwasher WHT/BLK switchON
Checkfor voltageto ground: Thereshould be battery voltage.
Blown No. 26 (20A) tuse in the under-dashfuselrefaybox Faultywindshieldwiper switch An open in the wire
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
Blown No. 26 (20A) fuse in the under-dashfuse/relaybox Faultywindshieldwasherswitch An open in the wire
(cont'd)
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23-69
lntegratedControlUnit InputTest-'97 Model(cont'd) At----------+A7
Key-in/SeatBelt Reminder,Lights-on RemindorSystem: Wire
Cavity
A8
B7
RED/BLU
B9
GRN
8 1 0 BLU/RED
Test condition
Test: Desiredrosult
C o m b i n a t i olni g h t switchON
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
lgnitionswitchON {lll. and driver'sseatbelt switchunbuckled
Checkfor voltageto ground: Thereshouldbe 1 V or less.
lgnitionswitchON (ll), and driver'sseatbelt switchbuckled
Checkfor voltageto groundl Thereshouldbe 4 V or more.
Driver'sdoor open
Checkior voltageto ground: Thereshouldbe 1 V or less.
Driver'sdoor closed
Checkfor voltageto ground: Thereshouldbe 4 V or more.
lgnitionkey insened into the ignitionkey switch
Checkfor voltageto ground; Thereshouldbe 1 V or less.
lgnitionkey removed trom the ignitionkey swrtch
Checkfor voltageto ground: Thereshouldbe 4 V or more.
Possiblecause if re3ult is nol obtainod B l o w nN o . 3 0( 7 . 5A ) f u s ei n t h e under-dashfuse/relaybox Faultycombinationlight switch An open in the wire Poorground (G552) Faulty seat belt switch Blownseatbelt reminderlight bulb An open in the wire . Faultydriver'sdoor switch . An open in the wire
Poorground(G401,G,[02) Faultyignitionkey switch An open in the wire
Bulb CheckSystem (BrakeSystem Light): Cavity
Wire
A4
A13
23-70
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Test condition
T6st: DGsirgd rosult
lgnitionswitchON {ll), brakefluid reservoir full, and parkingbrake teveroown
Connectto ground:Brakesystem l i g h ts h o u l dc o m eo n .
lgnitionswitchat START(lll),and A/T gear position switchE or E
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
Possiblecause if resuh is not obtainod Blown No. 25 (7.5A) iuse in the under-dashfuse/relaybox Blown brakesystemlight bulb An open in the wire Blown No.31 (7.5A) fuse in the under-dashfuse/relaybox Faultystartercut relay FaultyA/f gear positionswitch P o o rg r o u n d( G 1 0 1 ) An open in the wire
InputTest-'98 - 00 Models and proceduresin the SRS SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions, section(24)beforeperformingrepairsor service. L
Removethe driver'sdashboardlower coverand the kneebolster(seesection20).
2.
'l5P Disconnect the connectorfrom the inteqratedcontrolunit.
3.
Removethe integratedcontrolunit from the under-dashfuse/relaybox.
4.
Inspectthe connectorand socketterminalsto be surethey are all makinggood contact. . lf the terminalsare bent,looseor corroded.repairthem as necessary, and recheckthe system. .lftheterminalslookOK,makethefollowinginputtestsattheconnectorandthefuse/relayboxsocket. lf any test indicatesa problem,find and correctthe cause,then recheckthe system. - lf all the input testsproveOK,the controlunit must be faulty;replaceit.
UNDER-DASH FUSE/RELAY BOX
A8<------A14 INTEGRATED CONTROLUNIT
YEL/BLU 15PCONNECTOR
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LT GRN
WHT/BLK
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IntegratedControl Unit InputTest-'98 - 00 Models(cont'dl YEL/BLU A 1- - - - - - - - >
A7
LT GRN
WHT/BLK GRN/BLK
LT GRN/REO Wiresideof femaleterminals
A8------->A14
WHT/BLK
BLU/RED
Key-in/Se8t Beft Reminder,Lights-on Remindol System: Cavity
Wire
A8
RED/BLU
814
B8
GRN
BLU/RED
Test condition
Test: Desiredresult
Possiblecaus€ it result is not obtained
Combinationlight switch ON
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
Blown No. 30 (7.5A) fuse in the under-dashfuse/relaybox Faultycombinationlight switch An open in the wire
lgnitionswitchON (ll), and driver'sseatbelt switchunbuckled
Checkfor voltageto ground: Thereshouldbe 1 V or less.
lgnitionswitchON (ll), and driver'sseat belt switchbuckled
Checkfor voltageto ground: Thereshouldbe 4 V or more.
Poorground{G552) Faulty seat belt switch Blownseatbelt reminderlight b ul b An open in the wire
Driver'sdoor open
Checkfor continuityto ground: Thereshouldbe continuity,
Driver'sdoor closed
Checkfor continuityto ground: Thereshouldbe no continuity.
lgnitionkey inserted into the ignitionkey swrtch
Checkfor voltageto ground: Thereshouldbe 'l V or less.
lgnitionkey removed from the ignitionkey switch
Checkfor voltageto ground: Thereshouldbe 4 V or more.
. Faultydriver'sdoor switch . An open in the wire
Poorground(G401,G402) Faultyignitionkey switch An open in the wire
Bulb CheckSystem lBrake System Lightl: Cavity
Wire
A4
A13
23-74
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Test condition
Test: Desiredresult
lgnitionswitchON (ll), brakefluid reservoir full, and parkingbrake leverdown lgnitionswitchat START(lll),and A,/Tgear position switchE or E
Connectto ground:Brakesystem l i g h ts h o u l dc o m eo n .
Blown No. 25 (7.5A) fuse in the under-dashfuse/relaybox Blown brakesystemlight bulb An open in the wire
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
Blown No. 31 {7.5A) fuse in the under-dashfuse/relaybox Faultystarter cut relay FaultyA,/Tgear positionswitch(A,/T) Faultyclutchinterlockswitch(M/T) Poorground{G101:AfI. G401and G402:M/T) An open in the wire
Possiblecaus€ if result is not obtained
LightingSystem
l-.
ComponentLocationIndex I{IGHBEAM INOICATORI-IGHT
DAYNMERUNNINGLIGHTS REslsToi lCan!drl Test,page23-80
COMBINATIONLIGHTSWTCH Test,page 23-78 DAYTIMERUNNINGLIGHTS CONTROLUNIT lCanadal Input Test, page23-79
Replac€ment,Page23-80 Adjustment,Page23-81
FRONTTURNSIGNALLIGHT/ FRONTSIDEMARKERLIGHT page23-80 Replacemont,
HIGHMOUNT BRAKELIGHT Replacement,page23-84
LIGHT BRAKE/PARKING Replacement,page 23-82
BACK.UPLIGHT Replacement,page 23-82
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23-75
LightingSystem CircuitDiagram(USAI BATTERY
UNOER_HOOD FUSE/RELAY 8OX
@**'
rrf JLo -,.9,;,,
Td
UNDER-DASH FUSEiREIAY BOX
I No.5 tl0Al
i,"dii
f
l
I
Zt'"olli
I
No.4 {10A)
N0.30 17.5A)
I
RED/BLU
I
li':,.^i I
RED'BLK
lt
t
J
HIGHSEAI\4 INDICATOR LIGHT
BLK
I
G40l G4a2
23-76
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V
l
l
J
l
V
' DASHLIGHTS , PARKING LIGHTS . DASHLIGHTS . SIDEMARK€RLIGHTS BRIGHTNESS,TAILLIGHTS . LICENSE COIVTROLLER PLATETIGHT
BLK
.& G202
O,-
CircuitDiagram(Canada) 80X FUSEiRELAY UNDERHOOD BATTEBY
@*"
+WHT WHT/BLK
UGHTSWITCH c0t\48rNATroN
l = o ), : . , o F F 4
RED
U N D E RD - A S HF U S E / R E L8AO YX
BBAXE SYSTEM LIGHT ABSCONTROL UNIT
I
. DASHLIGHTS ' PARKING LIGHTS , DASHLIGHTS ' SIDEMAHKER LIGHTS E R I G H T N E S.ST A I L L I G H T S LIGHT C O N T H O L L E. RL I C E N SPEL A T €
I GRN/RED
NEO/CRN
I
T, HIGHBEAM INOICATOR LIGHT
8LK
BLK
I I
G401 c402
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G202
BLK
I
G20
8LK
8LK
-L -::
d --
G40l G402
G401 G402
23-77
LightingSystem CombinationLight Switch Test '1. Remove the driver'sdashboardlower coverand the kneebolster(seesection20). 2. Removethe steeringcolumncovers(seesection'17). 3. Disconnect the 4Pand 7P connectorfrom the switch. 4. Removethe screws,and slidethe switchtowardthe driver,sdoor, 5. Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
4P CONNECTOR
3
2 5
I
6
Terminal 1
Position
2
3
5
o-
----o o- _--_o_----o
6
OFF
:m:
Headlightswitch
L0w
=D
HIGH Passingswitch
OFF
ON r : Canada
23-78
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o_ ----o o-- ----o o_ ----o
o_ ---o
DaytimeRunningLightsControlUnit Input Test (Canadal 1.
DAYTIMERUNNINGLIGHTS CONTBOLUNIT
Removethe driver's dashboard lower cover and the knee bolstet (seesection 20). Disconnectthe connectorsfrom the daytime running lightscontrolunit. Inspectthe connectorand socket terminals to be surethey are all makinggood contact. lf the terminalsare bent,looseor corroded,repair them as necessary,and recheckthe system. l f t h e t e r m i n a l sl o o k O K , m a k e t h e t o l l o w i n g IP CONNECTOR inout testsat the connector' - lf anv test indicatesa problem,find and correct the cause,then recheckthe system. - lf all the input tests prove OK, the control unrt must be faulty; replaceit.
8P CONNECTOR
YEL/BLK GRN/RED BLK/WHT
RED/GRN
T€st condition
Cavity B1
BLK
Underall conditions Underall conditions
A2
82
A4
A1
R'I
B6
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BLK,4iVHT
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
Combinationlight " " switchin =D Posiuon
Checkfor voltageto ground: There should be battery voltage.
Combinationlight switchOFF;connecta jumperwire between WHT/RED the 82 and 41 terminals,then turn the ignition switchON (ll) lgnitionswitchON (ll), brakefluid reservoir GRN/RED full. and parkingbrake leverdown 8EDlGRN
Checkfor continuityto ground: Thereshouldbe continuity. Checktor voltageto ground: There should be battery voltage.
lgnitionswitchoN (ll)
YEUBLK
RED
Tost: Desiredresult
Parkingbrakeleverup
Possiblecauseii r$uh is not obtained . Poorground(G401,G402) . An open in the wire Blown No. 20 (7.5A) luse in the under-dashfuse/relaybox An open in the wire Blown No. 18 (7.5A) fuse in the under-dashtuse/relaybox Faultyignitionswitch An open in the wire Blown No.,tg (30A) fuse in the under-hoodfuse/relaybox Faultycombinationlight switch An open in the wire
Headlights(highbeam)should come on, (andhigh beam indicatorshouldcome on).
Poorground (G201.G202,G401, G402) Blown headlightbulbs Faultydaytimerunninglights resrslor An open in the wire
Connectto ground:The brake systemlight shouldcome on.
Blown No. 25 (7.5A) fuse in the box under-dashfuse/relaY Blown brake system light An open in the wire
Checkfor continuityto ground: Thereshouldbe continuity
. Faulty parking brake switch . An open in the wire
LightingSystem Dafime RunningLightsResistor
Test (Canada)
CAUTION: The d.ytime running lights resistor becomes very hot when the daytime running lights are on; do not touch it or the attaching hardware immediatelyaller the lighls have been turned off. 1.
Disconnect the 3P connectorfrom the resistor.
Headlights Replacement CAUTION: Halogen headlights bGcomevery hot in use; do not touch them or the attaching hardware immediately after they have been turned oft. 1.
Removethe front bumper(seesection2O).
2.
Removethe mountingbolts.
3.
Disconnecteach connector,then removethe headlight assembly.
HEADLIGHTASSEMELY
Measurethe resistancebetweenthe resistorterminal No. 1 (or No. 2) and the powerterminalNo. 3. Resistance: 1.0- 2.0 O Replacethe resistorwith a new one if any of the resistances are beyondspecification.
23-80
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HEADLIGHT:60/55 W TURN SIGNAL/SIDEMARKERLIGHT: 2118W {37 model} 2718W ('98 - 00 modelsl PARKINGLIGHT:5W l'97 modell 3CP{'98 - 00 modelsl
Adjustment Bstore adiusting the headlights: . Parkthe vehicleon levelground . Makesurethe fuel tank is tull . The driver or someonewho weighsthe same should sit in the driver'sseat. . Loadthe trunk with the itemsyou usuallycarry' . Push down on the front and rear bumpers several timesto makesurethe vehicleis sittingnormally' CAUTION: Halogen headlights become very hot in use; do not touch them or the atiaching hardware immediately after they have been turned off. 1.
ODenthe hood.
2.
Removethe left innerfender{seesection20).
3.
indicator. adjustment Checkthehorizontal "0" indicatorgear should the horizontal markon The be alignedwith the mark.
5.
"0" mark as lf eitherindicatoris not alignedwith its describedleft column,an adjustmentcan be made by usinga Phillipsscrewdriver. Adjustthe headlightsto localrequirementsby turning the adjusters. NOTE: . As the outer lensesare made of an acrylicoated, material,do not cover the headpolycarbonated lightswhen they areturnedon . When making horizontaladiustments,slide the horizontalindicatorgear rearward. After horizontaladjustment,put back the horizontalindicatorgear.
HORIZONTAL INDICATOR GEAR
"0" MARK
Checkthe verticaladjustmentindicator.The bubble should be centeredunderneaththe longest scribe markon the gauge. VERTICALINDICATOR:
olwww.emanualpro.com
)
23-A1
RearSide MarkerLights/ LicensePlateLight
Taillights
Replacement
Replacement
RearSide Marke. Light:
1.
Openthe hatchglass.
1.
Removethe retainingspring, and removethe rear side markerlight from the rearbumper.
2.
Disconnect the 6P connectorfrom the taillight.
3. 2.
Disconnect the 2P connectorfrom the light.
Removethe three screws,then pull out the outer taillight.
RETAINING
HOUSING
Licens€Plate Light: 1.
2.
Removethe two screwsfrom the licenseplate light, and pull the light out part of the way. Disconnect the 2Pconnectorfrom the light,
Brak€/Plrking light 2115W Back-uplight: 21CP(18 W) Turn signll light 21 W Inspect the gasket; replace it if it is distorted or $ays compressed. Installthe taillight, and run water over it to make sure it does not leak.
LIGHT(8 WI
23-A2
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Back-upLights CircuitDiagram FUSE/RELAY BOX UNDEN-HOOD
_*,,@_ "*" *"_,,. ]__ _..' iu.Er.w
-r-
(M/r) I
I BACK,UP LIGHT
swtTcH
/0n1he \ I lransmisson J \no!s{ / : Inposilion Rl lolosed
GRN/BLK
I
LEFI BACK,UP LIGHT 2 1 C P( 1 8 W )
T BLK
I
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A,/IGEAR Posrl0N swtTcH /Back'up \
RIGHT BACK,UP LGHT 2 1 C P0 8 W )
\l€hl swilch ,/ : Inposilion ICLOSED [8ll
8LK
I
G101
BrakeLights GircuitDiagram
BATTENY /,i\
High Mount BrakeLight Replacement
UNDER.HOOD FUSE/RELAY BOX
1.
No.s2 {15A) |
\Y*-I=f*-'o*T*'no"l |
I
P u s ht h e c l i p s , a n d r e m o v e t h e c o v e r f r o m t h e housing. HOUSING
V
HORNSYSTEM
T:,^-,
*",*"", i.t53l|
I
GRNA,VHT
-.1 GBNMHT
I
I
. ABSCONTFOL UNIT ' ECM/PCM . CRUISE CONTROL UNIT
2.
Disconnect the connectors. Removethe two nuts and the housing.
GRNAVHT
l
GRNWH
l
t l A[$^Jlr A (2rw) LEFI BFAKE LIGHT
Yi,?'il Y
BLK
t
BLK
lr
l
BLK
ll
I
BLK
I
I
G553
23-84
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RIGHT EFAKE LIGHT (21w)
Turn SignallHazardFlasherSystem O
-.
CircuitDiagram UNDER.OASH FUSE/RELAY BOX
IGNT]ONSWITCH
BOX FUSE/NELAY HOOD UNDEF BATTEFY
No12(7.sA)
@**' N0.30(7.54) FUSE
YEUBLK
V
WHTiELK
I
REO/BLK
l,
\ l----r-l-----i-F--
10
HAZARD WARNING swtTcH
GRN/ORN
_
q-
--------_
\
3 GRNAVHT
tI '
FqD
GRN/ORN
.+ DASHLIGHTS BSIGHTNESS CONTROLLER
INDICATOR (1.4W)
INDICATOR TFAILER LIGHTING CONNECTOR
BLK
BtK
G553
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G401 G402
:i1r'97model *2 :'98-00models
23-85
Turn SignallHazardFlasherSystem Turn Signal/HazardRelayInput 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 SRScomponent/ocations,precautions,ano proceoures in the SRSsection(24)beforeperformingrepairsor service. Removethe turn signal/hazard relayfrom the underdashfuse/relaybox.
1.
Inspectthe relay and luselrelaybox socketterminals to be surethey are all makinggood contact. l f t h e t e r m i n a l sa r e b e n t , l o o s e o r c o r r o d e d , reparrthem as necessary, and recheckthe system. l f t h e t e r m i n a l sl o o k O K , m a k e t h e f o l l o w i n g input testsat the fuse/relaybox socket. - lf any test indicatesa problem,find and correctthe cause,then recheckthe system. - lf all the input tests proveOK, the turn signal/ hazardrelaymust be faulty;replaceit.
'
1
IF\_-'l - ]
l
$ o{+ll
/ll
FUSE/RCLAY BOX SOCKET Cavity 2
3
1
Test condition
Tesl: Desiredresults
Possiblecause if result is not obtained . P o o rg r o u n d( G 4 0 1G , 402) . An open in the wjre
Underall conditions
Checkfor continuityto ground: Thereshouldbe continuity.
l g n i t i o ns w i t c h O N ( l l l
Connectfor voltageto ground: Thereshouldbe batteryvoltage.
Blown No. 12 (7.5A) fuse in the under-dashfuse/relaybox Faultyhazardwarningswitch An open in the wire
HazardwarningswitchON
Connectfor voltageto ground: Thereshouldbe batteryvoltage.
Blown No. 53 (10A) fuse in the underhood fuse/relaybox Faultyhazardwarningswitch An open in the wire
Hazardwarningswitch ON;connectthe No. 1 terminalto the No. 3 terminal.
Hazardlightsshouldcome on.
Poorground(G201.c202, c401, G 4 0 2G , 5 5 3G , 6 1 1 c, 6 3 1 ) Faultyhazardwarningswitch An open in the wire
l g n i t i o ns w i t c hO N ( l l )a n d t u r n s i g n a sl w i t c hi n r i g h t or left;connectthe No. 'l t e r m i n atlo t h e N o . 3 terminal.
R i g h to r l e f t t u r n s i g n a ll i g h t ss h o u l d come on.
23-86
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. Faultyturn signalswitch
Turn SignalSwitch Test
HazardWarningSwitch Test
1 . Removethe driver'sdashboardlower coverand the kneebolster(seesection20).
1.
Removethe centerpanel{seesection20).
2.
Removethe two screws,then remove the switch from the centerair vent.
Removethe steering column covers {see section 17]-. 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. 4.
Removethe screws,and slidethe switchtowardthe driver'sdoor.
lNol us€d)
HAZARD
q
swtTcH Checkfor continuitvbetweenthe terminalsin each switchpositionaccordingto the table. Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the table.
\
Terminal
2 3
5
7 8 10
t**--\ Terminal
1
2
OFF
Position RIGHT Neutral
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LEFT
o-
ON
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(_)
o @o o o
o
o- --o
23-87
lgnition Key Light System-'97
Model
CircuitDiagram IJNDER-HOOD FUSE/HELAY BOX
BATEBY
l-Noj',roo{ l;;f
tF*-'--ff::f-*"-l
.l-----
| ; )"tli|illsx"r
I WHT/CRN
I
,k ,0r,,o,u
( P I KEYLGHT
{14w)
Y
I
WHT/BLK
WNT/GRN
ORVER'S 000R
9!rl9rl^ ^ ULU5EU:UOOrOpen I I (OPEN :DoordosedJ
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ControlUnit Input Test l. Bemovethe driver'sdashboardlowercoverand the kneebolster(seesection20). the 5P connectorfrom the controlunit. 2, Disconnect 3. Inspectthe connectorand socketterminalsto be surethey are all makinggood contact. . .
and recheckthe system. lf the terminalsare bent,looseorcorroded,repairthemas necessary, lf the terminalslook OK, makethe followinginput testsat the connector. - lf any test indicatesa problem,find and correctthe cause.then recheckthe system. - lf all the inputtestsproveOK,the controlunit must be faulty;replaceit.
IGNITIONKEYLIGHT CONTROLUNIT
5P CONNECTOR
\
))
Cavity
Wire BLK
'I
WHT/BLK
Test: Desiredresult
Underall conditions
Checkfor continuityto ground: Thereshouldbe continuity.
lgnitionswitchON (ll)
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
Driver'sdoor open
Checkfor voltageto ground: Thereshouldbe 1 V or less.
Driver'sdoor closed
Checkfor voltageto ground: Thereshouldbe 4 V or more.
Underall conditions
Connectto ground:lgnitionkey light shouldcome on.
WHT/GRN
GRN
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Test condition
Possiblecauseif r€sult is not obtained . Poorground{G401,G402} . An open in the wire . Blown No. 33 (7.5A) fuse in the under-dashfuse/relaybox . An open in the wire . Faultydriver'sdoor switch . An open in the wire
Blown No. 33 (7.5A) fuse in the under-dashfuse/relaybox Blown ignitionkey light bulb An open in the wire
23-89
DashLightsBrightnessController CircuitDiagram
G401
23-9 0
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ControllerInput test NOTE:The controlunit is built into the dashlightsbrightnesscontroller. Carefullypry the controllerout of the dashboard.
1.
Disconnect the 3P connectortrom the controller, Inspectthe connectorterminalsto be sure they are all makinggood contact. .
lf the terminalsare bent,loose,or corroded,repair them as necessary, and recheckthe system. . lf the terminalslook OK, makethe followinginput tests at the connector. - lf any test indicatesa problem,find and correct the cause.then recheckthe system. - lf all the input tests prove OK, the controller must be taulty;replaceit.
OASHLIGHTS BRIGHTNESS CONTROLLER
Wire sideof lemaleterminals
Csvity
Wire
1
RED/BLK
2
BLK
5
RED
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T€st condhion
Tsst: Desiredresuli
Combinationlight switch ON
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
Underall conditions
Checkfor continuityto ground: Thereshouldbe continuitv.
Combinationlight switchON
Connectto ground: Dashlightsshouldcome on full bright.
Possible cause if result is not obi8inod
Blown No. 30 (7.5A) fusein the under-dashfuse/relaybox Faultycombinationlight switch An open in the wire . Poorground(G401,G402) . An open in the wire . An open in the wire
23-91
InteriorLights ComponentLocationIndex
FRONTCEILINGLIGHT Test,page 23-94 SPOTLIGHTS Test, page
FRONTPASSENGER'S DOORSWITCH REARCCILINGLIGI{T Test, page 23-94 RIGHTREAR
swtTcH
DRIVER'SDOORSWITCH
HATCHGLASS LATCHSWITCH LEFTREAR
oooRswtTcH TAILGATE LATCHSwlTCH
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23-92
I J
CircuitDiagram FUSERELIY UNOER.I]OOO BOX BA--FqY [t..*;;;;l
\:/-*-.........-='_Fn-'.,,
o-, INDCATOF !ICH'I
f7 I II BLU/EL(
I
I
rJ----r I| Y| l^,,o.orro | coNthoL
I F#l*'
FI
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LTG
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/f\ \9/
I FRoNT I PASSENGEF'S | 0@R
) | swrlcN D@' J lTcLosED
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I
-
23-93
InteriorLights CeilingLaghtTest
SpotlightTest
Front and rgar:
1. Turn the spotlightswitchOFF.
1.
Turn the light switchOFF.
2.
Pry off the lens.
2.
Pry off the lens.
3.
Removethe two screwsand the housing.
3.
Removethe two mountingnuts and the housing.
4.
Disconnect the 3P connectorfrom the housing.
4.
Disconnect the 3P connectorfrom the housing.
1' 3' 2'
1
aULB(5Wx2l
Checkfor continuitvbetweenthe terminalsin each switchpositionaccordingto the table,
Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the table.
t€rmtnar 1
\ Position
\
or 1'
ON
23-94
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t"",rr"
2'
3
3'
o-
Pd'l
/=\
oo-
/a\
\:/
-o -o -o
2 1
ol
2'
\ ON
OFF
MIDDLE
Terminal
\
R OFF
ON L OFF
oo oo-
--o
/-\ \:./
@
o --o
/a
\:./ (9
3
--o
AccessorySocket
o-.
Circuit Diagram
UNDER_HOOO FUSE/RELAY 8OX IGNITIONSWITCH txt Fffi^-.rr-.rrl wHT'BrK 6\ +*HT-137F wHr BLK t-'**1*fffiT
|
-*T]
I
REO/GRN
I
(
i ll%ti
) No.6
I
i{10A)
I
UNDER-DASH
i l9:,'3FUSE/RELAY BOX T
Y E LGRN
/BLK
l-
I
YEL/GRN
J-i,_, l ''l '"*' l ft-
€ l333iEi.''
I
,*1.I
t l
ir*?:r"$ |
t
l
BLK
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YEL/GflN YEL,
8LK
RED/BLK
t
t l t l
$Ni*" t-*rt
l
8LK
8LK
-:a
-:
tl t l lt l l -
G553
l
G40t G4A2
G401 G4A2
G40t G4A2
23-95
AccessorySocket AccessorySocketTest/Replacement 5.
Front AccessorySocket: 1.
Removethe centerdashboardlower cover (seesect i o n2 0 ) .
2.
Disconnect the 2Pconnectorfrom the front accessory socket.
If all the tests proveOK, replacethe front accessory socket.
Inspectthe connectorterminalsto be sure they are all makinggood contact. lf the terminalsare bent,looseor corroded,repair them as necessary, and recheckthe system. l f t h et e r m i n a l sl o o kO K ,g o t o s t e p4 .
PBOTECTOB FACEPANEL
ACCESSORY SOCKET
Turn the ignition switch to ACC (l), and checkfor voltagebetweenthe No. 1 and No. 2 terminals. . .
Thereshouldbe batteryvoltage. lf there is no batteryvoltage,checkfor: - b l o w n N o . 2 7 ( 1 0A ) f u s e i n t h e u n d e r - d a s h fuse/relaybox. - p o o rg r o u n d( G 4 0 1G , 402). - a n o p e ni n t h e w i r e .
23-96
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5.
RearAccessorySocket: '1. Removethe left rear side trim panel {see section 20t.
Removethe thermofusehousingand thermal pro tector,then removethe socketand cover.
Disconnect the connectors.
2.
lnspectthe connectorterminalsto be sure they are all makinggood contact.
3.
.
l f t h e t e r m i n a l sa r e b e n t ,l o o s eo r c o r r o d e d , repairthem as necessary,and recheckthe sys tem. l f t h e t e r m i n a l lso o kO K ,g o t o s t e p4 .
