Honda Accord 1998 - 2002 Service Manual COMPLETE

Service Manual 1998 - 2002 Accord 2/4 Dr

General Information Chassis and Paint Codes 1998 Model... .... .... ........ ...... ... ...... ...... 1-2 Chassis and Paint Codes 1999 Model ........................................ 1-3 Chassis and Paint Codes 2000 Model ........................................ 1-4 Chassis and Paint Codes 2001 Model ........................................ 1-5 Chassis and Paint Codes 2002 Model ........................................ 1-6 Identification Number Locations ........ 1-7 Warning/Caution Label Locations

1-8

Under-hood Emission Control Label ..................................... 1-12

Lift and Support Points ........................ 1-17 To~ing

.................................................. 1-18

Parts Marking .. ................ ..... ..... ..... ...... 1-19

Revised Component Terms ................. 1-20

General Information Chassis and Paint Codes - 1998 Model Vehicle Identification Number 1HG CG5 5 4

Engine Number

* W A 000001

F23A1 - 1000001

"rrrrrr-

a

b

II

cdefgh

a

b

a. Engine Type F23A 1: 2.3 g SOHC VTEC Sequential Multiport Fuel-injected engine F23A4: 2.3 g SOHC VTEC Sequential Multiport Fuel-injected engine F23A5: 2.3 g SOHC Sequential Multiport Fuel-injected engine b. Serial Number

a. Manufacturer, Make and Type of Vehicle 1HG: HONDA OF AMERICA MFG., INC., U.S.A. HONDA Passenger vehicle b. Line, Body and Engine Type CF8: ACCORD/F23A5 CG3: ACCORD COUPE/F23A1, F23A4 CG5: ACCORD/F23A 1 CG6: ACCORD/F23A4 c. Body Type and Transmission Type 1: 2-door Coupe/5-speed Manual 2: 2-door Coupe/4-speed Automatic 5: 4-door Sedan/5-speed Manual 6: 4-door Sedan/4-speed Automatic d. Vehicle Grade (Series) US model Canada model 4: DX, LX 4: DX, LX 5: EX 5: EX 7: EX-ULEV e. Check Digit f. Model Year W: 1998 g. Factory Code A: Marysville, Ohio Factory in U.S.A. h. Serial Number 000001-: US model 800001-: Canada model

Transmission Number BAXA - 5000001

II a

b

a. Transmission Type BAXA: 4-speed Automatic P2A8: 5-speed Manual b. Serial Number

Paint Code Code B-80P G-87P NH-578 NH-592P NH-612M RP-25P RP-29P R-94 YR-508P

Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification. Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification.

Color Mystic Blue Pearl Dark Emerald Pearl Taffeta White Flamenco Black Pearl Regent Silver Metallic Black Currant Pearl Raisin Pearl San Marino Red Heather Mist Metallic

COLOR LABEL

Example: INT. COLOR

TYPEE EXT. COLOR

.....--+-8-80P KAS84AOA Paint Code ' - - - - - - . . - /

1-2

BACK

Chassis and Paint Codes - 1999 Model En ine Number

Vehicle Identification Number

F23A1 - 2000001

I I a

1HG CG5 5 4 * X A 000001

1IIIIIri

a

8.

b.

c.

d.

e. f. g.

h.

b

b

a. Engine Type F23A1: 2.31A SOHC VTEC Sequential Multiport Fuel-injected engine F23A4: 2.3 1A SOHC VTEC Sequential Multiport Fuel-injected engine F23A5: 2.3 1A SOHC Sequential Multiport Fuel-injected engine b. Serial Number F23A1, F23A4: 2000001- (Ohio) F23A1, F23A4: 2500001- (Sayama) F23A5: 2000001-

cdefgh

Manufacturer, Make and Type of Vehicle JHM: HONDA MOTOR CO., LTD. HONDA Passenger vehicle 1HG: HONDA OF AMERICA MFG., INC., U.S.A. HONDA Passenger vehicle Line, Body and Engine Type CF8: ACCORD/F23A5 CG3: ACCORD COUPE/F23A1, F23A4 CG5: ACCORD/F23A 1 CG6: ACCORD/F23A 1, F23A4 Body Type and Transmission Type 1: 2-door Coupe/5-speed Manual 2: 2-door Coupe/4-speed Automatic 5: 4-door Sedan/5-speed Manual 6: 4-door Sedan/4-speed Automatic Vehicle Grade (Series) US model Canada model 4: OX, LX 4: OX, LX 5: EX, LX, LX-ULEV 5: EX 6: LX-ULEV 7: EX, EX-ULEV Check Digit Model Year X: 1999 