ACCESSORY SOCKET
COVER THEEMAL PROTECTOR
T$
THERMOFUSE HOUSING
SOCKET A (YEL/8LUI
ry \
4.
J
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J
I IBLK}
Turnthe ignitionswitchto ACC(l),and checktor volt agebetweenthe A and B terminals. o Thereshouldbe batteryvoltage. . lf there is no batteryvoltage,checkfor: - b l o w nN o . 6 ( ' 1 0A ) a n d N o . 2 7 ( 1 0A ) f u s e si n the under dashfuse/relaybox. - faulty rear accessorysocketrelay (test,page 23-53). - poor ground (G401,G402,G553). - a n o p e ni n t h e w i r e .
23-97
Glock-'98 - 00 Models CircuitDiagram UNDEE,HOOD FUSE/RELAY BOX BATTERY
@-*"
-l
IGNTIONSWlTCH
No.41(1004) N0.42140A) N0.47(7.54)
UNOEN.DASH FUSgFELAY
8ox
G40t G402
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23-9 8
Terminals
Removal 1.
Removethe centerair vent (seesection20).
2,
Disconnect the 4Pconnector.
3.
Removethe two screws.
CLOCK
Connectsto I
WHT/BLU YEL RED/BLK
4
BLK
Constantpower (time memory) lG1 (mainclockpowersupply) Lights-onsignal G r o u n d{ G 4 0 1G , 402}
CENTERAIR VENT
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I
t
I
23-99
StereoSoundSystem ComponentLocationIndex
AI{TENNA MAST Replacement,page 23'103
AUDIOUNIT page23-'102 Replacement. page23-102 Terminals,
SUB ANTENNALEAD
FROI'ITSPEAKERS page23-103 Replacement, REAR Beplacement,pago 23-103
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23-100
E t
J
CircuitDiagram
-T UNOEB,DASH FIJSE/RELAY BOX
IGNITIONSWITCH
FUSE/FELAY BOX UNDER.HOOO
l-^*"-l T'5 1
WHT,tsLK
I II II
(7.5A) No.30 FUSE
I
a,-,
YEURED
AUOIO UNIT
o o
o o s tr4 | 1l7l
1 sl 1 6 l |7 [ 6 1
BRN/BLK
GHY,ryVHT
LEFTREAR SPEAKER
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RIGHTBEAR SPEAKER
LEFI FRONT D O O FS P E A K E R
RIGHTFBONT DOOBSPEAKER
23-101
StereoSound System Audio Unit Removal
AudioUnit Terminals
1 . M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e radio's presetbuttons (with anti-theftfeature). Removethe centerpanel(seesection201, Removethe four mountingbolts,and pull the audio unit out. D i s c o n n e c t h e ' l 6 P c o n n e c t o ra n d s u b a n t e n n a lead,then removethe audio unit.
AUDIOUNIT
CENTEBPANEL
Cavrty
Installin the reverseorderof removal. After installingthe audio unit, enter the anti-theft code for the radio. then enter the customer's radio station presets(with anti-theftfeature).
Wire
Connoct3 to
1{7)
RED/GRN
Right front door speaker@
2 {8}
BLU
3 {9)
RED/BLK
Lights-onsignal
4 (10)
WHT/BLU
Constantpower (tuning memory)
5 (2)
YEURED
ACC (main sterso power supplyl
7 (6)
BLU/YEL
Left rear soeaker@
8 (s)
RED/VEL
Rightrearspeaker@
9 (17)
BRN/BLK
Riqht f.ont door speakerO
1 0( 1 8 )
GRY/BLK
Left front door soeakerO
1 2( 1 9 )
RED
Dashlightsbrightnesscontroller
14 (20)
BLK
G r o u n d( G 5 0 1 )
1 5( 1 6 )
GRYMHT
Left rear speakerO
1 6( 1 5 )
BRN^ll/HT
Rightresr speakerO
Left front door speaker@
T e r m i n aN l o . 6 , 1 1 ,a n d 1 3 :N o t u s e d ( T e r m i n aNl o . 1 , 3 ,4 , ' 1 1 , 1 21, 3 ,a n d ' 1 4N o t u s 6 d ) { ): '99 - 00 models
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23-102
SpeakerReplacement 1.
Removethe speakercover.
2.
Removethe threescrewsfrom the speaker.
3.
Disconnectthe 2P connector,and removethe door speaker.
Mast AntennaReplacement NOTE:To remove the antennalead, it is necessaryto removethe dashboard(seesection20). 1.
Disconnect the antennaleadfrom the audio unit.
2.
Removethe two mountingscrews,then removethe mast antenna.
Front speaker:
MOUNTINGSCREWS
FRONTSPEAKER
Rearspeaker:
/a--=-
2P CONNECTOR
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SPEAKER COVER
23-103
Horns ComponentLocationIndex SRScomponentsare locatedin this area,Reviewthe SRScomponentlocations,precautions, and proceduresin the SRS section(24)beforeperformingrepairsor service. HORN Test,page23-105
HORNSW|TCHES Test,page 23-106
m /\
HORNRELAY Test. page23-53
23-104
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CAELEREEL R e p l a c e m e n t ,s e c t i o n 2 4
HornTest
CircuitDiagram
1.
Removethe front bumper(seesection20).
2.
the 2P connectorfrom the horn Disconnect
3,
Removethe horn.
HORN
2P CONNECTOR
} -
BLU/FED
fl"'
KEYLESSi POWEF DOOR LOCK CONTROL UNIT
I
B L UFi E O
I
t l
Test the horn by connectingbatterypower to one terminaland groundingthe other.The horn should sound.
5.
lf the horn failsto sound,replaceit
BLU/RED
I
g)iirrN I BLK
4.
LOW HORN
BLK
l
l
I
BLK
I
I I G201
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23-105
Horns Switch Test 1 . Disconnectthe batterynegativecable,then disconnect the positivecable,and wait at ieastthreeminutes. Disconnect the driver'sairbagand front passenger's airbagconnectors(seesection24). Removethe drive.'sdashboardlower coverand the kneebolster(seesection20).
6. Removethe driver's airbag (see section 241,then disconnectthe horn connectorfrom the steerinq wneet. 7 . Checkfor continuity betweenthe No. 2 or No. 3 terminal of the cable reel sub-harness3P or 6P connectorand horn Dositiveterminal.
Disconnectthe cablereel sub-harness 3P or 6P connectorfrom the main wire harness.
CABI.I REEL SUB.HARNESS 3P or 6P CONNECTOR
MAIN WIRE HARNESS 3P o. 6P CONNECTOR
HORNCONNECTOR
37 modol
lf there is no continuity,replacethe cable reel (seesection 24). lf there is continuity.repair or replacethe horn switch.
,98- 0Omodots Terminal sideof maleterminals
Checkfor continuitybetweenthe No. 2 or No. 3 term i n a l o f t h e c a b l er e e l s u b - h a r n e s a snd body groundwith the horn switchpressed. '97 model:
'98 - (X)modols:
8. lf sll tests prove OK, reinstall the driver's airbag (seesection24), and reconnectthe cable reel subharnessconnector. 9 . Reconnect the driver'sand front passenger's airbag connectors,and reinstallthe accesspanel on the steeringwheel. 1 0 . Reconnectthe batterypositivecable,then the negative cable. 1 1 . After installing the airbags, confirm proper system
operatron: Terminalsideof
. .
Terminalsideof
lf there is continuity.the horn switchis OK. lf there is no continuity,go to step 6.
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23-106
.
.
Turn the ignitionswitch ON (ll);the SRS indicator light should come on for about six seconds and then go off. Makesure both horn buttonswork.
PowerMirrors CircuitDiagram IGNITION SWITCH
FUSURELAY BOX UNDER.HOOD
@"*'
N0.41(100A)
N0.42(40A)
+WHT WHT/8LK
-
lBAI \ € l
\
.Y^rc2l YEL
I
-t----t
UNDER,DASH FUSE/RELAY B0x
I lu.'xI I
BLKIryEL POWEN MIRRON SWTCH
3 YEURED
5
BLK
BLUMHT
+l vHT GRN
l,-
-: [ ]:
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'9&00rnodels
G551
23-107
PowerMirrors FunctionTest 1.
,
Pry the switch out of the dashboard.Be carefulnot to damagethe mirror switchor the dashboarddriver's lowercoverwhen pryingthe switchout. Disconnect the 10Pconnectorfrom the switch. Choosethe appropriatetest dasedon the symptom: . Both mirrorsdon't work, go to step 4. . Left mirror doesn't work, go to step 6. . Rightmirror doesn'twork,go to step 7.
Left mirror inoperative: 6.
Connectthe No. 2 {BLKI/EL)terminal of the ,l0p connectorto the No. 3 (YEUREDIterminal and the N o . 5 ( o r N o . 6 ) t e r m i n a lt o b o d y g r o u n d w i t h jumper wires. The left mirror should tilt down (or swing left) when the ignition switch is turned ON t). lf the mirror doei not tilt down (or does not swing left),removethe left door panel,and checkfor an open in the BLUMHT (or BLU/BLK)wire between the left power mirror and the switch. lf the wire is OK,checkthe left power mirror actuator, lf the mirror neithertilts down nor swings left, repairthe YEUREDwire. lf the mirror operatesproperly,checkthe mirror switch.
Right mirror inoperaiiva: 7.
Connectthe No. 2 {BLVYEL)terminat of the 1Opconnectorto the No. 3 (YEURED) terminaland the No. 9 (or No. 8) terminal to body ground with jumper wires. The right mirror should tilt down (or swing left) when the ignitionswitchis turnedON l). .
. -.t-..------'-
Both inoperative: 4.
Checkfor voltage between the No. 2 (BLVYEL)terminal and body groundwith the ignitionswitch ON
flr).
5.
Thereshouldbe bafteryvoltage, . lf there is no voltage,checkfor: - blown No. 17 (7.5 A) fuse in the under-dash fuse/relaybox. - an open in the BLK,/YEL wire. . lf there is battery voltage, go to step 2. Checkfor continuitybetweenthe No. 4 {BLK)terminal and body ground. Thereshouldbe continuity. lf there is no continuity,checkfor; . an open in the BLKwire. . poor ground (c551).
23-108
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.
lf the mirror does not tilt down (or does not swing left), remove the right door panel, and checkfor an open in the GRN,4TVHT (or yEUBLK) w i r e b e t w e e nt h e r i g h t p o w e r m i r r o r a n d t h e switch. lf the wire is OK, checkthe right power mtrror actuator. lf the mirror neithertilts down nor swings left. repairthe YEUREDwire. lf the mirror operatesproperly,checkthe mirror switch.
Actuator Test
Switch Test 1.
Removethe switch as describedin FunctionTest {seepage23-108).
2.
CheckJor continuitybetweenthe terminalsin each switchpositionaccordingto the table.
Teminal
\
t*t*
3
4
5
b
8
Prv out the mirror mount cover (seesection20).
2.
the 8P connectorfrom the power mirror. Disconnect MIRRORMOUtrlT COVER
I
\ UP DOWN
L LEFT RIGHT
UP DOWN R
J-
2
1.
RIGHT
o ooo oo oo o .o o o o oo o o oo oo o oo o o oo
o o o o Checkactuator operation by connecting power and groundaccordingto the table. Terminal -\
\
1
;;,i".
8 @
TILTUP @
TILTDOWN SWINGLEFT
o
@
SWINGRIGHT
@
o
POWERMIRROR
swtTcH
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23-109
RearWindow Defogger GomponentLocationIndex
rr^ja}
aia\
al I
rl
!
REABWINDOWDEFOGGER SWTTCH InputTest,p89e23-113 FUSE/RELAY BOX
REARWINDOW DEFOGGER FunctionTest.page23-112 DetoggerWreRepair,page23-112
23-110
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a-
EI CircuitDiagram IGNITION SWTCH
BOX FUSE/REI-AY UNDER-HOOD BATTERY
@-*"
N 0 . 4 1{ 1 0 0 A )
N 0 . 4 2( 4 0 4 )
+WHT WHT/8LK
-f
"r?h \_--,' I
I
II
l-
DEFOGGER SWITCH REAsWINDOW panel) control B1 {iniheheater
l"
8LK
I J www.emanualpro.com
G401 G402
23-111
RearWindow Defogger FunctionTest
DefoggerWire Repair
1.
NOTE:To make an effectiverepair,the brokensection m u s tb e n o l o n g e rt h a no n e i n c h .
Checkfor voltagebetweenthe positiveterminaland body ground with the ignitionswitch and defogger switchON. Thereshouldbe batteryvoltage. .
.
lf there is no voltage.checkfor: - faultydefoggerrelay. - faultydefoggerswitch. - an open ,n the BLK/BLU,WHT/GRN,BLU/YEL, or BLKwire. lf there is batteryvoltage,go to step 2.
1.
Lightlyrub the areaaroundthe brokensectionwith fine steelwool, then cleanit with alcohol.
2.
Carefullymaskaboveand belowthe brokenportion of the defoggerwire with cellophanetape. OPEN
POSITIVETERMINAL
CELLOPHANE TAPE Mix the conductivepaint thoroughly.Using a small brush, apply a heavy coat of the conductivepaint extending about 1/8" on both sides of the break. Allow 30 minutesto dry.
Checkfor continuitybetweenthe negativeterminal and body ground. l f t h e r e i s n o c o n t i n u i t yc, h e c kf o r a n o p e n i n t h e defoggergroundwire. Touch the voltmeter positiveprobe to the halfway point of eachdefoggerwire, and the negativeprobe to the negativeterminal.Be carefulnot to scratchor damagethe defoggerwireswith the testerprobe. Thereshouldbe approximately6 V with the ignition switchand the defoggerswitchON. .
lf the voltageis as specified,the defoggerwire is
oK. .
lf the voltageis not as specified,repairthe defogger wire. - lf it is more than 6 V, there is a breakin the negativehalf of the wire. - l f i t i s l e s st h a n 6 V , t h e r e i s a b r e a ki n t h e positivehalf of the wire. Checkfor continuityin the repairedwire. 5,
23-112
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Apply a secondcoat of paint in the sameway. Let it dry three hoursbeforeremovingthe tape.
Switch Input Test NOTE:Beforetesting, check for blown No. 17 (7.5 A) fuse in the under-dashfuse/relaybox. 1.
Removethe centerpanel{seesection20).
SWITCH REARWINOOWDEFOGGER lin the heatercontroloanel)
CENTERPANEL
Checkfor voltagebetweenthe 84 and 87 terminals in each switch positionwhen batterypower is connectedto the B l terminal. OFF
lessthan 0.4V
ON
baftery voltage
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I
23-113
Wipers/Washers ComponentLocationIndex SRScomponentsare locatedin this area.Reviewthe SRs componentlocations,precautions,and procedures in the s6s section(24)beforeperformingrepairsor service.
REABWINDOWWIPERMOTOB T€st,page23-120 WPSR/WASHER SWITCH Test.page 23-l't9
REARWINDOW WIPER CONTROL UNlT137mod.ll Inputtest.page23-118
WINDSHIELD WIPERMOTOR Tost,page23-119
n t ff UNDER.DASHFUSE/RELA BOX
INTERMITTENT W|PENRELAY CIBCUIT,REARWINDOWINTERMTNENT wlPER RELAYCIBCUITl'98 - 0Omod.t.l (ln the integratedcontrol unit) Input test, page 23-68
23-114
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-
l -
CircuitDiagram{Windshieldl
@*"
N0.41(1004)
UNDEB,DASH BOX FUSENELAY
IGNITONSWITCH
BOX FUSE/NELAY UNDEB.HOOD N0.42{40A)
BLUiBLK YEUBLU WHTiBLK
INTEGEATED CONTFOL UNIT / Hasbui[-in \ I inlermiltenl I relay \ wiper /
l-
BLK
8LK
BLK
II
I
I
_L G401 G402
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G401 G402
G401 G402
23-115
Wipers/Washers CircuitDiagram(RearWindow)-'97 Model UNDER.HOOD FUSE/RELAY BOX
@**'
N0.41(100A)
N0.42(40A)
WHT/BLK +WHT
, 7 ! i s - - - - - - -- - - -
JiJ frT
BLK
d-l G401 G4A2
23-116
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t'
8LK
I
G202
I
G611 G631
CircuitDiagram(RearWindowl-'98 - 00 Models 80X FUSEi RELAY UNDER.HOOD BATTERY
@*,'
N 0 . 4 (11 0 0 A )
N 0 . 4 (24 0 A )
+WHT WHT/BLK
GNITON SWTCH
UNDEF-DASH FTJSE/RELAY BOX
REAR WINDOW WPERMOTOR
J D L I
OFF
GRN/BLK
I
INTEGRATED CONTROLUNT /Has boll-inre wndow\ w perrelay ] t nlermillenl
OtI
vil8t8E
I
BLK
BLK
BLK
.L
n-
n_ -:
G202
G611 G631
-
G40l G402
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A n',$s".,,,
I
23-117
Wipers/Washers RearWindow WiperGontrolUnit lnput Test-'97 Model 1 . Removethe driver'sdashboardlower cover and the
kneebolster{seesection20). Disconnect the 8P connectorfrom the controlunit.
8P CONNECTOF
Inspectthe connectorand socketterminalsto be sure they are all makinggood contact. a lf the terminalsare bent,loose,or corroded,repair them as necessary.and recheckthe system. . lf the terminalslook OK, makethe following input tests at the connector. - lf any test indicatesa problem,find and correct the cause,then recheckthe system. - lf all the input tests are OK, replacethe control UNII.
LT GRN/BLK T GRN/RED\ LT 2
1
1
6
GRN/BLK
Cavity 4
Test condhion
BLK
LT GRN/ RED
Checkfor continuityto ground: Thereshouldbe continuity.
lgnitionswitchON (lll
Checkfor voltageto ground; There should be battery voltage.
Blown No. 3 (10A) fuse in the under-dashfuse/relaybox An open in the wire
lgnitionswitchON (ll), and rearwindow wiper/washerswitch ON
Checkfor voltageto ground: There should be battery voltage.
Blown No. 3 (10A) fuse in the under-dashfuse/relaybox Faultyrearwindow wiper/washer switch An open in the wire
lgnitionswitchON (lll
Checkfor voltageto ground; Thereshouldbe batteryvoltage.
Blown No. 3 {10A) fuse in the under-dashfuse/relaybox Faultyrearwindow wiper motor An open in the wire
lgnitionswitchON (ll)
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
B l o w nN o . 3 { 1 0A ) f u s ei n t h e under-dashfuse/relaybox Faultyrgarwindow wiper motor An open in the wire
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
B l o w nN o . 3 ( 1 0A ) f u s ei n t h e under-dashfuse/relaybox Faultyrearwindow wiper/washer switch An open in the wire
LT GRN/ BLK
LT GRN
5
lgnitionswitchON lll), and rearwindow GRN/BLK wiper/washerswitch at washerposition
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23-118
Possiblecause il rasuh is not obtained
Underall conditions
GRN
'l
Test Desir€dr93uh
. Poorground(G401,c402) . An open in the wire
Wiper/WasherSwitch Test
WindshieldWiperMotor Test
Windshield/ReErWindow Wiper/WasherSwitch:
1.
1.
Removethe driver'sdashboardlower coverand the kneebolster(seesection20).
2.
Removethe steeringcolumncovers{seesection17)
3.
D i s c o n n e c t h e 8 P a n d 6 P c o n n e c t o r sf r o m t h e switch, remove the two screws, and pull out the switch.
Open the hood, removethe cap nuts, and caretully remove the wiper arms so that they do not touch the hood. Removethe cowl cover(seesection201. Disconnectthe 5P connectortrom the windshield wiper motor.
\ lind3hi.ld:
tilt-rltl
IEZIA RaarWindow: 1 12 3
I t-7 al
J-
Checkfor continuitybetlveenthe termlnalsin each switchpositionaccordingto the tables. Windshield Wiper/WasherSwitch: Terminal ---__\ 4
\
3
2
1
7
o o o
o o
5
P*tOFF
oo
INT LO
o o
HI "0N" Mistswhch switch"0N" Washer
o o o o
o
Test the motor by connectingbattery power and groundaccordingto the table. \
-l
Terminal
;fi;"
4
LOW SPEED
@
H I G HS P E E D
@
RearWindow Wipsr/Washer Switch \
ti'"
ll www.emanualpro.com
---\Teminal
1
Washer switch'0N' (wiperswitchoFFl
G
OFF
G
ON
G
"ON' Washer switch "0N"1 (Wiper switch
G
2
3
-o -o o -o
4
6
G
-o
lf the motor does not tun or fails to run smoothly, replaceit. Connectan analogvoltmeterbetweenthe No. 5 (+) and No. 3 (-) terminals,and run the motor at low or high speed. The voltmeter should alternatelyindicate0 V 8nd 4 V or less.
G
-o 23-11 9
Wipers/Washers RearWindow WiperMotor Test
WasherMotor Test
1 . Removethe tailgatetrim panel(seesection20),
1.
Disconnectthe 4P connectorfrom the wiper motor assembly.
Removethe front bumper(seesection20). D i s c o n n e c t h e 2 P c o n n e c t o r sf r o m t h e w a s h e r molors,
REARWINDOW WASHERMOTOR
4P CONNECTOR
Pushtab to release,
4.
5.
WIPEB LOWERCOVEn
Test the motor by connecting battery power to the No. I terminal,and groundto the No. 3 terminal.
Test the washer motor by connecting battery power and groundaccordingto the table.
lf the motor does not run or fails to run smoothly, replaceit.
L_Iq'.r91
Reconnect the 4P connectorto the wiper motor.
Disconnected Connected
Connectan analogvoltmeterbetweenthe No. 4 (+) and No. 2 (-) terminals. Run the motor by turning the wiper/washerswitch
oN.
The voltmeter should alternatelyindicate0 V and 1 1V o r l e s s .
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23-120
,l
Battery @
a lf the motor fails to run smoothly, replaceit. a lf the motor runs smoothly, but little or no washer
f l u i d i s p u m p e d ,c h e c kf o r a d i s c o n n e c t e do r blockedwasherhose,or a cloggedpump outletin the motor.
HatchGlassOpener Switch Test
CircuitDiagram
1.
Remove the dashboard lower cover (see section 20).
2.
Disconnect the 2Pconnectorfrom the switch.
3.
R e m o v et h e s w i t c h f r o m t h e d a s h b o a r d l o w e r cover.
FUSE/RELAY BOX UNDER.H@D BATTEFY
@*"
|-*;rr^!...',r,*;l .......1<\o<\r+l
I I
I
WHT/GRN DASHBOAND LOWER COVER
WHT/GRN
II
WHT/GBN
rt
KEYLESSi POWEF DOOB LOCK CONTROL UNIT
V II
HATCHGLASS OPENERSWITCH
I
YEL
J T I
HATCH GLASS OPENER
soLENOr0
BLK
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Checkfor continuitybetweenthe No. 1 and No. 2 terminals. . .
There should be continuity when the switch is pushed. Thereshouldbe no continuitywhen the switchis released.
out, G631
23-121
HatchGlassOpener SolenoidReplacement
Solenoid Test 1.
Open the tailgateand removethe tailgatetrim (see section20).
2.
Disconnect the 2Pconnectorfrom the solenoid.
't. Removethe tailgatetrim (seesection20). 2.
Disconnect the 2P connector.
SOLENOID
Terminalsade of maletermtnals
Removethe rod from the key cylinder. Connectpowerto the No. 1 terminaland groundto t h e N o . 2 t e r m i n a l sm o m e n t a r i l vT. h e s o l e n o i d shouldooerate.
4.
Removethe three mountingbolts,then removethe solenoid. Installthe replacement solenoidin the reverseoader of removal.
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23-122
Power Door Locks ComponentLocationlndex TRANSMITTER Test, page23-130 Cod6 Input Procedure, page23-131
DOORL(rcK SWITCH DRIVER'S Test,page23-129
LOCKBUTTON
HATCHGLASS BUTTON
RIGT{TREARDOORLOCK ACTUATOR Test,page 23-129 Replacement,section20
PA rc AUTTO]II HATCHGLASSOPENERSOLENOIO fesl, page 23-122 Replacem€nt.pago 23-122
FRONTPASSENGER'S DOORLOCKACTUATOR Test, page 23-129 soction20 R6Dlacement,
LEFTBEARDOORLOCK ACTUATOB Tesr,page23-129 Beplacement, section20 . DRIVEB'SDOORLOCK KNOB SW|TCH Tesr,pag623-128 . DRIVER'SDOORLOCK ACTUATOR T6st,psge 23-128
-
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23-123
Power Door Locks CircuitDiagram(With KeylessEntrySystem) FUSE/FELAY UNDER.HOOD BOX
GNTIONSWTCH
UNDERDASH FUSE/RELAY BOX
EATTEFY
@*n' YEL
WHT/GFN
8 UNLOCK
nrrenu@
ITEYLES--l
I TRANSMIT]ER I Lr-------HORN RELAY
f7 II-
LOCK
@
GRY
HATCH OPENER swlTcH
FRONT CEILING LGHT
KEYLESS DOOsLOCK C O N T R OULN I T
f7
Y_o*,,.,,,0I
. PASSENGENS DOORSWITCHES . ]NTEGRATED CONTROL UNIT 5
I I
.,ufrro
I
,Y, I F",'*-{
YEL
L
fIl l B
INTEGRATED CoNTROL UNT
HATCH GLASS OPENER SOLENO D
+ l
BL(
I
G61l G63l
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23-124
t
l
L rthg#,i."J
8!?i"'[:lll',fffi)
T
BLK
BLK
DRIVER'S DOOFLOCK
swrTcH
8LK
I
I
G401 G402
I
G551
G551
I--
CircuitDiagram{WithoutKeylessEntrySystem) UNDER.HOOD FUSEi RELAY 8OX BATTEBY
+wqr-t_twrr3-K
@**'
UNDER-DASH FUSE/RELAYBOX
IGNTIONSWITCH
6\
tr.*;l
vEL
BLKYEL ffr
l-J';
t | I
HORN RELAY
KNOB
r
oBtvERs DOOn LOCK ACTUATOR
V (Nolused) LOCK HATCH GLASS OPENER SWTCH
o
FRONT CEILING TIGHT
POWER DOOR LOCK CONTROL UNIT
V
f7
l_
I r-
EIGHT REAR 00oRLocK ACTUATOR
INTEGRATED CONTROL UNIT
V I
YEL
BLU/RED
I
l-
8Lr
I
BLU/RED
t / |Iupl ::iii^
tFl
?
BLK
I
G6l1
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'tl
II
,#. L?Vno' ( li: ) swrTcH
YAil''"',4,.'{yrcLosED tottt l'
I
YEURED
-Tq.
GRNORN
+
GRNWHT
s l-lLocx^l , |
I
-=tGJ--
Locx
l,
I I
DRIVER'S D00RLOC( SWITCN
BLK
BLK
I':
I:
G()1 G402
G551
II
II
23-125
PowerDoor Locks GontrolUnit Input Test 1. Removethe driver'sdoor panel(seesection20). 2. Disconnect the 18Pconnectorfrom the controlunit. 3. lnspectthe connectorand socketterminalsto be surethey are all markinggood contact. . .
lf the terminalsare bent,looseorcorroded,repairthemas necessary, and recheckthe system. lf the terminalslook OK, makethe followinginput testsat the connector. - lf any test indicatesa problem,find and correctthe cause,then recheckthe system. - lf all the input testsproveOK,the controlunit must be faulty;replaceit.
18PCONNECTON
BLU GRN/BED
GRY
7
2
3
10
1t
YEL WHT/REO\ WHT/GRN
,/ 1 21 1 3
GRN/WHT I
14 LT
femaleterminals
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23-126
8
5 16
17
1E
Disconnocithe 18Pconnestor from the pow€r door lock control unit. Cavity
Wire
11
8LK
7
BLU
Test condition Underall conditions Connectthe No. 7 termi' nalto the No. 8 terminal, and the No.6 terminalto the No. 17terminal momentarily. Underall conditions
Tost: Dcsiredresult Checkfor continuityto ground: Ther€shouldbe continuity. Checkdoor lock operation: Driver'sdoor shouldunlock.
Connectto ground: Hornshouldsound,
GRY
YEURED
Connectthe No. 'l8 terminalto the No. 8 terminal, and the No.6 terminalto the No. 17terminal momentarily.
Connectthe No.6terminalto th6 No.I terminal, WHT/RED and the No. 18terminalto the No. 17terminal momentarily.
9
BLU/RED
Connectan ohmmeter betweenthe No. 9 terminal and the No. l7 terminal.Driver'sdoor lock knobin UNLOCK
Po$ible csuse il result is not obtainod . Poorground(G55'l) . An openin the wire Faultyactuator Faultyjunctionconnector(C577) An openin the wire BlownNo. 51 (20Al{use in the underhoodfuse/relay box BlownNo.52 (15A)tuso in the underhood fuse/relaybox Faultyhorn Faultyhorn relay An openin tho wire
Checkdoor lock operation: Passenger'sdoors should unlock.
Faultyactuator An openin the wire BlownNo.51 (20A)fuse in the underhood fuse/relaybox
Checkdoor lockoperationl All doorsshouldlock.
Faultyactuator An openin the wire BlownNo. 51 {20A) fusein ihe underhood fuse/relaybox
Checkfor conlinuity: Thereshouldbe continuity.
' Faultydriver's door lock actualor . An openin the wire
*: With keylessentry system NOTE:To preventdamageto the motor,apply batteryvoltageonly momentarily. Feconnoctthe 18Pconneqtorto the power door lock control unit, Cavity
Wir6
Test condition
BlownNo. 51 (20Alfuse in the underhood tuse/relaybox An openin the wire
Driver'sdoor lockknob in
Checktor voltageto ground: Thereshouldbe 1 V or less.
Faultydriver'sdoor lockactuator Poorground(G551) An openin the wire Faultyignitionkeyswitch Poorground(G401,G402) An openin the wire BlownNo. 25 (7.5A) fusein the underdashfuse/relay box An openin the wire
10
BLUAVHT LOCK
13
BLU/RED tion switch
lgnitionkeyis in the igni-
Checkfor voltage to ground: There should be battery voltage.
Connectthe No. 5 terminalto the No.I terminalmomentarily
Checkhatchglass lock operation: Hatchglassshouldunlock.
. Faulty hatch glass opener solenoid . An opon in the wire
Checkfor continuityto ground: Thereshouldb€ continuity. Checktor voltageto ground: There should be battery voltage. Checklor voltageto ground: Thereshouldbe 1V or less.
. F a ( l l t yd o o r s w i t c h . An open in the wire
14
LT Passengor's door open GRN,NED
2
GRN/R€D
12
-
'
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Checktor voltageto ground: Thereshouldb€ 1 V or less.
lgnitionswitchON (ll) YEL
YEL
Possiblecauseif result is not obtain€d
Checkfor voltageto ground: There should be batteryvoltage.
WHT/GRN
5
Tost: D€sirodresult
Underall conditions
Front ceiling light "MlDDLE" position
Driver'sdoor lock switch GRNAr'VHT in LOCK Driver'sdoor lock switch GRN/ORN in UNLOCK
Faultylront ceilinglight An openin the wire Faultydriver's door lock switch Poorground{G551) An openin the wire
23-127
Power Door Locks Driver'sDoorLockKnobSwitchTest
Driver'sDoorLockActuatorTest
1.
Removethe driver'sdoor panel(seesection20).
1,
Removethe driver'sdoor panel(seesection20).
2.
Disconnectthe 6P connectorfrom the actuator.
2.
the 6P connectorfrom the actuator. Disconnect
6P CONNECTOR
6P CONNECTOR
Terminalsideot maleterfiinals
Terminalsideof maleterminals
Checkfor continuitybetweenthe terminalsin each switch position accordingto the table. rsrmrnal
\ Position
\ LOCK
UNLOCK
?
Checkactuatoroperationby connectingpower and ground accordingto the table.To preventdamsge to the actuator. apply battery voltage only momentarilv,
6
o- -o o- --o
\
Terminal
F*'',1."
__l
LOCK UNLOCK
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23-128
@
o @
DoorLockActuatorTest Passenger's
Driver'sDoor LockSwitch Test
1 . Removethe passenger's door panel(seesection20).
L
Disconnect the 2P connectorfrom the actuator.
Removethe innerhandle{seesection20). Disconnectthe 3P connector.then removethe two mountingscrewsand driver'sdoor lockswitch.
NOTE: The left rear door lock actuator is shown; the front passenger's and right reardoor lockactuators are similar. 2P CONNECTOR
Checkfor continuitvbetweenthe terminalsin each switchpositionaccordingto the table. lermlnal
\ Position
\ LOCK OFF
UNLOCK
Terminal sideof maleterminals
1
2
3
o- --o o- -_o
Checkactuatoroperationby connectingpower and ground accordingto the table.To preventdamage to the actuator, apply battery voltage only momenraflry. \
Terminal
;;il;--r
,l
LOCK UNLOCK 4.
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@ @
lf the actuatordoes not work properly, replaceit.
23-129
PowerDoor Locks TransmitterTest (With KeylessEntrySysteml NOTE: . The ceilinglight (in middleposition)comeson within 30 secondswhen you unlockthe doorswith the transmitter. . The doorsdo not lockor unlockwith the transmitterif the ignitionkey is in the ignitionswitch. . lf any door is open,you cannotlockthe doorswith thetransmitter. o lf you unlockthe doorswith the transmitter,but do not open any of the doorswithin 30 seconds,the doors relockautomatically. . For hatchglassbuttonoperation,hold the buttonfor morethan two seconds. . lf you pressthe PANICbuttonfor more than two seconds,the horn soundsfor about 30 seconds,and the transmitter LEDcomeson. (The panic mode will not be activatedif the ignition key is in the ignitionswitch.)The panic mode is cancelledby pressingany of the transmitterbuftons. . The horn soundsonly the first time you press a transmitterbutton,(Pressingrepeatedlydoes not activatethe horn again.) Doors cannot bo locked or unlockedwhh lhe transmitter.
BATTERY {cR20251
R e w r i t et h e t r a n s m i t t e rc o d e , then try to locldunlockthe doors {seepage23-131}.
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23-130
TransmitterProgramming Storingtransmittercodes: The codesof up to three transmitterscan be read into the kevlessreceiverunit memory (lf a fourth code is stored.the codewhich was inDUtfirstwill be erased.) N O T E : l t i s i m p o r t a n tt o m a i n t a i nt h e t i m e l i m i t s betweenthe steps. 1 . Turn the ignitionswitchON (ll). Within 1 to 4 sec.,push the transmitterlock or unlock buttonwith the transmitteraimed at the vehicle. Within 1 to 4 sec.,turn the ignitionswitchOFF. Within 1 to 4 sec.,turn the ignitionswitchON (ll). W i t h i n 1 t o 4 s e c . . p u s h t h e t r a n s m i t t e rl o c k o r u n l o c k b u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e vehicle. o.
Within 1 to 4 sec.,turn the ignitionswitchOFF.
1 . Within 4 sec.,turn the ignitionswitchON {ll). W i t h i n 1 t o 4 s e c . , p u s h t h e t r a n s m i t t e rl o c k o r u n l o c k b u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e vehicle.
-
9 . Within 1 to 4 sec.,turn the ignitionswitchOFF, 1 0 . Within 4 sec.,turn the ignitionswitchON (ll). 1 1 . W i t h i n 1 t o 4 s e c . , p u s h t h e t r a n s m i t t e rl o c k o f u n l o c k b u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e vehicle. 1 2 . Confirm you can hear the sound of the door lock aduators.
1 3 .W i t h i n 8 s e c . ,a i m t h e t r a n s m i t t e r s( u p t o t h r e e ) whose codes you want to store at the receiver,and pressthe transmitterlockor unlockbuttons. Confirm that you can hear the sound of the door lock actuatorsafter each transmitter code is stored. 1 4 . Turn the ignitionswitchOFF,and pull out the key.
1 5 . Confirmproperoperationwith the new code{sl.
-
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23-131
PowerWindows ComponentLocationIndex
t L--JIJJ'JJL
t J
- -------------) ------------
1J
15-
t_.1
POWERWINDOWMASTER SWITCH (Hasbuilt in controlunit) Input Test,page 23-'134 Test,page 23-135
FRONTPASSCNGER'S WINDOWMOTOR Test,page23-137 FBOI{TPASSENGER'S WI{DOW SWTTCH Test,page23-138 LEFTREANWWDOW SwlTCH Test,page23-137 LEFTREARWINDOW MOTOR Test,page23-'t38
--.-\-.--t
DRIVER'SWINDOW MOTOR Test, page 23-137
\-
RIGHTREARWINDOW MOTOB Test. page 23-138
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23-132
RIGHT wtNDowswTcH T6sr,page23-137
GircuitDiagram L]NDEFH@O FISETRELAY BOX
@-*'
rblr (r0oA) rlo42t40A)
V I
PASSENGEAS
FFONTPASSENGEFS
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23-133
Power Windows MasterSwitch Input Test NOTE:The controlunit is built into the powerwindow masterswitchand only controlsdriver'sdoor window operations. 1. Removethe masterswitch,and disconnectthe 14P,2?and 1Pconnectorsfrom the masterswitch. 2. Inspectthe connectorand socketterminalsto be surethey are all makinggood contact. . .
lf the terminals are bent, loose or corroded, repair them as necessary,and recheckthe system, lf the terminalslook OK, makethe followinginput testsat the connector. - lf a test indicatesa problem, find and correctthe cause,then recheckthe system. - lf all the input tests prove OK, the power window maser switch must be faulty; replaceit.
lirP CONNECTOR 1P CONNECTOR
BLU/ORN
RED/BLU
BLU/YEL \ RED/YEL
YEL/BLK
GRN/YEL
GRN
WiresideoI femaleterminals
GRN/BLK aLu/BLK
BLK RED/WHTYEL/GRN YEL
Wire side of femaleterminals
POWERWINDOWMASTEBSWITCH
RED/BLK
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23-134
Cavity
Wi1€
A11
Test condition
Tesi: Dssiredrosult
Underall conditions
Checkfor continuityto ground: Thereshouldbe continuity.
lgnitionswitchON (ll)
Checkfor voltageto ground: Thereshouldbe batteryvoltage.
BLK
Po$ible causeif 183uhis not obtained . Poorground(G551) . An open in the wire
B1 A 1 0 BLU/BLK A9
GRN/BLK
A6
YEUBLK
Blown No. 7, 8, 10 or l1 (20A) fuse in the under-dashfuse/relay box Faultypowerwindow relay An open in the wire
412 RED/WHT
A4
A3
Connectthe A10 termiRED/BLU nalto the 43 terminal, and the A4 terminalto the A11 terminal,then RED/YEL turn the ignitionswitch
Checkthe driver'swindow motor: It shouldrun (thewindow moves down).
. Faultydriver'swindow motor . An open in the wire
oN flr). A1
-
A2
A14
A8
Connectthe A9 termiBLUI/EL nalto the A2 terminal, and the Al terminalto t h e 4 1 1 t e r m i n a lt,h e n BLU/ORN turn the ignitionswitch
Checkthe front Passenger's window motor: It shouldrun (thewindow moves down).
window Faultyfront passenger's motor Faultyfront passenger'swindow switch An open in the wire
Connectthe 46 terminalto the A13terminal, and the 414 terminal to the A11terminal, YEUGRN then turn the ignition switchON (ll).
Checkthe right rearmotor: It shouldrun (thewindow moves oown).
Faultyright rearwindow motor Faultyrightwindow switch An open in the wire
Connectthe A12 termi-
Check the leftrearmotor: ,t shouldrun {thewindowmoves down),
Faultyleft rearwindowmotor Faulty,eftrearwindowsrrvitch An openin thewire
Connectthe A10te.minalto the 43 terminal, and the A11 terminal to the 44 terminal. then turn the ignition switchON (ll).
Checkfor voltage betweenthe A5 and Al l terminals: ADorox.6V shouldbe indicatedas the driver'swindow motor runs.
Faultypulser Faultydriver'swindow motor An open in the wire
Combinationlight switch ON
Checkfo. voltageto ground: Thereshouldbe batteryvoltage.
Blown No.30 (7.5A) fuse in the under-dashfuse/relaybox Faultycombinationlight switch An open in the wire
Combinationlight switch ON
Connectto ground: Dashlightsshouldcome on full bright.
oN flr).
YEL
GBN/YEL nalto the A7 terminat,
GRN
and the A8 terminalto the A11terminal.then turn the ignitionswitch
oN flr).
A5
*cl
BLU
RED/BLK
RED
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' An open in the wire
PowerWindows MasterSwitch Test 1 . Removethe switch (seesection 20).
F.ont Passongsr'sSwitch:
Disconnect the 14P,2P and 1P connectorsfrom the power window masterswitch.
\
swrTcH
'**[ffi
ON
Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the tables. DRIVER'S
rermrnal
OFF
FRONT PASSENGER'S
UP
swncH
A1
oo- --o
ON
G-
OFF
o-
ON DOWN
A2
OFF
oo-
A9
B1
-_o --o C
--o --o
Right RearSwitch:
B \\N
\
7-.i::,,,
Terminal
'".'*l-$j[\ ON OFF
\\'. )),, UP
OFF ON OFF ON
DOWN OFF
A14
413
A6
B1
--o oo* --o --o o--o oo-- --o o- --o
Left R.ar Switch: t - _ _ _ _ _ r - _ _
I F---T-----r-----r----r-----T---------T-----'r I l l a l l A 2l A 3 l A { l A 5l A 6 l A 7l a B l l
e*Li*l$[\
l Fa # l e ll
l A 1 0 l l A 1 1 l A 1 2 llt-t___Jl A13lal.ll
ON
I r________r_____J
fr---r-l
Terminal
\
OFF OFF
r---- -------r
I t-------l -ll ll 'lr 8 1 ll ll l l c 1 |I c 2 ll lr
UP
L--:J
ON OFF ON
DOWN
Dliver's Switch: The driver'sswitchis combinedwith the control unit so you cannot isolatethe switchto test it. Inst€ad,run th6 masterswitchinputtest procedureson page23-134. lf the tests are normal.the drive/s switch is faulty.
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23-136
OFF
A12
A8
ooo-- --o o- --o oo-
A7
B1
o --o --o -_o --o
Swhch Light: '99 - 00 mod€ls \
Terminal
ti.*----_\ Underallconditions
o-
-o ILED)
Window Switch Test Passenger's
Driver'sWindow Motor Test
1 . Removethe inner handle(seesection20).
Motor Test:
Disconnectthe 5P connectorthen removethe two mounting screwsfrom the passenger'sswitch.
1.
Removethe driver'sdoor panel,and disconnectall connectors(seesection201.
2.
Disconnectthe 4Pconnectorfrom the window motor.
Terminalsideof maleterminals
Testthe motor in eachdirectionby connectingbatt e r y p o w e r a n d g r o u n d a c c o r d i n gt o t h e t a b l e . Whenthe motor stopsrunning.disconnectone lead immediately. Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the table
Terminal -\
\ ;;b"
Terminal __\ 1
\ ;"rL-
UP
o-
OFF
DOWN
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o-
2
3
5
-o -o o- -o -o
4.
UP
o
(!r
DOWN
@
o
lf the motor doesnot run at all or doesnot run smoothly.rePlaceit.
PulserTest: 5.
Connectthe test leadsof an analogohmmeterto the No, 3 and No. 4 terminals.
6.
Run the motor by connectingpower and groundto the No. 1 and No. 2 terminals.The ohmmeterneedle shquldmove backand forth alternately.
23-137
PowerWindows Passenger's Window Motor Test Front: l.
Removethe passenger'sdoor panel,and disconnect allthe connectors(seesection20).
2.
Disconnectthe 2Pconnectorfrom the window motor.
3.
Checkwindow motor operation by connectingpower and ground accordingto the table.When the motor stops running, disconnectohe lead immediatelv. Front: Terminal \ .l\ ;."b"
UP
@
DOWN
o
@
UP
o
@
DOWN
@
o
R€ar: I
;*r*
Terminal -l\
lf the motor doesnot run at all or does not run smoothly,replaceit.
Rear: 1.
Removethe passenger's doo. panel,and disconnect allthe connectors(seesection20).
2.
Disconnectthe2Pconnectorfromthe window motor.
23-138
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I J
Restraints .....24-1 SeatBelts SupplementalRestraintSYstem (sRSl......'.'. ""'.""".""""24-13
f,
-
l www.emanualpro.com
SeatBelts 24'2 ComponentLocationIndex.'."..'..'-'.' '......"'..24-3 FrontSeatBeltReplacement '.' 24-6 ......'.". RearSeatBeltReplacement .....""""""""' 24-9 lnspection ChildSeatTetherAnchor lnstallation-'97 - 99 Models."'."24-10 ChildSeatTetherAnchor Removal/lnstallation -'00 Model ....'......'.'....'.'.."-'-'."' 24'11
Seat Belts ComponentLocationIndex SRScomponentsare locatedin the partsareasmarkedwith an asterisk{*). Reviewthe SRScomponentlocauons,precautions,and proceduresin this section(24)beforeperformingrepairsor service(,98_ 00 models).
CHILDSEATTETHENANCHOR -'97 lnstallation 99 models,page24-10 - '00 model,page24-11 Removal/lnstallation CHILDSEATTETHER ANCHORCOVER('00 mod€tl REARSEATBELTBUCKLE/ CENTERBELTTONGUE (seepage24-7)
.FRONTSEATBELT page24 3 Replacement, page24-9 Inspection,
BELTEUCKLES (seepage24 5)
24-2
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J
FrontSeat Belt RePlacement SRScomponentsare locatedin this area.Reviewthe SRS and proceduresin this componentlocations,precautions, (24) performing or service('98 - 00 repairs before section models). CAUTION: Check the front seat bslts for damago. and replacothom if necessary.Be careful not to damage them during removal and in3tallation' Front scat bolt: 1.
2. 3. 4.
5.
M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e radio,then write down the frequenciesfor the preset buttons. Disconnectthe negativebatterycable,and wait at leastthree minutesbeforebeginningwork. Slidethe front seatforwardfully. Bemove(seesection20): . Centerpillarlowertrim Pane . Kickoanel . Frontsidetrim '97 model:Removethe upper anchorcover and the lower anchorcaP. '98 - oO models: Removethe upper anchor cover and pull the lower anchorcoverback. UPPENANCHORBOLT 7/1&20UNF 32 N.m (3.3kgt'm. 24 tbf.ft) Applyliquidthread lock.
UPPER COVER
SEATBELT TENSIONER
REARSIDE
7 . R e m o v et h e u D D e ra n d l o w e r a n c h o r b o i t s , t h e retractor bolt, the retractor mounting bolt, and remove the front seat belt and retractor. 8. Removethe centerpillaruppertrim (seesection20). 9 . Removethe shoulderanchoradjuster.
I x 1.25mm 23 N.m 12.3kgt.m, 1? tbf.ft)
10. lnstallationisthe reverseof the removalprocedure. NOTE: Checkthat the retractorlockingmechanismfunctions as describedon Page24-9. Assemblethe washers,collarand bushingon the uooerand lower anchorboltsas shown. Eeforeinstallingthe anchor bolts, make sure there are no twists or kinksin the front seat belt. Make sure the seat belt tensionerconnectorls connectedsecurelv. Enterthe anti-theftcode for the radio,then enter the customer's radio station presets
ANCHOR CAP ('97 modell LOWERANCHORBOLT ?,/1&20UNF 32 N.m {3.3 kgf.m,2,1lbf.ftl
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To avoid accidontal deployment and @ possibteinlury, always disconnectthe soat bsh tonsion€r connoctor bofore rsmoving th6 retractor l'98 - 00 modsls, se€ page 21-231.
SHOULDER ANCHOR ADJUSTER
ANCHOR COVER l'98- 00models) RETRACTORBOLT 7/1&20UNF 32 N.m 13.3kgt m, 24 tbt.ft)
Disconnectthe seat belt tensiongr connector.
SHOULDER ANCHOR ADJUSTER
{'98 - 0o modols) RETRACTOR MOUNTINGBOLTZ,, ./ Gx1.0mm 9.8N.m (1.0kgt.m, ?.2 tbtft)
o.
(cont'd)
24-3
Seat Belts FrontSeat Belt Replacement {cont'dl Uppgr anchorboh construqtion:
R€tractorbolt construqtion: UPPEBAI{CHOR
aolT Apply liquidthread tock.
T(X)THED LOCI(WASHCR
RETNACTOR BOLT
bwd RETBACTOR
Lower anchor bolt construction: '97 modol: LOWERANCHOR
24-4
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Csntor anchor bolt construstion:
Ssat belt buckle: 1.
Slidethe front seatforwardfully
2.
Removethe centercover(seesection20).
3.
Driver's: Disconnectthe seat belt switch connector, and detachthe harnessclips from the seatcushion frame.
TOOTHED LOCKWASHER
WAVE WASHER
CENTER ANCHOR BOLT
>: Cliplocations SPRING WASHER
5.
WASHER
CENTER ANCHOR
lnstallationis the reverseof the removalprocedure. NOTE:Assemblethe washerson the centeranchor bolt as shown.
To seat belt buckle.
SEATBELT swlTcH CONNECTOR 4.
Removethe centeranchorbolt,then removethe seat belt buckle. Pull out the seat belt switch harness (with seat belt switchl. SEATBELT BUCKLE
CENTERANCHORBOLT 7/1&20UNF 32 N.m {3.3kg{ m, 24 lbf ftl
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SEATB€LT SwlTCH HARNESS
24-5
Seat Belts RearSeat Belt Replacement CAUTION:Checkthe rear s€at belts for damage,and replacelhem if necessa.y.Be caretul not to damage them during temoval and installation. Rearseat belt: 1,
Removethe rearseat{seesection20}.
2.
Carefullypull on the upper anchorcover and lower anchorcoverto removethem.
6.
Installationis the reverseof the removalprocedure. NOTE: . Checkthat the retractorlockingmechanismfunctions as describedon page24-9. . Assemblethe washers,collarand bushingon the lower anchorbolt as shown. . Beforeinstallingthe anchorbolt, makesurethere are no twistsor kinksin the rearseatbelt.
Upper anchot bolt construction:
UPPERANCHORBOLT 7/16-20UNF 32 N.m 13.3kg{.m, 24 tbt.ft)
UPPERANCHOR TOOTHEO LOCKWASHER
/
A \tt
REARSEAT BELT
RETRACTOR
UPPER ANCHOR COVER
LOWER ANCHOR COVER
ANCHOR
COLLAF
Lowel anchor bolt construqtion: LOWERANCHOR BOLT
SPRING WASHEB
RETRACTOB MOUNTINGBOLT 6x1.0mm 9.8N.m (1.0kgt.m. 7.2 rbf.ftl RETRACIOREOLT 7/16-20UNF 32 N.m {3,3kgf.m, 24 rbr.ft)
3.
TOOTHED LOCI(WASHER
LOWERANCHOFBOLT 7/1S20UNF 32 N.m 13.3kgl.m, 2/r lbf.ftl
BUSHING
Removethe lower anchorbolt.
WASHERS
COLLAR
LOWERANCHOR
4.
Remove(seesection20): . Cargoareafloor and cargostoragebin . Reartrim paneland rearsidetrim panel
Rgtractor boll construction:
/\
f/F\-.
Removethe upper anchor bolt, the retractorbolt. the retractormounting bolt, and remove the rear seatbelt and retractor.
P \v*\ /
T(X)THED LOCKWASHER
24-6
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r>--->.
(t--nnnllH \ \
RETRACTOR
\ RETMCTOR BOLT
) J Seat belt buckles/Centerbelt tongue:
with tilt:
without tilt:
1.
forward.and tilt the rearseatup Foldthe seat-back
2.
While holdingthe trunk floor extensionup, remove the centeranchorbolts
1.
Removethe rearseaton eachslde.
2.
Raisethe trunk floor extensions,removethe cenler anchorbolts,then removethe seat belt bucklesand centerbelttongue.
SEAT.BACK
CENTERBELTYONGUE
CENTFRANCHORBOLTS 7/16-20UNF 32 N.m (3.3kgf.m, 2a rbtftt
CEiITER AT{CHORBOLTS 7/1e20 UNF 32 N.m {3.3kgt m, 2r bf.frl
SEATBELT BUCKLE
and returnthe seatto its origiRaisethe seat-back, position. nal
)
Removethe center anchor bolts, then remove the center belt tongue and seat belt buckle.
SEATBELT BUCKITS
\\ lnstallationis the reverseof the removalprocedure. NOTE:When reinstallingthe rear seats.make sure there are no twists or kinksin the centerbelt tongue and seatbelt buckle.
)
(cont'd)
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Seat Belts RearSeat Belt Replacement(cont'dl 5.
Installationis the reverseof the removalDrocedure. NOTE:Makesurethere are no twists or kinksin the centerbelttongueand seatbelt buckle.
Cenler anchor bolt construction:
€ \
TOOTHED LOCKWASHER ANCHOR
24-8
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Inspection Rear:
SRS componentsale located in this area. Reviewthe SRScomponentlocations,precautions,and procedures in this section(24)beforepreformingrepairsor service ('98- 00 models).
40.
/A
To avoid accidontaldeployment and possi!!!@ 6i6-'rnpry. att"ays aisconnsct th€ seat beh tensioner conn€ctor belore removing tho retrastor {.98 - 00 modols, seo
*1ix \| _t-. \ /
page2+231.
L = ls
Rgtlastor Insgection
RETRACTOR
1.
Beforeinstallingthe retactor,checkthat the seatbelt can be pulledout freely
2.
Make sure that the seat belt does not lock when the retractoris leanedslowlyup to 15'from the mounted Dosition.The seat belt should lock when the retractor is leanedover 40". CAUTION: Do not attsmpt to dbassemble ths relrac' tor.
Forwerd Forwerd
3.
Beplacethe seatbeltwith a new assemblyif thereis any abnormality.Do not disassembleany part of the seatbeltfor any reason.
In-vehicleS68t Belt InsPestion 1.
Front: '97 modol:
lnsida
Ch€ckthat the seat belt is not twistedor caughton anything. After installingthe anchors,checkfor free movement on the anchorbolts lf necessary,removethe anchorbolts,and checkthat the washersand other partsare not damagedor improperlyinstalled.
.: Mounted Position
Checkthe seatbeltsfor damageor discoloration. Cleanwith a shop towel if necessary. CAUTION: Uso only soap and wator to clean. NOTE:Dirt build-upin the metal loopsof the upper anchorscan causethe seat belts to retractslowly Wipe the insideof the loopswith a cleanclothdamP enedin isopropylalcohol.
RETRACTOR lnside
Forward -
Checkthat the seat belt does not lock when pulled out slowlv. The seat belt is designedto lock only duringa suddenstop or impact.
'98 - 00 modcls:
Makesurethat the seatbeltwill retractautomatically when released. For each passenger'sseat belt, make sure that the locking mechanism in the seat belt retractorwill engagewhen the seatbelt is pulledall the way out. '1. RETRACTOR Forward -
Replacethe seatbeltwith a new assemblyif there is any abnormality.Do not disassembleany part of the seatbeltfor any reason.
)
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24-9
Seat Belts ChifdSeat TetherAnchor Installation-,97 - 99 Models Canadamodel: Attachmentpointsare providedfor a rear searmounted childrestraintsystemwhich usesa top tether.The attach_ ment pointsare locatedon both rearcornersof the head_ liner,just behindthe rear seat-back. When using a child seatwith a top tether,installthe child seattetheranchor securelv.
NOTE: . Do not removethe toothedwasherfrom the childseat tether anchor.Use the seat anchorwith the toothed washerattachedto it. . When installinga child seat on the rear seat,follow the instructionsof the manufacturer of the childseat. . Additionalanchorsare available.
NOTE:To installa child seat on the rearseat,selectthe attachmentpoint you want to use,and removethe plug coverfrom the attachmentpoint of the headliner.Install the child seattetheranchorsecurely.
ATTACHMENT POINTS
PLUGCOVERS
CHILOSEAT TETHER ANCHOR
TOOTHEDWASHER
-
24-10
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l r
-'00 Child Seat TetherAnchor Removal/lnstallation
Model
AttachmentDointsare providedfor a rear seat mountedchild restraintsystemwhich usesa top tether'The attachment pointsare locatedon both rear cornersof the headliner,just behindthe rear seat-backThe child seattether anchorsare installedinto eachattachmentpoint.Eachchild seattetheranchoris coveredwith a childseattetheranchorcover. NOTE: . Do not removethe toothedwasherfrom the child seattetheranchor.Usethe anchorwith the toothedwasherattached to it. . When installinga childseaton the rearseat,follow the instructionsof the manufacturerof the childseat. U n i t im m ( i n . )
HEADLINER
TOOTHEOWASHEB
CHILDSEAT TETHERANCHOR
I x '1.25mm 22 N.m (2.2kgf m, 16 rbf.ft)
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24-11
)
SupplementalRestraintSystem (SRS)
\ )
.."....."" 24-14 Troubleshooting SpecialTools 24-26 Self-diagnosticProcedures............. Component/Wring Location '97 '....."""24-15 model ..........'.." .....".."'24'26 lndexReadingthe DTC .................. Component/WiringLocation Erasingthe DTCMemory ................24-28 24-16 lndex - '98 - 00 models ..............." Troubleshooting lntermittent .'.........."'.24'17 "'...........24'24 Description Faifures .........24'14 CircuitDiagram DiagnosticTroubleGode {DTC} "......24-29 Chart-'97 model ....""....... Precautions/Procedures (DTCI DiagnosticTroubleGode 24-19 GeneralPrecautions......".."'........... 24-31 Chart-'98 - 00 models ............. Airbag/SeatBelt Tensioner SRSIndicatorLight Wire 24-19 Handlingand Stolage ....''........... ','," 24'33 Connections 24-20 ...............'...... SRSUnit Precautions ....-........24'34 Ffowcharts lnspeciionAfter Deployment .......'.24'20 Driver's Airbag WiringPrecautions.............'............24-21 ..'......21'87 Repfacement SpringJoadedLockConnector with Built-inShort Contact '...'....24-21 Front Passenger'sAirbag .....'.',24'AS Repfacement Spring-loadedLock Connectors.."' 24-22 GableReel BackProbingSPring-loadedLock ,.......24-22 Conneetors .......'.24-91 Replacement and Connectors Airbag Disconnectingthe SRSUnit the Seat Beh Tensioner .........24-95 Replacement ....'....24-23 Connectors Airbag/SeatBelt Tensioner Steering-lelatedPrecautions..........24-25 .................24'97 Disposaf
)
-
e
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SpecialTools
Ref. No.
Tool Number
o"'
07HAz- SG00500 07PM- 0010100 07sAz- TB40114 07TAZ- SZ50114 o7TAZ - OO1O20A
@-, /a\
@ rA*,
Description
Oty
DeploymentTool SCSServiceConnector SRSInflatorSimulator SRSSimulatorLeadC BackprobeAdapter,l7 mm
1 1 '1 I 2
* 1: Includedin SRSTool Set 07MAZ- SM5000B *2: Use with the stacking patch cords from T/N 07SAZ0010004,BackprobeSet.
o
/n
24-14
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@
o
I
PageReference 24-91 24-21 24-50 24-50 24-43
Component/WiringLocationsIndex-'97 model
LIGHT(ln the gaugeassembly) SRSINDICATOR page24-27 Troubleshooting, Gaugeassembly,section23
To CRUISECONTROL
SET
DASHBOABDw|RE HARNESS LIGHTin to SBS INDICATOR GAUGEASSEMBLY 5P MAIN WIREHABNESS to DASHBOABDwlRE HARNESS 21P
DRIVER'SAIBMG Replacement, page 21-87 Disposal,page 24-97
To DRIVERSAnBAG
FRONTPASSEITGER'SAIRBAG Replacement,pago 24{9 Disposal,page 24-97
GOf$ECrOn PPI lBLr( 8R t
SRSMAIN HABNESS to UNOEB-DASH FUSE/BELAYBOX 2P CONNECTOR SRSMAIN HARNESS to MAIN WIRE HARNESS 3P OONNECTOR MEMORYERASESIGNAL IMES) CONNECTORI2PI [GRY. GRYI or twHT, BLr.l
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sBsitAr[ ] nNEss to FROI|T PASSEiIGEB.S ANBAG 2P
sns ut{fT GROUND SES MAIN HAR]GSS
tosnsU n
ItP OOIIITECTOR
24-15
Gomponent/WiringLocationsIndex-'98 - 00 models
SRSINDICAIORLIcHT (ln the gauge assembty) page24 27 Troubleshooting, Gaugeassembly.section23
CABLEREEL Replacement, page24-91
To HORNSWITCH
To CRUISECONTROL SET/RESUMESWTCH To DRIVER'SAIRBAG
DASHBOARDWIREHARNESS to SRS INDICATORLIGHf in GAUGEASSEMBLY 5P CONNECTOR
ORIVER'SAIRBAG Replacement, page 24-87 Disposal,page 24-97
FRONTPASSENGER'S AIRBAG page24-89 Replacement, Disposal,page24 97 SRSMAIN HARNESS to FROI{TPASSENGER,S AIRBAG 2P CONiIECTOR
SRSMAIN HARNESS
ro CABLEREEL 2PCONNECTOR MAIN VYIREHARNESS to DASHBOARDWIREHARNESS 24PCONNECTOR
SRSMAIN HARNESSto LEFTSIDEWIREHARNESS 2P CONNECTOR
SRSMAIN HARNESS to MAIN WIREHARNESS 3P CONNECTOB
RIGHTSIDEWIREHARNESSto SEAI BELTTENSIONER 2P CONNECTOR SRSUNIT (lncludingsafingsensor and impactsensor) page24-95 Replacement, SRSMAIN HARNESSto RIGHTSIDEWIREHARNESS 2P CONNECTOR
SERVICECHECK CONNECTOR I2PI IBLK BRNI
SRSMAIN
to UNDER-DASH BOX FUSE/RELAY 2PCONNECTOR MEMORYERASESIGNAL (MES)CONNECTOR I2PI IGRN,GRNIor IWHT,BLKI
SEATBELTTENSIONER page24 3 Replacement, Disposal,page 24-97 ORIVER'SSEATBELT Replacement,page 24-3 page24-97 Disposal, LEFTSIDEWIREHARNESSto SEATBELTTENSIONER 2P CONNECTOR
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24-16
Description )
J The SRSis a safetydevicewhich,when used in conjunctionwith the seat belt,is designedto help protectthe driver and front passengerin a frontalimpactexceedinga certainset limit.The systemconsistsof the SRSunit (includingsafingsenairbag. sor and impactsensor),the cablereel,the driver'sairbagand front passenger's Seat Bolt Tensioner {'98 - 00 models} of the seat belt. In a front-end The seatbelt tensioneris linkedwith the SRSairbagsto further increasethe effectiveness seats in their the occupants firmly to secure collision,the tensionerinstantlyretractsthe belt DRIVER'SAIRBAG
FRONTPASSENGER'S AIREAG FRONTPASSENGER'S SEATBELTTENSIONER {'98 - 00 modelsl
SRSUNIT
)
DRIVER'SSEATBELT TENSIONERl'98 - 0Omodeb)
Operation ignitesthe intlatorcharges.lf bat The main circuitin the SRSunit sensesand judgesthe forceof impactand, if necessary, voltage regulator and the back-uppower circuit impact, the power to the is disconnecteddue tery voltageis too low or will keepvoltageat a constantlevel. respectively For the SRSto operate: (1) The impactsensormust activate,and sendelectricsignalsto the microprocessor. (2) The microprocessor must computethe signals,and sendthem to the airbaginflators(andseatbelttensioners). (3) The inflatorsmust igniteand deploythe airbags(andactivatethe tensioners).
---__-l TENSTO1En I I
_-___J
1 9 8- 00 N4odes)
Selt-diagnosisSystem A self-diagnosis circuitis built into the SRSuniUwhen the ignitionswitchis turned ON (ll),the SRSindicatorIight comes on and goesoff afteraboutsix secondsif the systemis operatingnormally. lf the light does not come on, does not go off aftersix seconds,or it comeson while driving,it indicatesan abnormalityin the system.The systemmust be inspectedand repairedas soon as possible. For batteryserviceability, the memorywill storethe causeof the malfunction,and the data link circuitpasseson the infor mationfrom the memoryto the data link connector(DLC).This informationcan be readwith the HondaPGMTesterconnectedto the DLC{16P). www.emanualpro.com
24-17
CircuitDiagram
NOTE:The SRSmain harnessusesall GRY('97model)or GRN('98- 00 models)wires. UNDEF,HOOD FUSE/RELAY BOX
IGNITIONSWITCH
-'WHT/BLK
WHT
UNDER.DASH FUSE/RELAY BOX
+
YEUGRN
SFS INDICATOR CIRCUIT (lnlhegaugeassembly) SRS NDICATOR L G H T{ r . 4 W ) Shillloc*soenoid
FRONT PASSENGER'S ALRBAG INFLAlOR
P G MF I mamrelay
DRIVEB'S AIRBAG NFLATOR
A
t l
BLK
GRY (GFN)
1
0
5
GFY (GRN)
1
4
12
BLU
#+ tl . /t
t lI
d
GRY GRY (GRN) (GRN)
1 4
1
GR\
3 11
|
16
17
GRN (BLU/PNK)
15
I
GFY
GRY
?
FRONT PASSENGERS SEATBELT TENSIONEF
G401
DRIVER'S SEATEELT TENSIONER
U
r
V
?
F
?
r-? BRN t ?
V
BRN
F
t
V
I
GNY
(GlN)
lcFNt
I LTBLU t
18
H
DATA LINX PCM/ECMSERVICE MEMORY ERASE CONNECTOR CHECK S GNAL(MES) (Drc)(r6P) CONNECTOB CONNECTOR (2P) S8S UNT TERMINALS
('98- 00M o d e l s )
3 10 11
5
6
14 15
I
7
17 18
T e r m i n a sl i d eo f m a l et e r m i n a l s
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24-18
GRY
Precautions/Procedures GeneralPrecautions
)
Carefullyinspectany SRS part beforeyou install it. Do not installany partthat showssignsof beingdropped or improperlyhandled,such as dents,cracksor deformation: -
Airbags Cablereel SRSunit Seatbelttensioners
Airbag/SeatBeltTensioner Handlingand Storage Do not try to disassemblean airbag or a seat belt tensioner.They have no serviceableparts.Once an airbag or a seatbelttensionerhavebeendeployed.they cannot be repairedor reused. For temporarystorageof an airbag or a seat belt tensioner during service,pleaseobservethe following precautons: .
N
Store the removed airbag with the pad surface up. The driver's/frontpassenger'sairbagconnectorsand seat belt tensionerconnectorshave a built-in short contact (see page 24-211.
r th€ airb.g is impropcrty stor€d face down, @ accidental deployment could propel the unit with enough forc€to caus6serious iniury,
)
-
Use only a digital multimeterto checkthe system,lf it's not a Honda multimeter,make sure its output is 10 mA (0,01A) or lesswhen switchedto the smallest value in the ohmmeterrange.A testerwith a higher outputcould damagethe airbagcircuitor causeaccidentaldeploymentand possibleinjury. Do not install used SRS Dansfrom anothervehicle, When makingSRSrepairs,useonly new pans. E x c e p tw h e n p e r f o r m i n g e l e c t r i c a li n s p e c t i o n s , alwaysdisconnectboth the negativecable and positive cable from the batterv.and wait at least three minutesbeforebeginningwork. R e p l a c e m e not f t h e c o m b i n a t i o nl i g h t a n d w i p e r / w a s h e rs w i t c h e sa n d c r u i s ec o n t r o ls w i t c h c a n b e donewithout removingthe steeringwheel: -
Combinationlight and wiper/washerswitch replacement{seesection231. Cruisecontrolsevresumeswitchreplacement(see section41.
Wheneverthe ignition switch is ON {ll}, or has been turnedOFFfor lessthan three minutes,be carefulnot to bump the SRSunit; the airbagscould accidentally deployand causedamageor injuries. Wheneverthe airbaghas been activated,replacethe SRSunit.
)
The original radio has a coded theft protectioncircuit. Be sure to get the customer'scode number before disconnectingthe batterycables.
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AIRBAGCONNECTORS
Store the removed on a secureflat surfaceawav from a n y h i g h h e a t s o u r c e( e x c e e d i n g 2 1 2 " F / 1 0 0 ' Ca)n d free of any oil, grease.detergentor water. lmproperhandlingor storagecan internallydamage the airbagand seatbelttensioner.makingthem inoperative. lf you suspectthe airbagand seatbelt tensionerhave b e e n d a m a g e d ,i n s t a l l n e w u n i t s a n d r e f e r t o t h e Deploymenvoisposal for disposingof the Procedures damaoedunits.
Precautions/Procedures SRSUnit Precautions Takeextracarewhen paintingor doing body work in the area belowthe dashboard.Avoid directexposure of the SRS unit or wiring to heat guns, welding, or sprayingequipment. Disconnectthe driver's/frontpassenger'sairbagconnectors and seat belt tensioner connectorsbefore working belowthe dashboardnearthe SRSunit. After any degreeof frontal body damage,or after a collisionwithout airbagdeployment,inspectthe SRS unit for physicaldamage.lf it is dented,cracked,or detormed,reolaceit,
InspectionAfter Deployment After a collision in which the airbags were deployed. replacethe SRSunit,and inspectthe following: 1.
Inspectall the SRS wire harnesses.Replace,don't repair,any damagedharnesses
2.
Inspectthe cablereelfor heatdamage,lf thereis any damage.replacethe cablereel.
3.
After the vehicle is completely repaired,turn the ignitionswitch on. lf the SRS indicatorlight comes on for about six secondsand then goesoff, the SRS systemis OK. lf the indicatorlight does not function properly,go to SRSTroubleshooting.
Be surethe SRSunit is installedsecurelv. Do not disassemble the SRSunit. S t o r e t h e S R S u n i t i n a c o o l { l e s st h a n a b o u t 1 0 4 " F / 4 0 " Ca)n d d r y { l e s st h a n 8 0 o / o h u m i d i t y .n o moisture)place.Do not spill water or oil on the SRS unit,and keepit awavfrom dust. During installationor replacement,be carefulnot to bump (impactwrench,hammer,etc.)the areaa[ound the SRS unit, The airbagscould accidentallydeploy and causedamageor injury.
rD
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24-20
J
Wiring Precautions .
Spring-loadedLock Connestorwith Built-in Short Gontact
Neverattemptto modify,spliceor repairSRSwiring. NOTE:SRSwiring can be identifiedby specialyellow outercoveflng.
The driver's airbag/frontpassenger'sairbag and seat lockconnectorwith belttensionershave a spring-loaded a built-inshort contact.When this connectoris disconnected,the power terminal and the ground terminal in shorted. the airbagconnectorare automatically Conngctorhalvcs diSconnested: GROUNDTERMINAL
Be sureto installthe harnesswiresso that they are pinchedor interferingwith otherparts. ACT
SHORTCONTACT
CABIf REELCONNECTOR
Connector halves connected; GROUNDTERMINAL
M a k e s u r e a l l S R Sg r o u n d l o c a t i o n sa r e c l e a na n d groundsare securelyfastenedfor optimum metal-tometalcontact.Poorgroundingcan causeintermittent problemsthat are difficultto diagnose.
CONTACT
CONTACT
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24-21
Precautions/Procedures Spring-loadedLockConnectors
BackprobingSpring-loadedLock
Connectors
lock. SomeSRSsystemconnectorshavea spring-loaded . Disconnecting To releasethe lock,pull the spring-loaded sleevetoward the stop while holdingthe oppositehalt of the connector. Then pull the connectorhalvesapart.Be sure to pull on the sleeveand not on the connectorhalf.
When checkingvoltageor resistanceon this type of to removethe connectorthe first time, it is necessary retainerto insertthe testerprobefrom the wire side. It is not necessaryto reinstallthe removed retainer; the terminalswill stay lockedin the connectorhousinq.
SPRING-LOADED SLEEVE
RETAINER *Discardafter removal.
Connecting 1.
Hold the pawl-sideconnector hall and press on the backof the sleeve-sideconnectorhalf in the direction shown. As the two connector halves are Dressed together,the sleeve is pushed back by the pawl. Do not touch the sleeve.
To removethe retainer,insert a tlat-tip screwdriver betweenthe connectorbody and the retainer.then carefullypry out the retainer.Takecare not to break the connector.
RETAINEN
When the connec-torhalvesare completelyconnected, the pawl is released.and the spring-loadedsleeve locksthe connector. SPRING.LOAI'ED
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24-22
RETAINER
) 1 ,
andthe SeatBeltTensionerConnectors Disconnecting the AirbagGonnectors Beforeremovingthe airbagor SRSrelateddevices(the SRSunit,the cablereeland the seatbelttensionerconnector),disconnectingconnectorsfrom relateddevices,or removingthe dashboardor the steeringcolumn, disconnectthe airbag connectorsand seatbelttensionerconnectorsto Dreventaccidentaldeployment Turn the ignition switch oFF and disconnect ths nogative cable from the battery, and wait at least ihree @ minutes before beginning the tollowing proceduresA and B. lprocedure B follows the procedureA.l Beforedisconnecting the SRSmain harnessfrom the SRSunit,disconnectboth airbags(C,D) and both seatbelttensioners (F,H) {'98- 00 models). the cablereel2P connector(B),disconnectthe driver'sairbagconnector(C). Beforedisconnecting the left side wire harness2P connector(E).disconnectthe driver'sseat belt tensioner2P connector Beforedisconnecting (F)('98- 00 models). seatbelttensioner2P Beforedisconnecting the right side wire harness2P connector(G),disconnectthe tront passenger's (H) ('98 connector 00 models).
)
SRSMA1NHARNESS
i---
i
t
E
Jl
Jl
----l
l*",r*
I I
LEFTSIDE WIREHARNESS
)
{cont'd)
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24-23
Precautions/Procedures Disconneeting the AirbagConnectorsand the Seat BeltTensioner
Connectors(cont'd) 1.
Disconnectthe batterynegativecable,then disconnectthe positivecablefrom the battery.and wait at leastthree minutes. D i s c o n n e ctth e a i r b a g a n d t e n s i o n e rc o n n e c t o r s lsee page 24-22). Driver's Airbag: . R e m o v et h e a c c e s sp a n e l f r o m t h e s t e e r i n g w h e e l , t h e n d i s c o n n e c tt h e 2 P c o n n e c t o r betweenthe driver'sairbagand cablereel.When disconnected, the airbag connectoris automaticallvshorted.
Seat Bslt Tensioner(38 - 00 modebl: . Removethe left and (or) right centerpillar lower trim panels(seesection20). . Disconnectthe seat belt tensioner 2P connectors from the left sidewire harness(driver'sside)and (or)the right sidewire harness(frontpassenger's side).When disconnected. the seatbelttensioner is automatically shorted.
CLIPS
ACCESSPANEL
DRIVER'S AIRBAG 2PCONNECTOR Front Passsng€/sAirtag: . Disconnectthe 2P connectorbetweenthe front passenger's airbagand SRSmain harness.When disconnected. the airbagconnectoris automaticallYshorted.
DRIVER'SSIDE:LEFTSloE WIREHARNESS SIDE:RIGHTSIDEWIRE FRONTPASSENGER'S HARNESS
24-24
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)
Steering-related Precautions Stooring Wh€el and Csble Re6lAlignm€nt T o a v o i d m i s a l i g n m e n to f t h e s t e e r i n gw h e e l o n reassembly,make sure the wheels are turned straight aheadbeJoreremovingthe steeringwheel.
NOTE: . Whenthe airbagand cabler6elare disconnected, and the batteryis reconnectedand the ignition switch is turned ON (ll),the SRSunit will storethis as an open in the driver'sairbag inflator,and the SRS indicator light will come on, In such a case,makesure to confirm the DTC,then clearthe SRSunit memory. . For disconnectingthe spring-loadedlock type connector, refer to page24-22. '97
model: SRSMAIN HARNESS 2P CONNECTOR
CABLEREEL 2P CONNECTOR
To centerthe cable reel,rotatethe cable reel clockwise (approxiuntil it stops,Then rotate it counterclockwise matelytwo and a halfturns) until the arrow mark on the cablereel labelpointsstraightup.
'98 - 00 models:
LABEL
Steering Column Bemoval CAUTION: Before removing the stosring column, tirsi disconneqt tha connsctor between tho cabls roel and the SRSmain harness. lf the steering column is going to be removed without dismounting the steering wheel, lock the sieering by turning the ignition key to o-LOCKposition, or remove the key trom the ignition so that the steering wheel will not turn.
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UNDER-DASH FUSE/RELAY BOX Do not replacethe originalsteeringwheelwith any other d e s i g nb e c a u s ei t w i l l m a k e i t i m p o s s i b l et o p r o p e r l y installthe airbag(use only genuineHondareplacement partsl. After reassemblv,confirm the wheels are still turned straightaheadand that the steeringwheel spokeangle is correct.lf minor spokeangleadjustmentis necessary, do so only by adjustingthe tie-rods,not by removing and repositioning the steeringwhee .
24-25
Troubleshooting Self-diagnostic Procedures The self-diagnosticfunction of the SRSsystem allows it to locatethe causesof system problems and to store this information in memory,For easiertroubleshooting, this datacan be retrievedvia a data linkcircuit. When you turn the ignitionswitchON (ll).the SRSindicatorwill come on. lf it goes off aftersix seconds,the systemis normal. . lf there is 8n abnormality,the system locatesand definesthe problem.storesthis informationin memory,and turns the SRSindicatorlight on. The datawill remainin the memoryevenwhen the ignitionswitchis turned off or if the batterv is disconnected. . When you connectthe SCSserviceconnectorto the servicecheckconnector(2P),and turn the ignitionswitchON (ll), the SRSindicatorlight will indicatethe diagnostictroublecode (DTC)by the numberof blinks. . After readingand recordingthe DTC,proceedwith the troubleshooting forthis code. .
Precsutions . Useonly a digitalmultimeterto checkthe system.lf it's not a Hondamultimeter.makesure its outputis 10 mA (0.01A) or lesswhen switchedto the smallestvalue in the ohmmeterrange.A testerwith a higheroutput could damagethe airbagcircuitor causeaccidentalairbagdeploymentand possibleinjury. . Wheneverthe ignitionswitchisON (ll).or has beenturnedOFFfor lessthan three minutes,be carefulnottobumpthe SRSunit;the airbagscouldaccidentally deployand causedamageor injuries. . Beforeyou removethe SRSmain harness,disconnectthe airbagand tensionerconnectors(seepage24-23). . Make sure the battery is sufficiently charged (see section 23). lf the battery is dead or low, measuringvalues won't be correct. . Do not touch a testerprobeto the terminalsin the SRSunit or harnessconnectors,and do not connectthe terminals with a jumperwire. Use only the backprobeset and the SCSserviceconnector. For backprobingspring-loadedlock type connectors,.efet to page 24-22.
Readingthe DTC Whenthe SRSindicatorlight is on, readthe DTCusingone of thesemethods; A.
Connectthe HondaPGM Testerto the 16PData Link Connector{DLC),and follow the tester'sprompts.lf the tester indicatesno DTC,DTC9-1 and DTC9-2,double-check by jumping the servicecheckconnector(2P)and watchingthe SRSindicatorlight (seenext page).
DATA LINKCONNECIOR{DLCI{16P)
HONDAPGM TESTER
24-26
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) B . The SRSindicatorlight can also indicatethe DTCby the numberoJ blinkswhen the SCSserviceconnectoris connecred to the servicecheckconnector(2P). 1 . Turn the ignitionswitchOFF,and wait for ten seconds.Then connectthe SCSserviceconnectorto the servicecheck connector{2P).lf you do not wait ten seconds.the SRSunit will not be completelyresetand will not outputDTCS.
SEBVICECHECKCONNECTOR I2PI IALK,BRNI
SEBVICECONNECTOR 07PAZ- 0010100
2.
)
3. 4.
Turn the ignitionswitchON (ll).The SRSindicatorlight comeson for aboutsix secondsand then goesoff. Then it will indicatethe DTC: - The DTCconsistsof a main code and a sub-code. - Includingthe most recentproblem,up to threedifferentmalfunctionscan be indicated. - In caseof a continuousfailure.the DTCwill be indicatedrepeatedly(seeexample1 below). - In caseof an intermittent failure,the SRSindicatorlightwill indicatethe DTCone time,then it will stayon (seeexarnpte2 below). - lf both a continuousand an intermittentfailureoccur,both DTCSwill be indicatedas continuousfailures. - In casethe systemis normal {no DTC),the SRSindicatorlight will stay on (seeexample3). Readthe DTC. Turn the ignitionswitchOFF.and wait for ten seconds.Then disconnectthe SCSserviceconnectorJromthe service checkconnector(2P).
Examplesof DTCIndications: 1.
Continuousfailure,SRSIndicatorLight is:
0.3s
0.3s 0.35 0.3s
, s--l f.-, s--.l
--1 M.h@de
r-
-r f-
DTC21 Mo6t r.@nl p.oblem
2.
l
--l fl-!
i
Main code (1)
-
r
Sub-code (2)
D T Cr . 2
-l
F
M.a^ code (rt .............v_
--l F Sub-cod6ltl
otc I r Third.mGr .oconl
Intermittentfailure,SRSIndicatorLight is:
Light srayson in cas€ ol
DTC5,1
3.
Normal(no failure),SRSIndicatorLight is:
)
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24-27
Troubleshooting Erasingthe DTCMemory To erase the DTC{S)from the SRS unit, use a Honda P G M T e s t e r( s e et h e H o n d aP G M T e s t e rS R SV e h i c l e SystemSupplement)or the followingprocedure. 1. 2.
Makesurethe ignitionswitchis OFF. Connectthe SCSserviceconnectorto the MES con, nector(2P).Do not use a jumperwire.
TroubleshootingIntermittent Failures lf there was a malfunction.but it doesn'trecur,it will be storedin the memory as an intermittentfailure,and the SRSindicatorlight comeson. After checkingthe DTC,troubleshoot as follows: Readthe DTC(see"Readingthe DTC").
1.
E r a s et h e D T C m e m o r y ( s e e " E r a s i n g t h e D T C Memory"). With the shift leverin neutral,turn the ignitionswitch ON (ll),and let the engineidle.
3.
4 . The SRSindicatorljght comeson for about six seconds and then goesoff. MEMORYERASE SIGNAL(MES}CONNECTOR I2PI IGRY,GRYIor IGRN,GRNI
SCSSERVICE CONNECTOR 07PAZ- 0010100 3. 4.
5.
6.
7. L
Turn the ignitionswitchON (ll), The SRS indicatorlight comeson for aboutsix seconds and then goes off. Removethe SCSservjcecon nectorfrom the MES connector{2P)within four seconds afterthe SRSindicatorlight went otf. The SRSindicatorlight comeson again.Reconnect the SCS service connectorto the MES connector (2P)within four secondsafterthe SRSindicatorlioht comeson, The SRS indicatorlight goes otf. Removethe SCS s e r v i c ec o n n e c t o rf r o m t h e M E S c o n n e c t o r( 2 P ) within four seconds. The SRSindicatorlight indicatesthat the memoryis erasedby blinkingtwo times. Turn the ignition switch OFF,and wait for ten sec onos.
ON
t*F l
--- _l
t
Shakethe wire harnessand the connector, takea test quick braking,cornering), drive (quickacceleration, and turn the steeringwheel fully left and right,and hold it there for five to ten secondsto find the cause of the intermittent failure. lf the problem recurs,the SRS indicatorlight will stayon.
-+t
6!.c
l.-
,l sec or less Problemrecurs,light stayson. SRSindicator liqtfi OFF MES connac'lol terminals
CONNECTED
6.
lf you can't duplicatethe intermiftent tailure,the system is OK at thistime.
OISCONNECTEO
:-
24-28
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I
j
DiagnosticTroubleCode(DTG)Ghart-'97 model SRS indicator light doesn'tcome on
DTC none (doesn't come on) none*' (doesn't go off)
Corroctiveaction
Slc pago
FaultySRSindicatorlight circuit
Troubleshooting
24-34
FaultySRSindicatorlight circuit,internal tailureof SRSunit,faultySBS powersupply
Troubleshooting
24-37
Pos3iblscause
Openin the driver'sairbaginflator
24-50
in the driver'sairbag Increasedresistance inflator
24-50
Shortto anotherwire in the driver'sairbag inflatoror decreasedresistance
doesn't go off
r
,
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24-52
Shortto power in the driver'sairbaginflator
24-54
Shortto groundin the driver'sairbaginflator
24-56
airbaginflator Open in the passenger's
24-58
airbag Increasedresistancein the passenger's inflator
24-54
Shon to anotherwire in the passenger's airbag inflator or decreasedresistance
)
Troubleshooting
Troubleshooting
24-60
2-4
airbag Shortto power in the passenger's inflator
24-62
2-5
airbag Shon to ground in the passengar's inflator
24-64
(cont'd)
24-29
Troubleshooting DiagnosticTroubleCode(DTC)Chart-'97 model (cont'dl SRS indicator light
DTC
Possiblecause
Correstiveaction
See page
Internalfailureof the SRSunit
SRSunit replacement
24-96
Internalfailureof the SRSunit
SRSunit replacement
24-96
lnternalfailureof the SRSunit
SRSunit replacement
24-96
Internalfailureof the SBS unit
SRSunit replacemenr
24-96
Internalfailureof the SRSunit or two failures at a time
Troubleshooting
24-82
Internalfailureof the SRSunit
SRSunit replacemenr
24-96
9-2
FaultySRSpowersupply(VBline)
Troubleshooting
24-84
'101
SRSairbagsdeployed(SRSunit must be replaced)
SRSunit replacement
24-96
5-3 5-4 5-5 o-l
6-2 6-4
doesn'tgo off
7-2 7-3 8-1
a-2 8-5 8-6
*1: In caseof an intermittentfailureDTC9-1,it meanstherewas an internalfailure of the SRSunit or a faultv SRSindicator light circuit.Do the troubleshooting for intermittentfailures{seepage24-28), *2: DTCcannotbe readwith a HondaPGMTester;checkby jumpingthe SCSserviceconnector. NOTE: Before troubleshooting DTCS5-1 through 8-5, check battery/systemvoltage. lf voltage is low. repair the charging systembeforetroubleshooting the SRSsystem.
24-30
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l*
)
TroubleCode(DTCIChart-'98 - 00 models Diagnostic
;
SRSindicator light doesnt come on
DTC none (doesn't come on) none*3 {doesn't go off)
Correctivaagtion
See page
FaultySRSindicatorlight circuit
Troubleshooting
24-34
FaultySRSindicatorlight circuit.internal failureof SRSunit,faulty SRSpower supply ( V Bl i n e )
Troubleshooting
24-42
Troubleshooting
24-47
Possiblscause
No DTC (lightcomes FaultySRSpower supply(VA line) on afterselfdiagnosis) Open in the driver'sairbaginflator 1-1
24-50
in the driver'sairbag lncreasedresistance inflator
1-3 1-4
1-5 2-1
Shortto anotherwire in the driver'sairbag inflatoror decreasedreslstance
2,4
3-1 3-2
3-4 4-1
4-3 4-4
4-5
)
-
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Troubleshooting
24-52
Shortto power in the driver'sairbaginflator Shortto groundin the driver'sairbaginflator
24-54
airbaginflator Open in the passenger's airbag in the passenger's Increasedresistance inflator
24-54
Shon to anotherwire in the passenger's airbaginflatoror decreasedresistance doesn't go off
24-50
24-56
24-58
Troubleshooting
24-60
airbag Shortto power in the passenger's inflator
24-62
arrbag Shortto ground in the passenger's inflator
24-64
Openin the driver'sseatbelttensioner
24-66
lncreasedresistancein the driver'sseatbelt tensroner Troubleshooting Shon to anotherwire in the driver'sseatbelt tensroner Short to power in the driver'sseat belt tensioner
24-66
Shortto ground in the driver'sseatbelttensloner
24-72
seatbelttensioner Open in the passenger's seat in the passenger's Increasedresistance belttensioner seat Shortto anotherwire in the passenger's belttensioner Short to power in the passenger'sseat belt tensroner seatbelt Shon to groundin the passenger's tensroner
24-14
24-64 24-10
24-74
Troubleshooting
24-76 24-74 24-AO
(cont'd)
24-31
Troubleshooting
l*-
DiagnosticTroubleCode(DTC)Chart-'98 - 00 modets(cont,dl SRSindicator light
DTC
Po$ibla cause
Corroctivelction
Sec pag€
Internalfailureof the SRSunit
SRSunit replacement
24-96
lnternalfailureof the SRSunit
SRSunit replacement
24-96
Internalfailureof the SRSunit
SRSunit replacement
24-96
Internalfailureof the SRSunit
SRSunit replacement
24-96
Internalfailureof the SRSunit
SRSunit.eplacement
24-96
SRSunit replacement code (SRSunit must not be usedany longer)
SRSunit replacement
24-96
5-l 5-4 6-1
6-3 6-4
doesn'tgo off 8-1
8-2 8-3 8-4 8-6
9_2*2*3
10-1
1,.-
NOTE: *1: In caseof an intermittentfailureDTCg-1, it meanstherewas an internalfailureof the SRSunit or a faulw SRSindicator light circuit.Do the troubleshooting for intermittentfailures(seepage2,+_2g), *2: In caseof an intermiuentfairureDTc 9-2, it meansthere was an internarfairureof the power suppry(vB rine).Do the troubleshooting for intermittentfailures(seepage24-29). *3: DTCcannotbe readwith a HondaPGM Tester;checkby jumpingthe SCSservic€connector. NOTE: Before troubleshooting DTCS5-1 through g-6. check battery/systemvoltage. lf voltage is low, repair the charg_ ing systembeforetroubleshooting the SRSsystem.
\f
24-32
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..
SRSIndicatorLightWireConnections SRS Indicator Light Power Circuit WIREHARNESS DASHBOARD YEL BLK To UNDER-DASH FUSE/RELAYBOX <_ 20PCONNECTOR
csog
+
To GAUGE assEMBLy
SRS Indicator Light Control Circuit
SRSMAIN HARNESS
)
-
MAIN WIREHARNESS
V A I V B I t To UNDER-DASH FUSE/BELAYBOX 2P CONNECTOR
c414 c415 c502 c503 c509 c801 c803 c806
)
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MAIN WIREHARNESS3P CONNECTOR MAIN wlRE HARNESS24PCONNECTOR
Terminalside of msle t€rminals
WIREHARNESS2OPCONNECTOR DASHBOARD WIREHARNESS24PCONNECTOR OASHBOARD
Wire side of lemslo terminsls
DASHBOABDWIREHARNESS5P CONNECTOR SRSMAIN HARNESS2P CONNECTOR
Wire sid€ ot lemale te.minals
SRSMAIN HARNESS3P CONNECTOR
Wire side ol female terminals
SRSMAIN HARNESST8PCONNECTOR
Wire side of lomrle terminals
Terminalaide of male terminals Wire side of female t€rminal3 wire side ol f.male terminals
24-33
Troubleshooting The SRSIndicatorLight Doesn'tComeOn
lr-
CAUTION:Wheneverthe ignition switch is ON D, or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentallydeploy and causedamage or iniuries. Ch6ckthe power supply (fuse): Turnthe ignitionswitchON {ll),and checkwhetherthe other indicatorlightscomeon (brakesystem,e(c.r. Do the other indicator liglrts com6 on?
Checkthe No. 25 (7.5A) fuse in the under-dash tuse/relay DOX.
ls the tus€ oK? YES
NO
Checkthe bulb: Replacethe No.25 (7.5 A) fuse, and checkthat the SRSindicatorlightcomeson. Doesthe SRSindicator liqht come on?
YES
NO
END Checkthe wire h.rnesi kwe€n fus€.nd gauge .3sembly: Checkfor an open in the wire harnessbetween fuse No. 25 (7.5Al and the gaugeassembly,and repair.Check that lhe SRSindicato.lighi Doesthe SRSindic.tor liqht com6 on?
YES
NO
END Checkthe SRSindicator light bulb: 1. Turnthe ignitionswitchOFF. 2. Removethe gaugeassembly. 3. Checklor blown SRSindicatortightbulb. ls the SRSindicator tight bulb OK? YES
NO
Checkthe SRSindicator light circuit: Replacethe bulb, and reconnectthe gauge assembly conneclors. Thenturn the ignitionswitchON {ll). Doesthe SRSindicator light come on?
I YEs
No
:ND
(A)To page24-35
24-34
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(B)To page24 35
lu
)
Jt Frompage24 34 (A)
From page 24-34 (8)
DASHBOARDWIREHARNESS 5P CONNECTOR
Chockth6 SRSindic.lor light circuit: 1. Disconnectthe dashboardwire harness5P connector from the gaugeassembly. 2. Connecta voltmeterbetweenthe No l terminal (+) o{ the 5P connectorand grouncl. 3. Turn the ignitionswitchON {ll),and measurevoltage ls thero 8.5 V or lats for 3ix second! aflsr the ignition switch ha3 bo€n turnod ON (ll)7
YES
NO
Fdulty SRS indicator light cilctlit in ths gauge sssomblY; replaco tho SRS printod circuit board in the gauge aasombly,
DASHBOARDWIREHARI{ESS 5P CONI{ECTOR
c509
Wire side ol female terminals
MAIN WIREHARNESS
)
_
Chockth6 wire harn.$ of the SRSindicstor light circuh (11: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe main wire harness24Pconnectorfrom the dashboardwire harness3. Connecta voltmeterbetweenthe No 5 terminal (+) of the ma;nwire harness24Pconneciorand ground 4. Turnthe ignitionON {ll),and measurevoltage. ls there 8,5 V or l€r3 tor six s€cond3efter the ignilion switch has bssn turnod ON llll?
YES
NO WIRE DASHBOARO HARNESS24P CONNECfOR
Short to powor in the BLU wire of tho dashbosrd wire harne3s;Epait the harne3.s.
MAIN WIREHARI{ESS2/tP COI{ ECTOR
Terminalsideof maleterminals To page 24-36
(cont'd)
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24-35
Troubleshooting The SRSIndicatorLight Doesn'tComeOn (cont,dl From page 24-35
Checklhe wire harnessotthe SRSindicator light circuit l2l: L Turnthe ignitjonswitchOFF. 2. Disconnect the SRSmain harness3p connectorfrom the mainwire harness. 3. Connecta voltmeterbetweenthe No. I terminal (+) of the SRSmain harness3P connectorand qround. 4. Turnthe ignitionswitchON (ll),and measurevoltaqe. ls there 8.5 V o. less tor six seconds atter the ignition switch has beenturned ON
MAIN WIREHARNESS 3P CONNECTOR
UNDER.DASH FUSE/RELAY BOX '98 -
Short to power in th€ BLU wire of the main wiro halno3s;
J
'97 modol:
SRSMAIN HARN€SS 3P CONNECTOR
00 models:
MAIN WIREHARNESS 3P CONNECTOR
SRSMAIN HARNESS 3P CONNECTOR SRSMAIN HARNESS 3P COI{NECTOB
c803 Checkth€ wire hahess of th6 SRSindicator ci.cuit {31: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe battery negative cable, then the positive cable,and wait threeminutes. 3. Disconnectthe driver's and front passenger,sairbag connectors{anddisconnectthe seatbelt tensionerconnectors} (seepage24-23). 4. Disconnectthe SRS main harness18p connectorfrom 5. Reconnectthe battery positive cable, then reconnectthe negativecable. 6. Connecta voltmeterbetweenthe No. 6 terminal (+) of the SRSmain harness'l8Pconnectorand ground. 7. Turnthe ignitionswitchON (ll),and measurevoltage.There shouldbe 0.5V or less.
SRSMAIN HARNESS 18PCONNECTOR
Short to power in the BLU wire oI the SRS main harngas;
24-36
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FUSE/RELAY BOX
The SRSIndicatorLight Doesn'tGo Off -'97 model CAUTION:Wheneverth€ ignilion switch i3 ON (lll, ol has been turn€d OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accideniallydeploy and causedamag€ or iniuries. Try to reproducethe sRs indicator light: 1. ErasetheDTCmemory(seepage24 28) 2. Turn the ignitionswitchON {ll),and checkthat the SRS indicatorlight comeson for aboutsix secondsand then goes off. Doe3 the SRS indicator light slay on?
NO
YES
Intermiftent ftilure, system is OK at this time. S€o Troubl€_ shootingIntermittentFailuteson p.ge 24_28.
Checkthe No. 13 (15 Al fuse: 'L Turn the ignition switch OFF. 2. Checkfor blown No. 13 (15 A) fuse in the under dash fuse/relaybox. ls lhe tuse OK?
)
No. 13 115Al FUSE NO
YES
UNOER.DASH FUSE/RELAYBOX
Replacethe luse, and err3e the memory ' 1 . R e p l a cteh e N o .1 3 ( 1 5 A ) f u s e 2. Erasethe DTc memory(seepage24-28). 3. Turnthe ignitionswitchON (ll). ioes
the SRS indicatol light go off after 3ix s6conds?
YES
SRSUNIT
NO
ENO
Confirm tho OTC,and continuettouble3hooting.
Checkfor an open in the SRSmain hatn€ss{VA lins}: 1. Disconnectthe batterYnegativecable,then disconnect the positivecable,and wait for threeminutes. airbagcon the driver'sand front passenger's 2. Disconnect nectors(seepage24-23). 3. Disconnectthe SRS main harness18Pconnectorfrom the sRs unit. 4. Reconnectthe battery positive cable, then reconnectthe negativecable. 5. Connecta voltmeterbetweenthe No. 7 terminal (+) ot the SRSmain harnessl8P connectorand 9rouncl 6. Turnthe ignilionswitchON {ll). ls there battory voltage? YES
SRSMAIN HARNESS r8P CONNECTOR
SRSMAIN HARNESS18P CONNECTOR
NO
Ooen in the SRS main harness{VA line); replacethe natnoss.
(cont'd) (A) To page24 38 www.emanualpro.com
24-37
Troubleshooting The SRSIndicatorLight Doesn'tGo Off - '97 model (cont,d)
J
Frompage24 37 (A)
Checkthe SRSunit: Connectthe SRSmain harness18PconnectorterminalsNo. 6 and No.7 with a jumperwire and backprobe
Faulty SRSunit or poo. contact at the SRSmain ha.ness 18Pconnectoi; checkthe connector. lfthe conneqtoris OK, replacethe SRSunit.
SRSMAIN HARNESS18PCONNECTOR
Oidtuse No. 13 (15Al blow?
JUMPERWIRE
(B) To page24'39 Check for a short to ground in the SRS indicator tight circutl: 1. Turnthe ignitlonswitchoFF. 2, Disconnectthe dashboardwire harness5p connector from the gaugeassembly. 3. Checkresistance betweenthe No. 1 terminalofthe dash board wire harness5P connectorand ground. There shouldbe 1 MOor more.
Wlresidoot tomaleterminsls
) DASHBOARDWIREHARNESS 5P CONNECTOR
(c) To page 24-40 Shon to ground in th6 gaugo assembly;replacothe gau96
DASHBOANDWIRE HARI{ESS 5P CONNECTOR
c509
Wire side ol female terminals
T 243a
www.emanualpro.com
Frompage24-38 {B)
DASHBOARDWIREHARNESS 5P CONNECTOR
Checklhe SRSindicalor circuit: 1. Turnthe ignitionswitchOFF 2 . R e m o v et h e g a u g e a s s e m b l y D o n o t d i s c o n n e ctth e dashboardwire harness5P connectorfrom the gauge assemoly. 3. Turn the ignition switch ON (ll). 4. Connecttie dashboardwire harness5P connectorterminalsNo. I and No 5 with a iumperwire. Doesthe SRSindicator light 90 otn
Faulty SRS indicator light circuit in the 9aug6 a$embly; reolace the SRS printod circuit boa.d in th' gauge
DASHBOARDWIREHARNESS 5P CONI{ECTOR
Y;yfivvcsos ffi BLU I
)
Checktor rn open in the SRSindicator light circuit: 1. Turnthe ignitionswitchOFF 2. Disconnectthe dashboardwire harness5P connector from the gaugeassemblY. between the No. 6 terminal ol the SRS 3. Checkres]sta-nce main harness18Pconnectorand No l terminal ol the dashboardwire harness5P connector;there should be
IYEL
JUMPERWIRE
Wir6.sideof female lormrna|s
SRSMAI HAN ESS t8P CO I{ECTOR
Wire side oI fsmale terminals
{D) To page24-41
)
1E) To page24-41
DASHBOARDWIREHARNESS 5P COI{NECTOR
(cont'd)
www.emanualpro.com
24-39
Troubleshooting The SRSIndicatorLight Doesnt Go Off -'97 model {cont'dl Frompage24-38 1C)
i,
MAIN WIRE HARNESS24PCONNECTOR
Checkfor a short to ground in tho main wire ha.n.3s: 1. Disconnectthe dashboardwire harngss24p connector from the main wire harness, 2. Checkresistancebetweenthe No. 5 terminal of the dash_ board wire harness24P connectorand ground. There shouldbe 1 M0 or more.
OASHBOARD WIRE HARNESS 24PCONNECTOR
Short to ground in tho deshbosrd wire harne.r; raD.ir the dashboardwiro harness. DASHBOARDWIREHAff{ESS 24P COi{NECTOR
BLU
Wire side of female t6rminals
)
MAIN wlRE HARNESS 3P CONNECTOB
Checktor a short to ground in tho SRSmain hfina3!: 1. Disconnectthe SBS main harness3p connectorfrom the maanwire harness. 2. Checkresistancebetween the No. 1 terminal of the SRS main harness3P connectorand ground.Thereshouldbe 1 MO or more.
SRSMAIN HARNESS 3P CONNECTOR UNDER.OASH FUSE/RELAYBOX SRSMAII{ HARI{ESS 3P CONNECTOR
cao3 Short to ground in tho main wire harnesr; ,opair th6 main wire hamoss.
Short to ground in the SRS main hsrn6sa;.oplac. thc SRS main harn6ss.
)
24-40
www.emanualpro.com
r
) DASHBOARDwlRE hARNESS 5P CONNECTON
From page24-39 (D)
Checkthe SRSindicator circuit input voltage: the SRS main harness18Pconnectorto the 1. Reconnect SRSunit 2. Connecta voltmeterbetweenthe No 1 terminal (+) of the dashboard5Pconnectorand ground. 3. Turn the ignition switch ON (ll), wait for six seconds, then measurevoltage fs there 8.5 V or more?
YES
NO
The oroblem hts disappoareddue to disconnoctingand connecting the connectors. Be 3ure all terminals make good contact, and rocheckthe system {see Trouble' shooting Intermittent Failur6 on pagg2'l-281'
Pool contacl at the SRS main harness18Pconnector;check the connector. . lf the connoctor is OK. aubstituta a known-good SRS unit, and recheck. . ll the problem is still present, replaco the SRS main h'r-
DASHBOAROWIREHARI{ESS 5P CONI{EC'OR
c509
ness. Frompage24-39 iE)
)
Checkfor an oPen in the dashboardwire hatn8s: 1. Disconnectthe main wire harness24P connectorIrom the dashboardwire harness 2. Check resistancebetween the No. 6 terminal of the SRS and No 5 terminalotthe main mainhamess18Pconnector wire harness24Pconnector;thereshouldbe 0- 1 0 O 15the resistance.s specified?
YES
NO
ODen in the BLU wire ot the dashboard wit6 harness; rep.ir the dashboaldwite harness.
Terminalsideof malelerminals
Checkfor an open in the main wirc harness: '1. Disconnect the SRSmain harness3P connectorfrom the mainwire harness, 2. Checkresistancebetweenthe No. 6 terminal of the SRS and No 1 terminalofthe SRS mainharness18Pconnector shouldbe 0 - 1 0 u main harness3Pconnector;there |3 lhe re3istanceas sPecifiod? YES
NO
Oo€n in the BLU wire ol the main wire harness; rcpair tha main wire harness
)
SRSMAIN HABN€SS 3P CONNECTOR
Op€n in the SRS main harn4s; replacethe SRS msin har' no3s.
www.emanualpro.com
24-41
Troubleshooting
tl-
The SRSIndicatorLight Doesnt Go Off - ,99- 00 models CAUTION:Wheneverthe ignition switch is ON {lll, or has been turnod OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentallydeploy and causedamage or iniuries. T.y to reproducethe SRSindicator tight: 1. Erasethe DTCmemory(seepage24-28). 2. Turn the ignitionswitchON { }, and checkthat the SRS indicatorlight comeson for aboutsix secondsand then goes off. Doesthe SRSindicator tight stey on? YES
NO
Intermittent failure, system b OK at this time. 56€ TroubleshootingInle.mittent Failureson page24-2g.
Checkthe No. 23 (10Alfuse: 1. Turnthe ignitionswitchOFF. 2. Checkfor blown No. 23 flO A) fuse in the under dash luse/relaybox. ls the fuse OK? No. 23 110Al FUSE
YES
NO
FUSE/RELAY BOX
Repl.ce the tuse, and erasethe memory 1. Beplacethe No. 23 (10Ai fuse. 2. Erasethe DTCmemory(seepage24-28). 3. Turnthe ignitionswitchON flt). Doesthe SRSindicator light go ott after six secondt YES
I
NO
END
Conti.m tha DTC,and continue troubl*hooting.
Chockfor an open in the SRS main harness(Vg line): 1. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 2. Disconnectthe driver,sand front passenger,sairbag con_ nectors,and discoonectthe seat belt tensionerconnectors (seepage 24-23). 3. Disconnectthe SRS main harness18p connectorfrom the sRs unit. 4. Reconnect the bafterypositivecable,then reconnectthe negativecable. 5. Connecta voltmeterbetweenthe No. 3 terminal (+) of the SRSmain harness18pconnectorand oround. 6. Turnthe ignitionswitchON 0l). ls there battery voltage? YES
SRSMAIN HARNESS18PCONNECTOR
NO
Open in the SRS main harness(VB line); replacothe natness,
| (A)
To page24 43
24-42
www.emanualpro.com
\
) Ftom page 24-42 (A)
SRSUNIT SRSMAIN HARNESS Checkthe SRSunit: Connectthe SRSmain harness18PconnectorterminalsNo. 3 and No.6 with a iumperwire and backprobe Doesthe SRSindicator light go otf?
Faulty SRSunit or poor contact at the SRSmain harness 18Pconnedor; checkthe connector. lf the connoctoris OK, replacethe SRSunit
SRSMAIN HARNESS18PCONNECTOR Did tuseNo. 23 {10A} blow? JUMPERWIRE
1B) fo page24-44
)
Check for a short to ground in the SRS indicator light circurl: 1. Turnthe ignitionswitchOFF. 2, Disconnectthe dashboardwire harness5P connector from the gaugeassembly, betweenthe No l terminalofthedash3. Checkresistance r n d g r o u n d .T h e r e b o a r dw i r e h a r n e s s5 P c o n n e c t o a shouldbe 1 Mo or more.
Wiresideof lemalelerminals DASHBOAEDWIREHARNESS 5P CONNECTOR
(c) To page24-45 Short to ground in the gauge assembly;replacethe gauge DASHEOARDWIREHARNESS 5P CONNECTOR
c509
)
(cont'd)
www.emanualpro.com
24-43
Troubleshooting The SRSIndicatorLight Doesn'tGo Off -'99 - 00 models(cont,d) Frompage24,43
(B)
J
DASHBOARDWIREHARNESS 5P CONNECTOR
Checkthe SRSindicator circuit: 1. Turnthe ignitionswitchOFF. 2 . R e m o v et h e g a u g e a s s e m b l y D . o n o t d i s c o n n e ctth e dashboardwire harness5p connectortrom the gauge assemDty. 3. Turnthe ignitionswitchON 0l). 4. Connectthe dashboardwire hamess5p connectortermi nalsNo. 1 and No. 5 with a iumoerwire. Dooslhe SRSindic.tor light go offl YES
NO
Fauhy SRS indic.tor light circuit in lho gruge a3samblv; replaco the SRS print6d circuit bo.rd in the g.uge assombly.
Checkfor an opeo in the SRSindicaior light circuit: 1. Turnthe ignitionswirchOFF. 2. Disconnectthe dashboardwire harness5p connector from the gaugeassembly. 3. Checkresistance betweenthe No. 6 terminalof the SRS main haroess18Pconnectorand the No. 1 terminal ot the dashboardwire harness5P connector;there should be0-1.0O. |3 the rosbtance a3 sDecified?
YES
DASHBOARDWIREHANNESS 5P CONNECTOR
liTv;Tv;1c5i0s # lsru lYEr JUMPERw|RE
Wiresadeol lernale rerminats
SRSMAIN HARNESS 18PCONNECTOR
I
NO
Wir€sideot lemaleieminals
(D) To page24-46
(E) To page24-46 DASHBOARDWIREHARNESS 5P CONNECTOR
J 24-44
www.emanualpro.com
J From page 24-43 1C)
MAIN WIRE HABNESS2,lP CONNECTOR
Chockfo. a short to glound in tho main wire harn63: 1. Disconnecttho dashboardwire harnoss24P connector from the mainwire harness. betweenthe No 5terminaloIthedash2. Checkresistance board wire harness24P connectorand ground. There shouldbs 1 Mo or more.
WIRE OASHBOARD HARNESS 2,rP CONNECTOR
Short to ground in tho dashboatd wilo harnots; repair OASHBOARDWIREHARI{ESS 24P CONNECTOR
BLU
)
MAIN WIRE 3P CONNECTOR Chcckfor a short to ground in the SRSmain harnoss: 1. Disconnectthe SRS main hart\ess3P connector{rom the main wire harness, 2. Checkresistancebetween the No. 1 terminal of the SRS main harness3P connectorand ground.Thereshouldbe 1 MOor more.
cToR
BOX FUSE/RELAY
SRSMAIN HARNESS 3P CONIIECTOR
c803 Short to ground in the mlin wire harnoss; .epair lh€ mlin wira harness.
Short to ground in thc SRS mtin hemess; replacetho SRS
) (cont'd)
www.emanualpro.com
24-45
Troubleshooting The SRSIndicatorLight Doesn'tGo Off -,99 - 00 models(cont,d) Frcm page 24-44 {D)
J)
DASHBOARDWIREHARNESS
Ch€ckthe SRSindicator circuit input voltage: 1. Reconnectthe SRS main harness18p connectorto the SRSunit. 2. Connecta voltmeterbetweenthe No. 1 terminal {+) of the dashboard5P connectorand ground. 3. Turn the ignition switch ON {ll}, wait for six seconds, then measurevoltage. ls there 8.5 V or more?
YES
NO
The problem has disapp€areddue to disconnectingand connecting tho connectors. Be sure all terminals make good contact, and .echeck the system {seo Troublo_ shooting Intermiftent Failureson page2it-2E). DASHEOARDWFE HARNESS 5P CONNECTOR Poo. contact at the SRS main harn8s 18p connector;check the connector. . lf the connoctor is OK, aubstitute a known-good SRS unit, end recheck. . lf the problem is still present, .6place tho SRS m.in harne33.
c5ott
Wiresideof lemale terminals
J
Ftom lage24-44
(E)
Checkfor an open in the dashboa.dwire harnessi 1. Disconnectthe main wire harness24p connectorfrom the dashboardwire harness. 2. Checkresistancebetween the No. 6 terminal of the SRS main harness18Pconnectorand No. S te.minalof the main wire harness24Pconnector;thereshouldbe 0 - 1.00. ls th€ resistancers speciliedT YES
NO
Open in the 8LU wi.o ol the dashboard wire hrmess: repair the dashboardwire ha.ness.
Torminalsideol maletermtnal
Checkfo. an open in the m.in wire hamess: 1. Disconnect the SRSrnainharness3p connectorfrom the main wire harness, 2. Check resistancebetweenthe No. 6 terminal of the SRS rnain harness18Pconnectorand No. 1 terminalof the SRS main harness3Pconnector;there shouldbe 0 1.0O.
SRSMAIN HARNESS 18PCONNECTOR
c806
b the rGbtanco as sDecified?
YES
NO
ca03 Open in the BLU wir6 of th6 main wire hernos3;reori. the main wire hamess, Open in the SRS main harness;r€placethe SRS main ha.noss.
24-46
www.emanualpro.com
SRSMAIN HARNESS 3P CONNECTOR
No DTC CAUTION:Wheneverthe ignition switch is ON {lll, ol has been tulned OFF for less than three minutes, bs careful not to bump the SRS unit; the airbags could accideniallydeploy and causedamago or iniuries. Ch€ckthe fuse: 1. Turnthe ignitionswitchOFF. 2. Checkfor blown No. 13 ('15A) fuse in the under-dash Iuse/relay box. b th€ fuse OK? YEs
NO
1A)To page24 48 Replacethe fuse.Turn the ignitionswitchON {ll),and check that the luse doesn'tblow.
No. 13(r5 Al FUSE
ls the fuse OK? YES
UNDER-DASH FUSE/RELAYBOX
NO
The probl€m has disappeared.Ted{rive the v€hicle and see TroubfeshootingIntermittont Failureaon page21-28.
)
Check Ior short to ground between tho underdash tuse/ relay box and the SRSunil. 1. Turnthe ignitionswitchOFF. 2. Disconnectthe batterynegativecable,then disconnect the positivecable, and wait for threeminutes. 3. Disconnectthe driver's and front passenger'sairbag connectors,and disconnectthe seat belt tensionerconnectors (seepage24-23). 4. Disconnectthe SRS main harnessl8P connectorfrom the sRs unit. betweenthe No. 7 terminalof the SRS 5. Checkresistance main harness18Pconnectorand ground. Thereshouldbe 1 M0 or more.
SBSMAIN HARNESS 18PCONNECTOR
ls the .esistancoas soecified? YES
NO
SRSMAIN HARNESS18PCONNECTOR
Faulty SRSunit; replacelhe SRSunit {seepage 24-951.
)
(B) To page24-48
www.emanualpro.com
(cont'd)
24-47
Troubleshooting No DTC(cont'dl
1 ltofi
page 24-47
(B) Chockfor short to ground in the SRSmain harne3s: 1. Disconnect the SRSmain harness2P connectorlrom the underdashfuse/relay box. 2. Checkresrstance betwoenthe No.7 terminalof the SRS main harness18Pconnectorand ground.There should be 1.0M0 or more. k the ro3irtancc as specifi€d?
YES
NO
Short to ground in tho under-da3hlus6/rolay box; replacethe under-dashfuse/relav box, Short to glound in the SRS m.in hernoss;roplacetho SRS main hatnei3.
FUSE/RELAYBOX
J (A)Frompage24-47
SRSMAIN HARNESS18PCONNECTOR
Checktor an op€n in the SRSmain harness: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe batterynegativecable,then disconnect the positivecable.and wait for threeminutes. 3. Disconnectthe driver's and front passenge/sairbag con, nectors,and disconnectthe seat belt tension€rconnectors {seepage 24-23}. 4. Disconnectthe SRS main harness18Pconnectorfrom the SRSunit. 5. Reconnectthe battery positive cable, then reconnectthe negativecable. 6. Connecta voltmeterbetweenthe No. 7 terminaloI the SRSmain harness18Pconnectorand ground. 7. Turnthe ignitionswitchON (lll , and measurevoltage.
SRSMAIN HARNESS18PCONNECTOR Poor conlact .t the SRS main harness l8P connesto.: checkth6 connector, . It the connector is OK, substitute a known-good SRS unit, and rgcheck. . It lhe problem ii still p.es6nt, rcplace the SRS mlin hamess.
To page24-49
24-48
www.emanualpro.com
J 3
) Frompage24-48
Checktor an open in the SRSmain harne$: 1. Turnthe ignitionswitchOFF. 2. Disconnect the SRSmain harness2P connectorlrom the undeFdashfuse/relaybox. 3. Checkresistancebetween the No. 1 terminal of the SRS main harness2P connectorand the No. 7 terminalof the SRSmain harnessl8P connector. Thereshouldbe 0 - 0.5O. ls the re3istanc€as soecitiod?
YES
NO
Poor contact at iho SRS main harnoss2P connoctor; checkthg connocior. . lf the connector is OK. substitute a known-good underda3hfuse/rolav box, and .echeck. 'lf tho probl€m is still present. replace tho SRS main harne3s.
UNDER-DASH BOX FUSE/RELAY
SRSMAIN HARNESSlEP CONNECTOR Opon in the SRS main ha.ness;replacethe SRS main har ness.
)
c801 SRSMAIN HARNESS 2P CONNECTOR
)
www.emanualpro.com
24-49
Troubleshooting DTC1-1and DTC1-2 J
CAUTION:Wheneverthe ignition switch is ON {ll}, or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentallydeploy and causedamage o1 iniuries.
DRIVEF'SAIRBAG 2P CONNECTOR
Try to reproducethe SRSindicator light: 1. Erasethe DTCmemory(seepage24-28). 2. Turn the ignitionswitchON (ll),and checkthat the SRS indicatorlight comeson tor about six secondsand then ooes off.
CABLEREEL 2P CONNECTOR
Doesthe SRSindicator liqht stav on?
YES
NO
Intermiltent failure, svstem is OK at this time. See Trouble3hootingIntermittent Failureson page 24-28.
Checktor an open in the driver's airbag inflatori 1. Turn the ignitionswitchOFF2. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 3. Disconnectthe driver's airbag 2P connectorfrom the cable reel 2P connector-Do not disconnectthe passen ger'sairbagconnector. 4. Connectthe specialtool(2 O)to the cablereel2P connec tor. 5. Reconnect the battervpositivecable,then reconnectthe negativecable, 6. Erasethe DTCmemory(seepage24-28). 7. Readthe DTC{see page 24-261. ls DTC 1-1or DTC 1-2 indicsted?
YES
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR t2 0 JACKI 07saz - TB40r1A
'98 - 00 models:
'97 modol: CABLEREEL 2P CONNECTOR
NO SRSMAIN HARNESS2P CONNECTOR
Open or increasedresistancein the driver'sairbaginflato.; replacethed.ive.'s airbag (s6epage24-871.
Checkfoi an ooen in the cable reel: 1. Disconnectthe batterynegativecable,then disconnect the positivecable,and waatfor threeminutes. 2. Disconnect the specialtool (2 Oi from the cable reel 2P 3. Removethe dashboardlower cover,and disconnectthe cablereel2P connectorfrom the SRSmain harness. 4. Connectthe specialtool (2 0) to the SBSmain harness2P (cont'd) connector,
To page24'51
24-50
www.emanualpro.com
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR 120 JACKI 07sAz - TB4011A
J
) Frompage24 50
Checkfor an opon in the cabl€ re€l (cont'd): 5. Reconnect the battervpositivecable,then reconnectthe negativecable, 6. Erasethe DTCmemory(seepage24-28). 7. Readthe DTC(seepage24-2d. ls DTC 1-1or DTC 1-2 indic.ted? YES
NO
Open or increased resistance in the cable reel; replace the cable reel (seepaqe 24-91J.
)
Checkfor an open in the SRSmain harne$: 1. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait lor threeminutes. 2- Disconnect the front passenger's airbagconnectorland disconnect both seatbelttensionerconnectors), 3, Disconnectthe SRS main harness18Pconnectorfrom the SRS unit. Do not disconnectthe specialtool 12 O) from the SRSmain harness. 4. Checkresistance betweenterminalsNo. 1 and No. 13 of the SRSmain harness18Pconnector. Thereshouldbe aoorox.2.0 3.0 0.
SRSMAIN HARNESS 18PCONNECTOR
ls the rcsistanc€as soecified?
YES
NO
Poor contact at the SRS main harnoss 18P conn€ctor; check the connector. . It the connecior is OK, substitute a lnown-good SRS unit, and recheck. .lf the problem is still present,.eplacethe SRS main harness,
Opon or inc.oasedrc3istancein the SRS main harnoss; roDlacetho ha]nss.3.
www.emanualpro.com
24-51
Troubleshooting DTC1-3 J
CAUTION: Whonovor the ignition switch is ON (ll), or has been turnod OFF for less thsn three minutss. be caroful not to bump the SRS unit; tha ailbags could accidentallydoploy and cau3odamage or iniuries. Try to r.produce the SRSindicator light: 1. Erasethe DTCmemory(seepage24-28). 2. Turn the ignitionswitchON (ll),and checkthat the SRS indicatorlight comeson for about six sacondsand then goes off. Do.s the SRSindic.tor light stay on?
YES
2P CONNECTOR
NO
Intermittenl failuro. sy3tom i3 OK at this time. Soo Trouble3hootingIntormittenl Failure3on prqo 24-28.
Chockfor a short to enother wirG in the driver's sirbag inf,artor: 1. Tlrn tho ignitionswitchOFF. 2. Disconnectthe battery negativecable,then disconnect the positivecable,and wait for three minutes. 3. Disconn€ctthe driver's airbag 2P connectorfrom the cablo re€l 2P connector,Do not disconnectthe oassenger'sairbagconn€ctor. 4. Connectthe specialtool(2 Olto the cablereel2P connector. 5. Reconnectthe baftery positive cable, then reconnectthe negativecable. 6. Erasethe DTCmemory (seepage 24-28). 7. Readthe DTC(see page24-261. b DTC1-3 indicatod? YES
SRSSIMULATOR tfAD c 0?TAZ- SZ5olrA and SRSINFLATOR /SIMULATOR / Q a JACKI 07s,A-TB411A /'
ffi '97 model:
,98 - 00 models: CABLE REEL 2PCONNECTOR
NO
Sho.t in the driv6r's airb.g intletor; replacethe d v€r's .irb.g l3oo pag6 24€7).
Ch6cklor a short in the cablc reol: '1. Disconnectthe battery negativecable,then disconnect the positivecable,and wait for threeminutes. 2. Disconnectthe specialtool {2 O) lrom the cable reel 2P conneclor. 3. Removethe dashboardlower cover,and disconnectthe cablereel2P connectorfrom the SRSmain harness. 4. Connectthe specialtool (2 O) to the SRS main harness 2P connector. {cont'd}
To pago 24-53
24-52
www.emanualpro.com
SRSSIMULATOR LEADC 07TAZ- SZ50114 and SnS INFLATOR SIMULATOR {2 0 JACK} 07sAz - TB{011A
Frompage24-52
Chockfor a shon in th6 cablo recl {cont'dl: 5. Reconnectthe battery oositive cable,then reconnecttha negativecable. 6. Erssethe DTCmemory (seepage 24-28). 7. Readthe DTC(see page24-26l'. ls DTC'l-3 indic{tod?
NO
YES
SRSUNIT
Short in the csble reel; replacetha cabls rcol lsao paga 24-911.
Chockfor a short in th€ SRSmain ha.nors: 1. Disconnectthe batterynegativecable,th€n disconnect the Dositivecable,and wait for three minutes. 2. Disconn€cttho lront passengor'sairbag connector (and disconnectboth seat belt tensionerconnectors). 3. Disconnectthe SRS main harness18Pconnectorfrom the SRS {rnit.Do not disconnectthe specialtool (2 0) from the SRSmain harness2Pconnector. 4. Checkthe resistancebetweenterminals No. 1 and No. 13 of SRSmain harness18Pconnector. Thereshouldbe aDorox.2.0- 3.00.
)
b th€ rsciitlnce
SRSMAIN HABNESS 18PCONNECTOR
a3 sDecifi6d?
YES
NO
( . ,L z l3 l l Faulty SRSunit; rspl.c. th6 SRSunit l.co p.sc 2a-95,,
6
c806
3
15
18
Wiresideot tormrnats Shori in the SRS m.in h.rn.e!; ropbce the SRS main htrne33.
)
www.emanualpro.com
24-53
Troubleshooting DTC1-4 ial
CAUTION: Whonover the ignition switch is ON (ll), or has boen turned OFF for less than throe minutos, bs carelul nol to bump tho SRS unit; the airbags could accidentallydeploy and causedamago or iniuri63. Try to rop.oducotho SRSindicator light: 1. Erasethe DTCmomory(soepage24-28). 2. Turn the ignitionswitchON {ll},and checkthat the SRS indicatorlight comeson for aboutsix secondsand then goes off. Doe3th6 SRSindicltor light 3tay on?
YES
REEL 2P CONNECTOR
NO
Intormittent tailure, rystem is OK rt this timo. See Troubl$hooting Intermittent Failurcson pago 2G28.
Chacklor a 3hort to powor in ths driyar's airbag inflrtor: 1. Turnthe ignitionswilchOFF. 2. Disconnectthe batterynegativecable,th€n disconnect the positivecable,and wait for threeminutes. 3. Disconnectthe driver's airbag 2P connector{rom the cable reel 2P connector.Do not disconnectthe passenger'sairbagconnector. 4. Connectthe specialtool (2 0) to the cablereel2P conn6ctor, 5. Reconn€ctthe battery positive cable.then reconnectthe negativecable. 6. Erasethe DTCmemory (seepage 24-28). 7. Readthe DTC{see page 24-261. ls DTC 1-4 indicatod? YES
SIMULATOR LEAD C 07TAZ- SZ5011A .rd SRSINFIATOR /SIMULATOR ./ ea JA0KI
1(
ffi
otstz-terore
ltl
'97 model:
'98 - 00 models: CABLE REEL
NO
Short to powe. in the driv.r's rirbrg inflator; replacethe ddver's airbeq (!o€ D.qa 2447).
Ch€ckfor. short to powe. in tho cabl6.ool: 1. Disconnectthe batterynegativecable,then disconnect the oositivecable,and wait lor three minutes. the specialtool (2 O) from the cable reel 2P 2. Disconnect connefior, the 3- Removethe dashboardlower cover,and disconnect cablereel2Pconnectorlrom the SRSmain harness. 4. Connectthe specialtool (2 0) to the SRS ma;n harn€ss (cont'dl 2P connoctor.
SIMULATOR I-EADC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR (2 0 JACKT 07sAz - lB4011A
To page 24-55 !
24-54
www.emanualpro.com
Ftom page24-54
Checkfor 6 short power in the cable r6el {cont'd): 5. Reconnectthe battery positive cable, then reconnectthe negativecable. 6. Erasethe DTCmemory (seepage 24-28). 7. Readthe DTC(see page 24-261. b DTC1-4 indicarodz
YES
NO
Short to power in lhe cablo roel; replace th€ cabl€ ieel {seepago24-91).
Checktor a short to power in th. SRSmain harn$s: 1.Disconnectthe batterynegativecable,then disconnect the positivecable, and wait for three minutes. 2. Disconnectthe front passenger's airbagconnector{and disconnect both seatbelttensionerconnectors). 3. Rernovethe specialtool (2 O)from the SRSmain harness 2P connector. 4. Disconnectthe SRS main harness18Pconnectorfrom the SRSunit. 5. Beconnectthe batterv positive cable, then reconnectthe negativecable. 6. Connecta voltmeterbetweenthe No. 1 {+) terminalol the SRSmain harness18Pconnectorand body ground. 7. Turn the ignition switch ON (ll), and measurevoltage. Thereshouldbe 0.5V or less. 8. Turnthe ignitionswitchOFF. 9. Connecta voitmeterbetweenthe No. 13 {+i terminalof the SRSmain harness18Pconnectorand body ground. 10.Turnthe ignitionswitch ON lll), and measurevoltage. Thereshouldbe 0.5V or less. Are voltagesas specified? YES
SRSMAIN HARNESS 18PCONNECTOR
NO
Faulty SRSunit; replacoth€ SRSunit lsoo pas6 24-95).
Short to power in th€ SRS main hamoss; roplecethe SRS main haanass.
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24-55
Troubleshooting
O'-
DTCl-s CAUTION: Whenever tho igniiion switch is ON {ll), or has been lurned OFF for loss lhan thrse minules, be caretul not to bump the SRS unit; the airbags could accidentallydeploy and causedamage or iniuries.
DRIVER'SAIRBAG 2P CONNECTOR
Try to reproducethe SRSindicator light: 1. Erasethe DTCmemory(seepage24-28). 2. Turn the ignitionswitchON lll), and checkthat the SRS indicatorlight comeson for aboutsix secondsand then goes off.
CAALEREEL 2P CONNECTOR
Doostho SRSindicator liqht stav on?
YES
NO
Inte.mittent tailure,3y3tem is OK at this timo. 506 TroubleshoolingIntermittent Failureson Daq€24-28.
Checktor a short to ground in the driver's ai.bag intlator: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe battery negativecable,then disconnect the positivecable,and wa:l for threeminutes. 3. Disconnectthe driver's airbag 2P connectorfrom the cable reel 2P connector,Do not disconnectthe passen, ger'sairbagconnector. 4. Connectthe specialtool {2 O}to the cablereel2Pconnector. 5. Reconnectthe battery positive cable. then reconnectthe negativecable. 6. Erasethe DTCmemory(seepage24 28). 7. Readthe DTClsee page 24-261. ls DTC1-5 indicated? YES
NO
ar h / ffi
'97 model:
SRSSIMULATOR LEADC 07TAZ- SZ50r1A .nd SRSINFLATOR SIMULATOR {2 0 JACK) 07sAz - TBaolrA
'98 - 0Omodels: CABLE REEL 2PCONNECTOR
Short to ground in the driver's airbag inflator;replacethe driver's airbag (s6epage 24-871.
Chockfor a short to ground in the cablo reel: 1. Disconnectthe battery negativecable,then disconnect the positivecable,and wait for threeminutes. 2. Disconnect the specialtool i2 O) from the cable reel 2P 3. Removethe dashboardlower cover,and disconnect the cablereel2P connectorfrom the SRSmain harness. 4. Connectthe specialtool {2 O) to the SRS main harness (cont'd) 2P connector.
SRSSIMULATOR LEAOC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR t2 0 JACKI 07sAz - TB{01rA
To page24-57
J.. 24-56
www.emanualpro.com
) Frompage24 56
Check{or a short to ground in the cable reel (cont'd): 5. Reconnectthe batterv positive cable, then reconnectthe negativecable. 6. Eraselhe DTCmemoty lsee page 24-28). 7. Readthe DTClsee page24 26). ls OTC1-5 indicated?
YES
NO
Short lo ground in the cable reel; replacethe cable reel {seeoaoe 2,1-91}.
)
Checkfor a short to ground in the SRSmain harness: '1. Disconnect the batterynegativecable,the disconnect the positivecable,and wait for threeminutes. 2. Disconnectthe tront passenger'sairbag 2P connector (6nddisconnect both seatbelttensionerconnectors). 3. Removethe specialtool 12{))fromthe SRSmain harness 2P connector. 4- Disconnectthe SRS main harness18Pconnectorfrom the sRs unit. 5. Checkresistance betweenthe No. l terminalo{theSRS main harness18Pconnectorand ground,and between the No. 13terminalof the SRSmain harness18Pconnector and ground. Thereshouldbe I M0 or more.
SRSMAIN HARNESS 18PCONNECTOR
ls lhe resistanceas soecitiod? YES
NO
Faulw SRSunit reDlacethe SRSunit lsee paqe 24-951.
Short to ground in the SRS main harness;replacethe SRS main ham€ss,
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24-57
Troubleshooting DTC2-1 and DTC2-2
!a SRSMAIN HARNESS
CAUTION:Wheneverthe ignition switch is ON lll), or has been turned OFF tor less than throe minutes, be careful not to bump the SRS unit; the airbags could accidentallydeploy and causedamage or iniuries. Try to reproducethe SRSindicator light: 1. Erasethe DTCmemory(seepage24-28). 2. Turn the ignitionswitchON (ll),and checkthat the SRS indacator light comeson for aboutsaxsecondsand then Doesthe SRSindicator lioht stav on?
Intermittent tailure, svstem is OK ai lhis time. See Troubl*hooting Intermittent Failureson paqe24-28.
Chockfor an open in the passongor'sairbag inflator: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 3- Disconnect the front passenger's airbagconnectorlrom the SRSmain harness(seepage24-2:,,. 4. Connectthe specialtool (2 0) to the SRS main harness 2P connector.Do not disconnect the driver'sairbagcon, nector. 5. Reconnectthe battery positive cable, then reconnectthe negativecable. 6. Erasethe DTCmemory(seepage24-28). 7. Readthe DTC(seepage 24 26!'. ls DTC2-1 or DTC2-2 indicated?
Open or incrcased resistance in tho passenger'sairbag
To page 24'59
24-58
www.emanualpro.com
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ffi
SIMULATOR I-EADC 07TAZ- SZ5tt11A and SRSINFLATOR /StMULATOR / Q A JACKI
07slz-TA411A
) Frompage24 58
sRsUNIT
Checkfo. an oD6nin the SRSmain harness: 1. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 2. Disconnectthedriver'sairbag2P connectorland disconnect (seepage24 23). both seatbelttensionerconnectors) 3. Disconnectthe SRS main harness18Pconnectorfrom the SRS unit. Do not disconnectthe soecialtool (2 Oi from the SRSmain harness. 4. Checkresistance betweenthe No. 10terminaland No. 14 terminalof the SRS main harness18Pconnector.There shouldbe aoorox.2.0- 3.0g. ls the .osistanc€as soecified? YES
NO
Poor contacl ai the SRS main harness 18P conneclori checklhe connector, .lf the conneclor is OK, substitute a known-good SRS unit, and recheck. .lf the problem is still present,replacethe SRS main
18PCONNECTOR
hatnesli,
Open or increasedresistancein the SRS main harness; replacethe harness.
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24-59
Troubleshooting DTC2-3
{J
CAUTION: Whenevor the ignition switch is ON { }, or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; lhe airbags could accidentallydeploy and causodamage or iniuries.
SRSMAIN HARNESS
Try to reproducethe SRSindicator light: 1- Erasethe DTCmemory{seepage24 28). 2. Turn the ignitionswitchON (ll),and checkthat the SRS indicatorlight comeson for aboutsix secondsand then goes off. Doesthe SRSindicator light stay on?
YES
NO
Intermittont failur€, syslem is OK at this time. 560 T.oubloshootinglntormittent Failur6 on page 24-28.
Checkfor a short to another wiro or decreasedresbtanc€ in the pa$€nger's airbag inflator: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 3. Disconnectthe front passenger'sairbag 2P connector from the SRSmain harness(seepage24-23). 4. Connectthe specialtool (2 O) to the SRS main harness 2P connector.Do not disconnectthe driver,sairbagconnector. 5. Reconnectthe battery positive cable, then reconnectthe negativecable. 6. Erasethe DTCmemory(seepage24 28i. 7. Readthe DTC(seepage 24-26). ls DTC2-3 indicated? YES
NO
Short to another wir6 or decaea3€dr€aktance in the oassenger's airbag intlatoi; replac€ the passenger'sairbag {see pago 24-8t1.
To page24 61
24-60
www.emanualpro.com
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SIMULATOR LEAD C 07TAZ- SZ50I1A and SRSINFLATOR /STMULATOR / I2n JACKI
07sAz-fB1011A
) Frompage24 60
in Ch6cktor a short to another wire or decreasodaGsistance lh€ SRSmain harness: 1. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 2. Disconnectthe driver'sairbag2P connector(anddisconnect both seatbelttensionerconnectors). '18Pconnectorfrom 3. Disconnectthe SRS main harness the specialtool (2 O). the SRSunit.Do not disconnect 4. Checkresistance betweenthe No. 10terminaland No. 14 terminalof the SRS main harness18Pconnector.There shouldbe aoorox.2.0- 3.00. ls the rosistanc6 as specified?
YES
NO
Faultv SRSunit; replacelhe SRSunit lsee page 24-95).
Short to anothor wire or decre.sed re3i3t.nce in the SRS main harness;replac€the SRSmain harn*s.
SRSMAIN HARNESS 18PCONNECTOR
)
)
www.emanualpro.com
24-61
Troubleshooting
Ot-
DTC2-4 GAUTION: Wh€never tho ignition switch is ON 0t). or has been turned OFF for less than threo minutes, bo careful not to bump the SRS unit; the airbags could accidentallydeploy and causedamaga or iniuriss.
SRSMAIN HARNESS
Try to reproducethe SRSindicator light: 1. Erasethe DTCmemory(seepage24-28i. 2. Turn the ignitionswitchON (lli, and checkthat the SRS indicatorlight comeson tor about six secondsand then goes off. Do€sthe SRSindicator light stay on? YES
NO
Inlermittent tailure, system is OK at this tim€. Sce Troubleshooting Intermitt€.f Failureson page 2+28.
Checkfor a short to power in the passengar,sai.bag inflator: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe bafterynegativecable,then disconnect the positivecable,and wait for threeminutes. 3. Disconnectthe front passenger'sairbag 2P connector Irom the SRSmain harnesslseepage24-23). 4. Connectthe specialtool (2 O) to the SRS main harness 2P connector.Do not disconnect the driver,sairbagcon, nector, 5. Reconnectthe battery positive cable, then reconnectthe negativecable. 6. Erasethe DTCmemory(seepage24-28). 7. Readthe DTC(see page 24-26|'. ls DTC2-4 indicsted?
YES
NO
Sho.t power in the passenger's airbag infator; rsplece tho paisonge/i airbag {s€e pag€ 2il-89).
To page24-63
24-62
www.emanualpro.com
SIMULAYOR LEAD C
//
ffi
07TAZ- SZ5011A .nd SRSINFLATOR /stMU|_ATOR / t2 tr JAoKI olsAz-Tsn11A
Frcm page24-62 Checklor a short to power in the SRSmain harness: 1. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 2. Disconnectthe drive/s airbag2P connector(anddisconnect both seatbelttensionerconnectors). 3. Disconnectthe SRS main harness18Pconnectortrom the SRSunit. 4. Removethe specialtool(2 0) from the SRSmain harness 2P connector, 5. Reconnectthe batterv positive cable,then reconnectthe negativecable. 6. Connecta voltmeterbetweenthe No. 10 (+) terminalof SRSmain harness18Pconnectorand ground. 7. Turn the ignition switch ON (ll). and measurevoltage Thereshouldbe 0.5V or less. 8. Connecta voltmeterbetweenthe No. 141+)terminalof the SRS main harness18Pconnectorand ground,and measurevoltage.Thereshouldbe 0.5V or less.
sRs
.I8PCONNECTOR
Are voltages .3 specifiedT YES
NO
FaultySRSunit; replacethe SRSunit (sce page 24'95).
Short to powor in the SRS main ha.ne3s; replace the SRS main hdrness.
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24-63
Troubleshooting DTC2-5 tl
CAUTION:Wheneverthe igniiion switch is ON {ll}, or has be€n turn€d OFF for less than three minutes, be careful nol to bump the SRS unit; the sirbags could accidentallydoploy and causo damage or iniuries. Try to rep.oducethe SRSindicstor tight: 1. Erasethe DTCmemory(seepage24-28). 2. Turn the ignitionswitchON 0l), and checkthat the SRS indicatorlight comeson for aboutsix secondsand then goes off. ooes th6 SRSindicaror light st.y on?
YES
NO
Inte.mitt.nt failure, system is OK at thi3 time. S€e Troubl6hooting Intermittem Failur6 on page2+28.
Checkfor a short to gaound in th6 prsenger,i airbag inllator: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe batterynogativecable,then disconnect the positivecable,and wait for threeminutes. 3. Disconnectthe front passenger,sairbag 2p connector from the SRSmain harness{seepage24-23). 4. Connectthe specialtool (2 0) to the SRS main harness 2P connector.Do not disconnectthe driver,sairbagcon, nector. 5. Reconnectthe battery positive cable, then reconnectthe negativecable. 6. Erasethe DTCmemory (seepage 24-28). 7. Readthe DTClsee page2[-261. ls DTC2-5 indicated? YES
NO
Short to ground in the pas€ngert airbeg inflator; ,cplace the passenge/s airbag (s€e page 2+991.
To page24 65
24-64
www.emanualpro.com
/
ffi
SIMULATOR LEAOC 07TAZ- SZ5011A .nd SRSINFLATOR /StMULATOR / t2 a JACKI 07saz-fB&11^
)
J Frompage24'64
Checkfor a short to ground in the SRSmain harnessl 1. Disconnectthe batterynegativecable,then disconnect the posilivecable.and wait for threeminutes. 2. Disconnect the driver'sairbag2P connector(anddisconnectboth seatbelttensionerconnectors), 3. Disconnectthe SBS main harness18Pconnectorfrom the sRs unit. 4. Removethe specialtool (2 O)from the SRSmain harness 2Pconnector, 5. Checkresistance betweenthe No. 10terminalof the SRS main harness18Pconnectorand ground,and between the No. 14terminalof the SRSmain harness18Pconnec tor and ground.Thereshouldbe 1 M0 or more. ls the resistanceas sD€citied?
YES
NO
sRs Faultv SRSuniu replacethe SRSunit {seepaqe 24-951.
18PCONNECTOF
Short to ground in the SRS main harn€ss;replac€ihe SRS main harness.
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24-65
Troubleshooting DTC3-1and DTC3-2
-
CAUTION:Wheneverthe ignition switch is ON flll, or has been turned OFF for less than three minutes, b€ careful not to bump th€ SRS unit; the airbags could accidenlallydeploy and causedamage or iniuries.
DRIVER'S SEATBELTTENSIONER 2P CONNECTOR
LEFTSIOEWIRE HARNESS 2P CONNECTOR
Try to reproducethe SRSindicatoi light: 1. Erasethe DTCmemory(seepage24-29). 2. Turn the ignitionswitch ON 1 ), and checkthat the SRS indicatorlight comeson for aboutsix secondsand then goesoff. Doesthe SRSindicaior lighr stay on? YES
NO
Intermittent failure, system is OK at this time. See Troubleshootinglfiermittent Failu.6son page24-28.
Checktor an open in the driver's seat b6lt tensioner: 1. Disconnect the negativebatterycable,and wait lor three minutes. 2. Disconnect the drave/sseat belt tensioner2p connector from the left side wire harness2P connector(see page 24-23).Do not disconnect the lront passenger,s seatbelt tensioner2P connector. 3. Connectthe specialtool {2 O) to the left side wire harness 2P connector, 4. Reconnect the negativebafterycable 5. Erasethe DTCmemory{seepage24,28). 6. Readthe DTC(see page 24-26). ls OTC3-1or DTC3-2 indicatedT YES
NO
Open or increasedresistancein the d.iver's seat belt tensioner; replacethe driver's seat belt {seepage 2il-91).
To page24 67
www.emanualpro.com
24-66
SRSSIMULA LEADC
07TAZ- SZ501rA andSRSINFLATOR STMULAToR I t2 0JACKI I oTsaz- TB4otlA t
\
) Frompage24-66
Checkfor an oFn in thc aide wir6 harne$: 1. Disconnect the left sidewire harness2P connectorfrom the SRSmain harness2P connector. 2. Connectthe specialtool (2 o) to the SRS main harness 2Pconnector. 3. Erasethe DTCmemory. 4. Readthe DTC. ls DTC3-l or DTC3-2 indicated?
YES
NO
LEFTSIDEWIRE HARNESS 2P CONNECTOR
SRSMAIN HARNESS 2P CONNECTOR
Ooen or incrers€d reeidance in the lelt side wire hame3s; r€Dlacathe hamess.
)
art
C
00
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR
Checkfor an open in the SRSmain harness: 1. Disconnect the negativebatterycable,and wait for three minutes. 2. Disconnectthe driver'sand front passenger'sairbags, and front passenger's seatbelttensionerconnectors(see page24-231. 3. Disconnectthe SRS main harness18Pconnectorfrom the SRS unit. Do not disconnectthe specialtool (2 O) from the SRSmain harness2P connector. 4. Checkresistance betweenthe No. 4 and No. 11terminals Thereshouldbe of the SRSmain harness18Pconnector. 2.0- 3.0 0.
{2 0 JACKI 07sAz - T84011A
13lhe resistance as soecified?
YES
NO
sRsUNIT
Faulty SFS unil or poor contad at the SRS main h.m€ss 18P connector and th€ SRS unit. check the connection between the SRS main harn$s 18P connector and the SRS unit. lf the connector i3 OK. r€Dlacoihe SRS unit (s66pas6 24-951.
ODen or incaoasedresistancein the SRS msin harness; reolacethe SRSmain harn€ss.
SRSMAIN HARNESS .I8PCONNECTOR
) terminals
www.emanualpro.com
24-67
Troubleshooting DTC3-3
ra
CAUTION; Whenever the ignition switch is ON llll, or has b€on turned OFF for l6ss than three minutes, be carelul not to bump the SRS unit; the airbags could accidontallydeploy and causedamage or iniuries.
ORIVER'S SEATEELTTENSIONER 2P CONNECTOR
Try to r€producethe SRSindicator light: 1. Erasethe DTCmemory(seepage24-28). 2. Turn the ignitionswitchON (lll, and checkthat the SRS indicatorlight comeson for about six secondsand then goes off. Doesthe SRSindicator lighl stay on?
YES
NO
Intarmittent failure, system is OK at this time. 506 Troubl€shootingIntormittantFailureson paqe24-28.
Checktor a 3hort to anoth€r wire or decreasedresistancein ihe driver's seat bolt tan3ioneri 1. Disconnect the negativebatterycable,and wait for three minutes, 2. Disconnectthe driver's seat belt tensioner 2P connector from the left side wire harness2P connector(see page 24-23).Do not disconnect the front passenger's seat belt tensioner2P connector, 3. Connectthe specialtool (2 O) to the left side wire harness 2P connector. 4. Reconnectthe negativebattery cable 5. Erasethe DTCmemory (seepage 24-28). 6. Readthe DTC(seepage 24.26l'. ls DTC3-3 indicated?
YES
NO
Short to another wire or decreased.esistancein the driver's s6at beh tcnsioner; replac€the diive.'s seat bolt {se€prge 24-911. To page 24 69
24-64
www.emanualpro.com
SRSSIMULATOR LEAOC 07TAZ-525011A and SRSINFLATOR
srMULAroR I t2 0 JACK| t ozsAz- ls{orra !
s
LEFTSIDEWIRE HARNESS 2P CONNECTOB
\.p Frompage24-68
Checklor a short to another wire or decreasedreaistancein the side wire harnoss: 1. Disconnect the left side wire harness2P connectortrom the SRSmain harness2P connector. 2. Connectthe specialtool (2 0) to the SRS main harness 2P connector. 3. Erasethe DTCmemory. 4. Readthe DTC. ls OTC3-3 indicated? YES
NO
LEFTSIDEWIRE HARNESS 2P CONNECTOR
SRSMAIN HANNESS 2P CONNECTOR
C
0a
Short to another wire or decrcased resbtance in the le-h side wire harness;reglacethe harneas.
I J
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLAToR SIMULATOR {2 0 JACK} 07sAz - TB4011A
Checklor a 3hort to another wire or dec.easedresistancein the SRSmain ha.ne$: 1. Disconnect the negativebatterycable,and wait for three minutes, 2. Disconnectthe driver's and front passenger'sairbags, (see and front passenger's seatbelttensionerconnectors page24 23l'. 3. Disconnectthe SRS main harness18Pconnectorfrom the SRSunit. 4. Disconnectthe specialtool (2 O)from the SRSmain harness 2P connector. 5. Checkresistancebetweenthe No. 4 and No. 11terminalsof the SRS main harness18Pconnector.There should be 1 M0 or more. ls the resistanc€as soocified?
YES
NO
SRSUNIT
Faulty SRSunit; replacethe SRSunit lso€ paqe 24-95).
Short to another wire or decr€asodrosistanco in the SBS main harness;replacethe SRSmain harness.
SRSMAIN HARNESS 18PCONNECTOR
I J lerminals.
www.emanualpro.com
24-69
Troubleshooting DTC3-4
{
CAUTION: Whenever the ignition switch is ON (lll, ol has been turned OFF for l6ss than thr6e minutes, b€ careful not to bump the SRS unit; lho airbags could accidentallydeploy and caus€damage or iniuries.
DRIVER'S SEATBELTTENSIONER 2P CONNECTOR
Try lo reproducoth6 SRSindicator light: 1. ErasetheDTCmemory(seepage24-28). 2. Turn the ignitionswitchON (ll),and checkthat the SRS indicatorlight comeson for aboutsix secondsand then ooes off, Doe3the SRSindicator liqht stav on?
YES
NO
Intcrmitt.nt f.ilur., iystem is OK at this time. Soe Troubla3hooting Intermittent Failurca on Dage24-28.
Checklor a shortlo Dowar in the driver'33€at beh tonsioncr: 1. Disconnoctthe negativebattery cable, and wait for three minutes. 2. Disconnect the driver'sseat belt tensioner2P connector from the left side wire harness2P connector(see page 24 23).Do not disconnect the front passenger's seat belt tensioner2P connector, 3. Connectthe specialtool {2 0) to the left side wire harness 2P connector. 4. Reconnectthe negativebattery cable. 5. Erasethe DTCmemory {see page24-28). 6. Readthe DTC(see page 24-26). ls DTC3-4 indicsted?
YES
NO
Short to powar in the d.iver's seat belt tensioner; replacethe d.iver's seat belt tensione. {3eepago 2il-31.
To page24'71
24-70
www.emanualpro.com
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR
SIMULATOR I {2 o JACK} I ozsaz- tamrrl i
LEFTSIDEWIRE HARNESS 2P CONNECIOR
) Frompage24-70 Chocktor a short lo power in the sid€ wi.e harness: 1. Disconnect the left sidewire harness2P connectorfrom the SRSmain harness2P connector. 2. Connectthe sDecialtool {2 O) to the SRS maanharness 2P connector, 3. Erasothe DTCmemory. 4. Readthe DTC. b DTC3-4 indiclted?
YES
NO
SRSMAIN HARNESS 2P CONNECTOR
Short to power in the left side wire ha.n6ss;replecethe narness.
)
(
C
00
SRSSIMULATOR LEAOC 07TAZ- SZ5011A and SRSINFLATOR
Checkfor a short to power in the SRSmein harness: 1. Disconnect the negativebatterycable,and wait for three mrnutes. 2. Disconnectthe driver'sand lront passenger'sairbags, and front passenger's seatbelttensionerconnectors(see page 24-231. 3. Disconnectthe SRS main harness18Pconnectortrom the SRSunit. 4. Disconnectthe specialtool(2 0)fromthe SRSmainharness 2Pconnector,then reconnectthenegativebatterycable. 5. Turn the ignitionswitchON (lll. 6. Checklor voltage betweenthe No. 4 terminal ol the SFS main harness'18Pconnectorand body ground. There shouldbe 0.5 V or less.Checkfor voltagebetweenthe No. 11terminalsol the SRSmain harness18Pconnector.There shouldbe 0.5V or less. ls tho voltage as specffied?
YES
h
LEFTSIDEWIRE HARNESS 2P CONNECTOR
(2 0 JACKI 07SAZ- TB/t011A
NO
Faulty SRSunit; replacetho SRSunit lsee paqe 24-95).
Short to power in the SRS m.in harness;.eplace the SRS main hame3a.
SRSMAIN HARNESS 18PCONNECTOR
)
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24-71
Troubleshooting DTC3-5
*r
CAUTION: Whonover tho ignition switch is ON (ll), or has been turned OFF for less than thres minutes, b€ careful not to bump the SRS unit; the airbags could accidontallydeploy and causedamsgo or iniurirs.
DRIVER'S SEATBELTTENSIONER
Try to reproducothe SRSindioto. light: 1. Erasethe DTCmemory (s66 pag624-28). 2. Turn the ignitionswitchON (ll),and checkthat the SRS indicatorlightcomoson Ior aboutsix seconds,and then goes off. Do€. the SRSindicsto. light 3tav on?
YES
NO
lnto.mitlont hilure, ryltom is OK at thia timc. Ses T.oubleshootinqIntermittont Failuroson page 2+28.
Ch€ck for a short to ground in the djivoi's soat b6h tonsioner: 1. Disconnectthe negativebattery cable, and wait tor three mtnutes. 2. Disconnoctthe driver's seat belt tensioner 2P connector Irom the l€ft side wire harness 2P connector (see page 24-23).Do not disconnectthe front passenger'sseat belt tensioner2P connector. 3. Connectthe specialtool (2 0) to the left side wire harness 2P connector, 4. Rgconnectthe negativebattery cable. 5. Erasethe DTCmemory (seepage 24-28). 6. Readthe DTC(see page21-26). ls DTC3-5 indicated?
YES
NO
Short to ground in the driver's soai belt tensioner; repllce the driver'3 seat belt ls€e Daq624-31.
To page2a-73
24-72
www.emanualpro.com
SRSSIMULATOR LEADC 07TAZ-S25011A and SRSINFLATOR SIMULATOR \ (2 0 JACK' I
ozsnz-teronl t
) Frcm page24-12
Checklor . short to ground in lhe lido wire hrrnassi 1. Disconnect the l€lt sidewiro hamess2P connectorfrom the SRSmain harness2P connector. 2. Connectthe specialtool (2 0) to the SRS main harness 2P connoctor. 3. Erasethe DTCmemory. 4. Readthe DTC.
\r
LEFTSIDEwlRE HARNESS 2P CONNECTOR
(
SRSMAIN HARNESS 2P CONNECTOR
C
Short to ground in the lolt side wi.e harno3s;.eplscethe hamer3.
)
00
Checkfor a short to ground in tho SRSmain harna+t: 1. Disconnecttho negativebattery cable, and wait for three mtnutes. 2. Disconnectthe drive/s and front passenger'sairbags, and front passenger'sseat bolt tensioner 2P connectors (seepage24-231. 3. Disconnectthe SRS main harnessl8P connectorfrom the SRSunit. 4. Removethe spacialtool {2 0) from the SRSmain hamess 2P connector, 5. Checkresistancebetween the No. 4 terminal of the SRS m a i n h a r n e s s1 8 Pc o n n e c t o ra n d b o d y g r o u n d ,a n d betweenthe No. ll terminalsofthe SRS main harness 18Pconnectorand body ground.Thereshouldbe 1 M0 or more.
/ I
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR / (2 o JACK) 07sAz - TB4o11A
Short to ground in the SRS m.in hrrnar3; roplacotho SRS mein hamoSs.
SRSMAIN HABNESS 18PCONNECTOR
)
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24-73
Troubleshooting DTC4-1and DTC4-2 !|
CAUTION: Whenever tho ignition 3witch is ON (ll), ot has boen turn€d OFF for less than thro6 minutos, bo car€ful not to bump ihe SRS unit; the airbags could accidentallydeploy and causodamage or iniurios,
FRONT PASSENGER'S
RIGH1SIDEWIRE HARNESS 2P CONNECTOR
Try to roproducathe SRSindicator light: 1. Erasethe DTCmomory(seepage24'28i. 2. Turn the ignitionswitchON (ll).and checkthat the SRS indicatorlight comeson for aboutsix seconds.and then ooes off, Doesthe SRSindicator lisht stay on? YES
NO
Intermittent failure, syatem i3 OK at this tim6. Soo Trouble3hootingInta.mittent Failuroson page24-28.
Ched( for an open in the front p.ssongo/s 3eat bolt teruiona.: 1. Disconnect the negativebatterycable,and wait for three mrnutes. 2. Disconnectthe front passenger's seat belt tensioner2P connectorfrom the right side wire harn€ss2P conneclor (see page 24-23).Do not disconnectthe driver's seat belt tensioner2Pconnector. 3. Connectthe specialtool (2 O)to the right sido wire harness2P connector. 4. Reconnectthe negativebatterycable. 5. Erasethe DTCmemory lsee page 24 28). 6. Readthe DTC(seepage 24'26). k DTC4-1 or DTC4-2 indicatodT
YES
NO
Open or increaaad resistance in lhe tront pa$enger's seat belt tensioner; roplace the front p.s3engar's 3eat belt lsee p.ge 24-31.
fo page24-75
24-74
www.emanualpro.com
SRSSIMULATOR LEADC
07TAZ- SZ5n11A andSRsINFLATOR SIMULATOR
f
/izo.ncri -
ozsAz T8.011A
o
) Ftom page 2!-7a
Checklor .n oo.n in the side wire hsrness: 1. Disconnect the rightsidewire harness2P connectorfrom the SRSmain harness2Pconnector. 2. Connectthe specialtool (2 Oi to the SRS main harness 2Pconnector. 3. Erasethe DTCmemory. 4. Beadthe DTC. ls DTC4-1 or DTC4-2 indicated?
YES
NO
Open or inc.oasedresistancein th€ right side wire harness;replacethe harness.
)
"r$
Checktor an open in the SRSmain harness: 1. Disconnect the negativebatterycable,and wait for three mtnutes. 2. Disconnectthe driver'sand front passenger'sairbags, and driver'sseatbelt tensionerconnectors(seepage2423\. 3. Disconnectthe SRS main harness18Pconnectorfrom the SRS unit. Do not disconnectthe specialtool (2 0) from the SRSmain harness2P connector. 4- Checkresistance betweenthe No. 5 and No. 12 terminals of the SRSmain harness18Pconnector. Theresho!ld be 2.0- 3.00. ls the resistancaas soecified?
YES
RIGHTSIDEWIRE HARNESS 2P CONNECTOR
SRSMAIN HARNESS 2P CONNECTOR
SRSSIMULATOR LEADC 07TAZ- SZ5011A .nd SRSINFLATOR SIMULATOR (2 0 JACK) 07sAz - TB4011A
NO
Faulty SRSunit or poor contact at the SRSmain harne3s 18P conneclor and the SRS unit, check the connestion b€tween the SRS main harness 18P conn€ctor and th6 SRS unit. lf the connector is OK, reDlacethe SRS unit {seepage 24-951.
Open or increesedresistancoin the SRS main h.rnes3; replacethe SRSmain harness.
SRSMAIN HABNESS 18PCONNECTOR
) le.minals.
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24-75
Troubleshooting DTC4-3
{
CAUTION: Whonev.r ths ignition switch is ON (ll), or has been turned OFF tor less than throe minutes, b€ careful not to bump tho SRS unit; the airbags could accidentallydeploy and csuse damage or iniuries.
FRONT PASSENGER'S
RIGHTSIDEWIRE HARNESS 2P CONNECTOR
Try lo reproducothc SRSindicator light: '1. Erase the DTCmemory (seepage 2{-28). 2. Turn the ignitionswitchON {ll},and checkthat the SRS indicatorlight comeson for aboutsix seconds,and then goes off. Doosthe SRSindicstor light stay on? YES
NO
Intermittent failure, rystgm ia OK rt this timo. S6c TroubloshootingIntermittont Failu.oson pago 2+28.
Chock to. a short to .nothor wira or decre8od ro3btance in the froni pa3sengor'3aoat belt ten3ioner: 1. Disconnect the negativebatterycable,and wait for three mrnutes. 2. Disconnectthe front passenger's seat belt tensioner2P connectorfrom the right side wire hamess 2P connector (see page 24-23).Do not disconnectthe driver's seat belt tensioner2P connector. 3. Connectthe specialtool (2 O)to the right side wire harness2P connoctor. 4. Reconnectthe negativebattgrycable. 5. Erasethe DTCmemory (see page 24-28). 6. Readthe DTClsee page 24-261. |3 DTCG3 indicatod?
YES
NO
Short to .noth6r wire o. dc6e.r€d r€aktanco in the front passenger'3s€at boh teniioner; roplaccthe lront pass6ng6r's aeat belt (s€epsge 2a-31.
To page24-77
24-76
www.emanualpro.com
SRSSIMULATOR LEADC 07TM - SZ5011A and SRSINFLATOR SIMULATOR
/2 o JACKI l07sAz - TB4011A
tt2s>,-ar' na --\>
Frompage24-76
Chockto. a aho.l to lnothcr wire or d€creslod rosbtanco in th. side wiro harn.$: 1. Disconnoct the rightsidewire harness2Pconnectorlrom the SRSmain harness2P connector. 2. Connoctthe specialtool (2 O) to the SRS main harness 2P connector. 3. Erasethe DTCmemory. 4. Readtho DTC. 13DIC +3 indicated? YES
RIGHTSIOEWIRE HARNESS 2P CONNECTOR
NO SRSMAIN 2P CONNECTOR
Short to .noth6r wiro or doc.oasod r.sistanco in thG dght sida wiro ha]ne3s;rapl.ce the hamcas.
SRSSIMULATOR LEADC 07TAZ- SZ50114 and SRSINFLATOR SIMULATOR {2 0 JACK) 07saz - Ta1ol1A
Chackloi a short to anothor wire o. docreas€drGbtancc in tho SRSmain h.]n€$: 1. Disconnectthe negativebattery cable, and wait for three mtnutes, 2. Disconnectth6 driver's and front passenger'sairbags, and driver's seat belt tensionerconnectors(see page 24-
)
3. Disconnectthe SRS main harness18Pconnectorfrom the SRSunit. 4. Disconnectthe specialtool (2 0) from the SRS main harness2P conn€ctor. 5. Checkresistancebetweenthe No. 5 and No. '12terminals of the SRSmain harness18Pconnector. Thereshouldbe 1 MO or more. b the raaistanco aa soscifiedT
YES
NO
F.ulty SRSunit; roplac€tho SRSunit lseo pase 24-951.
Short to enothor wi.o or decree3odr*istance in the SRS main harnoit rophco the SRSmain ha.nsss.
SBSMAIN HARNESS 18PCONNECTOR
6
\
l; www.emanualpro.com
c806
15
iid€ of {6male
terminals,
24-77 I
Troubleshooting DTC4-4 CAUTION:Wheneverthe ignition switch is ON (ll), or has been turned OFF tor less than thlee minutes. be careful nol to bump the SRS unit; the airbags could accidontallydeploy and causedamage or iniuries.
RIGHTSIDEWIRE HARNESS 2P
FRONT PASSENGER'S
Try to reproducethe SRSindicator light: 1. Erasethe DTCmemory{seepage24-28). 2. Turn the ignitionswitchON (ll),and checkthat the SRS indicatorlight comeson for aboutsix seconds,and then goes off. Doosthe SRSindicator light 3t.y on?
vEs
NO
Intermittent f!ilure, system is OK at this time. See T.oubleshootingIntermittent F.ilures on page 24-28.
Checktor a 3horl lo power in the frolt pass€nge.'ss€at belt tensaoneri '1. Disconnect the negativebatterycable,and wait for three mrnutes. 2. Disconnect the front passenger's seat belt tensioner2P connectorfrom the right sidewire harness2P connector the driver'sseatbelt {seepage24-23}.Do not disconnect tensioner2P connector. 3. Connectthe specialtool (2 O) to the right sidewire harness2P connector. 4. Reconnectthe negaiivebafterycable. 5. Erasethe DTCmemory (seepage 24-28). 6. Readthe DTClseepage24-261. ls DTC4-,1indicated?
YES
NO
Short to power in the front passong6r'3seat belt tensioner; replacethe front passongar'3s€at beh {see page 21-31.
To page24'79
24-78.
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SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR
,StMULATOR /(2 o JACK) t _07SAZTBiro11A
) Ftom page24 78
Checkfor a short to power in the side wire harn6s: 1. Disconnect the rightsidewire harness2P connectorfrom the SRSmain harness2Pconnector, 2- Connectthe specialtool (2 0) to the SRS main harness 2Pconnector. 3. Erasethe DTCmemory. 4. Readthe DTC. ls DTC4-{ indicated? YES
NO
Short to power in the right side wire harness; replace the harness.
) J
RIGHTSIDEWIRE HARNESS 2P CONNECTOR
Checktor a short to oow6r in the SRSmain harness: 1. Disconnect the negativebatterycable,and wait for three mtnutes, 2. Disconnectthe driver'sand front passenger'sairbags, and driver'sseatbelttensionerconnectors(seepage2423). 3. Disconnectthe SRS main harness18Pconnectorfrom the sRS unit. 4. Disconnect the specialtool i2 0) from the SRSmain har ness2P connector,then reconnectthe negativebattery caore. 5. Turnthe ignitionswitchON (ll). 6. Checkfor voltagebetweenthe No. 5 terminalof the SRS m a i n h a r n e s s1 8 Pc o n n e c t o ar n d b o d y g r o u n d .T h e r e should be 0.5 V or less.Checkfor voltagebetweenthe No. 12 terminalsof the SRSmain harness18Pconnector. Thereshouldbe 0.5V or less.
SRSMAIN 2P CONNECTOR
SBSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR \ (2 0 JACK) \ 07sAz-T84011A
\
\
@
ls the voltage as specified? YES
NO
Faulty SRSunit; replacethe SRSunit (seepase 24-95).
Short to power in the SRS main harness;replacethe SRS main harness. SRSMAIN HARNESS 18PCONNECTOR
)
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24-79
Troubleshooting DTC4-5
\
GAUTION: Whonever the ignition switch is ON fll). ol has be6n turned OFF for less than thrso minuter. be careful not to bump the SRS unit; the airbags could accidontallydeploy and causodamage or iniurias.
RIGXTSIOEWIRE HARNESS 2P
FRONT PASSENG€R'S
Try to roproducoth. SRSindicrtor tighi: 1. Erasethe DTCmemory(seepage24-28). 2. Turn the ignitionswitchON (ll),and checkthat the SRS indicatorlight comeson for aboutsix seconds,and then goes off. Doe3the SRSindicator light stay on?
YES
NO
Int€rmittent t.ilurG, syst.m is OK at thi! timo. So€ TroubleshootingInte.mift€nt Failure3on psqa 2+28.
Chcck Ior a shon to ground in the trodt pars€nge/s lert beh tensionea: 1. Disconnect the negativebatterycable,and wait for three mrnutes. 2. Disconnectthe front passenger's seat belt tensioner2p connectortrom the right sidewire harness2p connector (see page 24-23).Do not disconnectthe driver's seat bek tensioner2P connector. 3. Connectthe specialtool (2 0) to the right sidewire harness 2P connector, 4. Reconnectthe negativebatterycable. 5. Erasethe DTCmemory lsee page 24-28). 6. Readthe DTC(seopage 24-26!-. k DIC G5 indicated?
YES
NO
Short to ground in the Lont passengc.'33€rt boh tonsioner; replacetho from p.rlenger's sort beh ls€a page 21-3t.
To page24-81
24-80
www.emanualpro.com
SRSSIMULATOR LEADC 07lAz - s25011A and SRSINFLATOR SIMULATOR t2 0 JACKT
o?saz- Taaol1A
Frompage24'80
Checklor a short to ground in the sido wir€ harness: 1. Disconnect the rightsidewireharness2P connectorfrom the SRSmain harness2P connector. 2. Connectthe specialtool {2 O) to the SRS main harness 2P connector. 3. Erasethe DTCmemorv. 4. Readthe DTC. b DTC4-5 indicrtad?
YES
NO
Short to ground in the right side wire harness; replac. the harne3!.
)
RIGHTSIDEWIRE HARNESS 2P CONNECTOR
Checktor a short io ground in the SRSmain ha.nessi 1. Disconnect the negativebatterycable,and wait for three minotes, 2. Disconnectthe driver's and front passenger'sairbags, and driver's seat belt tonsionerconnectors(see page 24231. 3. Disconnectthe SRS main harness18Pconnectorfrom
SRSMAIN HARNESS 2P CONNECTOR
SRSSIMULATOR LEADC 07TAz- SZ5011A and SRSINFLATOR SIMULATOR \ {2 0 JACK} \ 07SAZ-TB,O114
\
I
ffi
4. Disconnect the specialtool (2 0) from the SRSmain harness2Pconnector. 5. Checkresistancebetweenthe No. 5 terminal oI the SRS m a i n h a r n e s s1 8 Pc o n n e c t o ra n d b o d y g r o u n d ,a n d betweenthe No. 12 terminalof the SRS main harness 18Pconnectorand body ground.Thereshouldbe 1 M0 or more, b th€ re3i3tance as specified?
YES
NO
Faulty SRSunit replacethe SRSunit {seepace 2a-951.
Short to ground in the SRS main harness;replacethe SRS main harnoss. SRSMAIN HANNESS 18PCONNECTOR
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24-81
Troubleshooting DTC8-6 -'97
model \
CAUTION: Whonever th€ ignition switch is ON fll). ol has b€en turned OFF for les3 than thro€ minutes, be caretul not to bump the SRS unit; tho airbags could accidentallydeploy and causedamage or iniurios. Besidesindicatingan abnormalityin the SRS unit, DTC 8-6 may also indicatethat two problemsequivalentto DTC1-1 and 2-4, 'l-4 and 2-1,or 1-4and 2-4 occurredat the sametime. Proceedin the ordershown below. Chockthe SBS main harnGs: 1. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 2. Disconnectthe driver's airbag and front passenger,s afrDagconnectors{see page 24-23). 3. Disconnectthe SRS main harnesst8p connectorfrom the sRs unit. 4. Reconnect the batteryposative cable,then reconnectthe negativecable. 5. Turnthe ignitionswitchON 0t). 6. Connecta voltmeterand measurevoltagebetweenthe No. 10 terminalot the SRSmain harnessl8p connector and ground,and betweenthe No. 14terminaland qround. Thereshouldbe aDorox.0-0.5V. Are voltagesas specitied?
YES
NO
Shon to power in tho SRSmain harness;reglacethe SRS main harn€63.
Chockthe SRSmein harnels and the cable re€l: Connecta voltmeterand measurevoltagebetweenthe No. 1 t e r m i n a l o f t h e S R S m a i n h a r n e s sl 8 p c o o n e c t o ra n d ground,and betweenthe No. 13terminaland ground.There shouldbe approx.0 0.5V. Are voltagesas specifiod? YES
NO
Faulty SRSunit; replacethe SRSunit {saepago 24-951.
To page 24-83(A)
24-82
www.emanualpro.com
18PCONNECTOR
) Frompage24-82iA)
Checkthe cable reeli 1. Turnthe ignitionswitchOFF. 2. Disconnectthe cable reel 2P connectorfrom the SRS main harness, 3. Turnthe ignitionswitchON lli). 4. Connect a voltmeter and fieasute voltage beNveenthe No. 'l terminaloI the SRS main harness18Pconnector a n d g r o u n d , a n d b e t w e e nt h e N o . 1 3 t e r m i n a l a n d ground.Thereshouldbe approx.0 - 0.5V. Are voltagcs as specifiod?
YES
NO
Short to powor in the cable reel; replace the cable reel {soooaqa 24-921.
Short to powe. in ths SRS main harn633;replaco tho SRS main harness.
)
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24-83
Troubleshooting DTC9-2-'97 model \ CAUTION: Whenever the ignition switch is ON flll, or has been turned OFF tor loss than thrse minute3, bs careful not to bump the SRS unit; lhe airbags could accidentallydoploy and causodamage or iniuriss. Ch6ckthe tuso: 1. Turnthe ignitionswitchOFF. 2. Checktor blown No. 23 (10 A) fuse in the !nder-dash Iuse/relaybox.
(A)To page24-85 Replacethe fuse.Turn the ignitionswitchON {ll},and ch€ck thatthe fusedoesnt blow.
No. 23 110Al FUSE FUSE/RELAYBOX Tho problem has dilappeared. T6t-drive the vohid€ and see Troubl6hogting Intermittedt Failur6 on prgc 2il-2g.
Check for shon to ground botween the undor-darh fu36,/ relay box and tho SRSunit. 1. Turnthe ignitionswitchOFF. 2. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 3. Disconnect the driver'sand front passenger,s airbagconnectors{seepage 24,23). 4. Disconnectthe SRS main harness18p connectorfrom 5. Checkresistancebetween the No. 3 terminal of the SFS main harness18Pconnectorand grouncl. Thereshouldbe 1 M0 or more.
sRs 18PCONNECTOR
FauftySRSunit; replacoth6 SRSunit {3e€page 2t-951.
To page 24-85
24-84
www.emanualpro.com
from page 24'84 (B) Ch6ckfo. short io ground in the SRSmain harnes!: 1. Disconnect the SRSmain harness2P connectorlrom the under-dash fuse/relay box. 2. Checkresistance betweenthe No. 3 terminalof the SRS main harness18Pconnectorand ground.There should be 1.0MO or more. ls the resbtancoas soecitied?
YES
NO
Short to ground in the undor-dalh fuse/relay box; r€placoth€ under-da3hfuse/relav box. Short to ground in the SRS main harneas;replacothe SRS main harneas.
(A) From page 24-84
FUSE/RELAY BOX
SRSMAIN HARNESS 18P CONI{ECTOR
Ch€ckfor an open in the SRSmain harnes: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe batterynegativecable,then disconnect the positivecable, and wait tor threeminutes. 3. Disconnect the driver'sand front passenger's airbagconnectors{see page2il 23). 4. Disconnectthe SRS main harness18Pconnectorfrom the sRs unit. 5. Reconnectthe baftery positive cabie, then reconnectthe negativecable. 6. Connecta voltmeterbetweenthe No. 3 terminalof the SRSmain harness18Pconnectorand oround. 7. Turnthe ignitionswitchON (ll), and measure SBS MAIN HARNESS 18P COI{l{ECTOR Poor contrct at the SRS main harn€ss 18P connector; checkthe connectoa. . lf the connsctor is OK, substitute a known-good SRS unit, and rccheck. . lf the problom is still present. replaco the SRS main harness,
To page 24'86
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(cont'd)
24-85
Troubleshooting DTC9-2-'97
model lcont'dl Frompage24-85
Checkfor an open in the SRSmain harness: 1. Turnthe ignitionswitchOFF. 2. Disconnect the SRSmain harness2p connectorfrom the under-dashfuse/relaybox. 3. Checkresistance betweenthe No. 2 terminalof the SRS main harness2P connectorand the No. 3 terminalof the SRSmain harness18Pconnector. Thereshouldbe 0-0.5 0. ls th6 resistanceas soecified? YES
NO
Poor contact at the SRS main harness2p connector; checktho connector, . lf the connectori3 OK, substituto a known-good und€rdash fuse/relaybox, and recheck. . lf the problem is still present, roplace the SRS main natness,
UNDER.OASH FUSE/RELAY BOX
Open in the SRS main harn$s;.eplace the SRS main harness.
SRSMAII{ HARI{ESS 2P CONNECTOR
24-86
www.emanualpro.com
Driver'sAirbag Replacement After a collisionin which the airbagswere deployed,the airbags,the seat belt tensioners(if so equipped),and the SRSunit must be replaced. Store a removed airbag with the pad su.@ tacs up, lf th€ airbag is improperly stored face down. accidental deployment could propal the unit with enough forc€ io causgseriouginiury.
3.
Removethe two Torx bolts from the steering whsel, and disconnectthe horn connector. Remove the driver'sairbag,
DRIVER'S
CAUTION: . Always disconnoct the drivor's airbag connector when the SRSmain harnessis disconnactod. . Do not disassembleor tamper with ihe airbag. NOTE: Do not install used SRSparts from anothervehicle, When repairing,useonly new SRSparts. Carefullyinspectthe airbag beforeyou install it. Do not install an airbag that shows signs of being droppedor improperlyhandled,suchas dents,cracks or deformation. 1 . Disconnectthe batterynegativecable,then disconnect the positive cable from the battery, and wait at leastthree minutes. Remove the access panel from the steering wheel. then disconnectthe 2P connector between the drivthe er'6 airbag and cable reel.When disconnected. shorted. airbagconnectoris automatically
ACCESSPANEL 2P CONNECTON
(cont'd)
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24-87
Driver'sAirbag Replacementlcont'd) CAUTION: 8. sure to instattthe SRSwiring so that it is not plnched or inlerfsring with other parts. 4.
5.
P l a c et h e n e w d r i v e r ' s a i r b a g i n t o t h e s t e e r i n g wheel, and secure it with new Torx bolts.
C o n n e c tt h e d r i v e r ' sa i r b s g 2 p c o n n e c t o rt o t h e c a b l e r e e l 2 P c o n n e c t o r ,t h e n i n s t a l l t h e a c c e s s panelon the steeringwheel.
TORXEOLTS 9.8N,m11.0kgl.m,7.2tbf,ftl Feplace.
2PCONNECTOR
Connectthe battery positive cable.then connectthe negativecable. 7.
24-88,
www.emanualpro.com
After installingthe airbagassembly,confirm proper systemoperation: . Turn the ignitionswitch ON llt); the SRS indicator light should come on for about six seconds and then go off. . Mske sure both horn buttons work. o Takea test-drive,and make sure the cruisecontrol switcheswork.
Airbag Front Passenger's Replacement After a collisionin which the airbagswere deployed,the airbags,the seat belt tensioners(if so equipped),and the SRSunit must be reolaced. store a rsmovod airbag with lhe pad sur@ face up, It the airbag is improporly stor6d face down, accidental doploym€nl could propsl ths unit with gnough forco to causeserious iniury. CAUTION: . Always disconnsqt the front pa3s6ng6r'3airbag connoctor when tho SRSmain harnessis disconnocted, . Do not disassambl6or tamper with tho airbag,
Removethe three mountingnuts from the bracket. 5.
Lift the front passsnger'sairbag out of the dashDOaro. NOTE:The airbag lid has pawls on its side which attach it to the dashboard.To remove the airbag, cover the lid and dashboardwith a cloth, and pry carefullvwith a flat tip screwdriver.
FRONTPASSENGER'S
NOTE: . Do not install us6d SRSparts from anothervehicle. When repairing,useonly new SRSparts. . Carefullyinspectthe airbag beforeyou install it. Do not install an airbag that shows signs of being droppedor improperlyhandled,suchas dents,cracks or deformation. 1.
Disconnectthe battery negative cable, then disconnect the positive cable from the battery. and wait at leastthree minutes. Removethe glove box (seesection 20). Disconnect the 2P connectorbetweenthe front Dassenger'sairbag and SRS main harness,When disconnected,the airbag connector is automatically shorted. FRONT PASSENGER'S
FRONTPASSENGER'S AIRBAG MOUNNNG NUTS
(cont'd)
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24-49
Front Passenger's Airbag Replacement(cont'd) GAUTION: Be sure to installthe SRSwiring so that it is not pinched or interfering with olher parts. 6.
7.
Attachthe airbagconnectorto the connectorhold_ er, then reinstallthe glove box.
P l a c et h e n e w f r o n t p a s s e n g e r ' sa i r b a g i n t o t h e d a s h b o a r dT. i g h t e nt h e f r o n t p a s s e n g e r ,as i r b a g mountrngnuts. FRONTPASSENGER'S
FRONTPASSENGER'S
FRONTPASSENGER'S AIRBAGMOUNTINGNUTS 9.8 N.m {1.0kgJ.m,7.2lbf ft) Replace.
Connectthe b8tterypositivecable,then connectthe negativecable. After installingthe airbag.confirm proper sysrem ooerauon: Turn the ignition switch ON ( ); the SRS indicator l i g h t s h o u l d c o m e o n f o r a b o u t s i x s e c o n d sa n d then go off.
24-90
www.emanualpro.com
CableReel Replacement
)
stors a removed airbag with the pad sur@ tace up. lf th€ airbag is improperly stored face down, a c c i d e n t a ld 6 p l o y m e n t c o u l d p r o p e l t h e u n i t w i t h gnough force to causeserious iniuty.
Makesurethe wheelsare alignedstraightahead. Removethe two Torx bolts from the steering wheel, a n d d i s c o n n e ctth e h o r n c o n n e c t o r R , e m o v et h e driver'sairbag,
CAUTION: . Always disconnect the airbag connector whgn the SRS msin harnessis disconnoctod. . Do not disassembloor tamper with the airbag.
TORXBOLTS Use a Torx T30 bit.
NOTE:Carefullyinspectthe airbag before installingit. Do not installan airbagthat shows signs of being droppedor improperlyhandled,suchas dents,cracksor deformation, '1.
Disconnectthe batterynegativecable,then disconnectthe positivecablefrom the battery, and wait at leastthree minutes. Removethe accesspanelfrom the steeringwheel, then disconnectthe 2P connectorbetweenthe driver's airbagand cablereel.
DRIVER'S
DRIVER'SDASHBOARDLOWERCOVER
5.
*f www.emanualpro.com
Removethe driver's dashboard lower cover (and the knee bolster).
(cont'd)
24-91
GableReel Replacement(cont'dl 6,
Disconnect the connectorsfrom the horn and cruise control sevresumeswitches.
8. Removethe columncovers,
cRursE coNtRoL SET/RESUME SWITCHCONNECTOR
2P CONNECTOR COVER
1.
Loosenthe steeringwheel bolt, then install a steering wheel puller on the steeringwheel and remove it. Note these items when removing the stee.ingwheel: . Do not tap on the steering wheel or the steering columnshaftwhen removingthe steeringwheel, . lf you threadthe puller bolts into the wheel hub more than five threads,the boltswill hit the cable reel and damageit. To preventthis. installa pair of jam nutsfive threadsup on eachpullerbolt. STEERINGWHEEL
STEERING
Disconnectthe 3P [6P] connector betweenthe main wire harnessand cable reel sub-harness,and the 2p connectorbetweenthe cable reel and SRS main harness.
STEERINGWHEELBOLT 39 N.m 14.0kgf.m.29 lbf.ftl
CAALEREELSU8 HARNESS 3P l6PlCONNECTOR [ ]:,98_00modets 10. Remove the cable reelfrom the cotumn,
24-92
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)o NOTE: . Before installing the steering wheel, the front wheelsshouldbe alignedstraightahead. . Be sure to installthe harnesswires so that they are not pinchedor interfering with other parts. . After reassemblv,confirm that the wheels are still turned straightaheadand that the steering wheel spokeangle is correct(roadtest).lf minor do so only spokeangleadjustmentis necessary, by adjustingthe tie-rods,not by removing and repositioning the steeringwheel,
1 3 . Installthe steeringcolumncovers. 1 4 . lf necessary,center the cable reel. {New replacement cable reels come centered,lDo this by first rotating the csble reel clockwise until it stops, Then rotate it counterclockwise(approximatelytwo and a half turns) until the arrow mark on the cable reel labelpointsstraightup.
11. Set the cancel sleeve so that the projectionsare alignedas shown.
VERIC AL
t
PR(NECNONS
)...0 t5.
Installthe steeringwheel on to the steeringcolumn shaft,makingsurethe steeringwheelshaftengages the cable reel and cancelingsl€eve.Do not tap on the steeringwheel or steeringcolumn shaft when installingthe steeringwheel. CABLEREEL
I l: 38 - 00 models
't2. Carefullyinstallthe cable reel on the steeringcolumn shaft. Then connectthe 3P t6Pl connectorto the cablereel sub harness,and connectthe 2P connectorto the SRSmain harness. (cont'd)
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24-93
CableReel (cont'dl Replacement 1 6 . T i g h t e nt h e s t e e r i n gw h e e l b o l t t o t h e s p e c i f i e d torque,and connectthe horn connectorto the steer ing wheel.Then installthe driver'sairbag. TORXBOLTS 9.8N.m(1.0kgd.m,7.2 lbnftl
Reconnectthe driver's airbag 2P connectorto the cable reel 2P connector,and reinstall the access panelon the steeringwheel. 1 9 . Reconnect the batterypositivecable,then the negative cable.
Replace. DRIVER'S
20. After installingthe cable reel,confirm proper system operation: .
Turn the ignitionswitch ON (ll);the SRS indicator light should come on for about six seconds and then go off. a Makesure both horn buttonswork. . Go for a test drive.and makesurethe cruisecontrol switcheswork.
STEERING WHEELBOLT 38 N.m (3.9kgl.m,28lbf.ftl Replace.
1 1 . Attach the cable reel 2P connectorto the connector holder.Theninstall(thekneebolsterand)thedriver,s dashboardlower cover. CABLEREEL
BOLSTER l'98 - 00 modalsl DRIVER'SDASHEOARDLOWERCOVER
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SRSUnit
).0
Replacement CAUTION: . Before disconnecting any part of the SRS wire harnesg,disconnectthe airbag connoctors (and soat beh tensioner connectorsl. . During installation or replacament,do not bump (impact wrench, hammer etc.) the area near the SRS unit. Do not damage the SFS unit terminalg or connsclors. Do not disassemblethe SRS unit it has no saryiceable parts, a Store the SRS unit in a clean,dry area. a Do not use any SRS unit which has been subiected to water damage or shows signs ot being dropped or improperly handlgd, such as dents, cracks or deformation. '1.
Disconnectthe batterynegativecable,then disconnectthe positivecablefrom the battery, andwaitat leastthree minutes.
2.
Disconnect the airbagconnectors(andseatbeltten(Whendisconnected, sionerconnectors). the airbag and seat belt tensionerconnectorsare automatically shorted.)
3.
SRSUNIT
TORX AOLTS Use a Torx T30 bir.
COVER
Removethe left slde cover from the SRSunit. then d i s c o n n e ctth e S R S m a i n h a r n e s s1 8 Pc o n n e c t o r from the SRSunit.
Driver's Side: . R e m o v e t h e a c c e s sp a n e l f r o m t h e s t e e r i n g w h e e l , t h e n d i s c o n n e c tt h e 2 P c o n n e c t o r betweenthe driver's airbag and cable reel (see page 24-231.
)
Removethe right sidecoverfrom the SRSunit.
Front Passenger'sSide: . Disconnectthe 2P connectorbetweenthe front passenger'sairbag and SRS main harness(see page 24-231. Soat Beh Tensionor('98 - 00 modelsr: . Removethe left and right centerpillar lowertrim panels(seesection20). . Disconnect the seat belt tensioner2P connectors from the left sidewire harness(driver'sside)and the right wire harness(front passenger'sside) (seepage24'231.
sRs HARNESS 18PCONNECTOR
TORX BOLTS Us€ a Torx T30 bir.
stoE COVER
) o www.emanualpro.com
Removethe four Torx boltsfrom the SRSunit.then oull out the SRSunit from the driver'sside. (cont'd)
24-95
SRSUnit (cont'dl Replacement 6.
l n s t a l lt h e n e w S R S u n i t . l f t h e T o r x b o l t s y o u r e m o v e di n t h e p r e v i o u ss t e p h a v e r e d t h r e a d s , replacethe Torx bolts.
9. Reconnectthe driver's aibag 2P connectorto the cable reel 2P connector,then reinstallthe access panelon the steeringwheel.
1 0 . Reconnectthe front passenger'sairbag connector to the SRSmain harness.
1 ' t . Reconnectthe left side wire harness2P connector to the driver'sseat belt tensionerand the right side wire harness 2P connector to the front passenger's seatbelttensioner('98- 00 models). 12. Reinstallthe centerpillar lowertrim panels{'98- 99 modelsl.
1 3 . Reconnectthe battery positive cable,then the negative cable.
TORXBOLTS 9.8 N.m {1.0 kgf.m,?.2 Use . Torx T30 bh,
SRSUNIT
TORXBOLTS 9.8N.m11.0 kgf.m,7.2 lbtft) Usoa TorxT30bit.
7.
Connectthe SRSmain harnessl8P connectorto the SRSuniu push it into positionuntil it clicks.
8.
Install the SRS unit covers (right and left). Make surethe coverssnaptogetherin the middle.
24-96
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1 4 . After installing the SRS unit, confirm proper system operation:Turn the ignitionswitch ON (ll);the SRS indicatorlight shouldcome on for aboutsix seconds and then go off,
Airbag/SeatBelt Tensioner )
Disposal Beforescrappingany airbags{and seat belt tansioners) (includingthose in a whole vehicleto be scrappedl.the airbags(and seat belt tensioners)must be deployed.lf the vehicleis still within the warrantvoeriodthe Honda District ServiceManager must give approval and/or special instructions, beforeyou deploythe airbags(andseat belttensioners). Only afterthe airbags{andseat belttensioners)havebeendeployed(asthe resultof vehiclecollision,for example),canthey be scrapped. lf the airbags (and seat belt tensioners)appear intact (not deployed),treatthem with extremecaution. Followthis procedure:
6.
Cut off the airbag(and seatbelt tensioner)connectors. Strip the ends of the airbag (and seat belt tensioner) wires. and connectthe deploymenttool alligatorclips to the airbag (and seat belt tensioner).Placethe deploymenttool at least thirty feet (10 meters)away from the airbao(and seatbelttensioner),
DRIVER'S AIBBAG
FRONTPASSENGER'S AIRBAG
Doployingtho Airbags (and Soat B6li Ten3ione6): ln-vehicle lf an SRSvehicleis to be entirelyscrapped,its airbags (and seat belt tensioners)should be deployedwhile still in the vehicle.The airbags (and seat belt tensioners) s h o u l d n o t b e c o n s i d e r e da s s a l v a g e a b l ep a r t s a n d shouldneverbe installedin anothervehicle. confirm that each airbag {and seat belt @ tonsiongr) i3 ggcurely mountod; othgrwise, severe personal iniury could result from d6ploym6nt,
)
1.
Disconnectthe batterynegativecable,then disconnectthe oositivecable.
AI.IIGATOR
cuPs
lY6llowl
At lcast thirty feot 110motersl
Confirmthat the specialtool is functioningproperly by following the checkprocedureon the tool label or on page24-98. Removethe accesspanel,then disconnectthe 2P connector betweenthe driver's airbag and the cable reel(seepage24-23). Removethe glove box, then disconnectthe 2P connector between the front passenger'sairbag and SRSmain harness(seepage24-23). Removethe centerpillar lower trim panel,then disconnect the 2P connector betweenthe seat belt tensionerand side wire harness('98- 00 models)(see page 24-231.
(cont'd)
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24-97
Airbag/SeatBelt Tensioner
I
Disposal(cont'dl 1.
Connecta 12 volt batteryto the tool'
Deploying tho Airbag: Out-ot.vohicle
It the green light on the tool comes on, the airbag ignitercircuitis defectiveand cannotdeploy t h e a i r b a g .G o t o D a m a g e dA i r b a g S p e c i a l Procedure. . l f t h e r e d l i g h t o n t h e t o o lc o m e so n ,t h ea i r b a gi s readyto be deployed.
lf an intact airbag has been removedfrom a scrapped vehicle,or has beenfound defectiveor damagsdduring transit.storageor seryice,it should be deployedas follows:
.
P u s h t h e t o o l ' s d e p l o y m e n ts w i t c h . T h e a i r b a g should deploy (deploymentis both highly audible and visible;a loud noise and rapid inflationof the bag,followedby slow deflation). . .
.
lf the airbagsdeploy and the green light on the tool comeson, continuewith this procedure. lf an airbag doesn't deploy,yet the green light comes ON, its igniter is defective.Go to DamagedAirbagSpecialProcedure. During deployment,the airbag can become hot enough to burn you, Wait thirty minutes after deploymentbeforetouchingthe airbag.
Disposeof the completeairbag.No part of it can be reused.Placeit in a sturdy plasticbag, and seal it securety.
'L
2.
3. CAUTION: . Wear a faco shield and gloves when handling a deployedairbag. . Wash your hands and rinse them well with water after handling a deployed airbag.
Confirmthat the specialtool is functioningproperly by followingthe checkprocedureon this pageor on the tool label. Positionthe airbagface up, outdoorson flat ground at leastthirty feet (10 m) from any obstaclesor peoDte, Followsteps6, 7, 8. and 9 of the in-vehicledeployment proceoure.
Dlmaged Airbsg {or Seat Beh Ten3ion6r}Sp6cial Procgdure r an airbag {or seat Beh rensioner} cannol !@ be doployod,it should not be treated as normal scrap; it should still be considereda pot€ntially explosive device lhat can causeserious iniury. 1. 2. 3. 4.
5.
lf installedin a vehicle.follow the removal procedure on page24-3and 24-87through90. In all cases,makea shortcircuitby twistingtogether the two airbag inflator wires. Packagethe airbag in exactlythe same packaging that the new reDlacement Dartcame in. Mark the outside of the box "DAMAGEDAIRBAG { o r T E N S I O N E RN) O T D E P L O Y E Ds"o i t d o e s n o t get confusedwith your parts stock. Contactyour Honda District Service Manager for how and whereto returnit for disposal.
DeploymentTool: CheckProcedure l.
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24-98
Connectthe yellow clips to both switch protector handleson the tool; connectthe tool to a battery. Pushthe operationswitch:green meansthe tool is OK: red meansthe tool is faultv. Disconnect the bafteryand the yellow clips.
t
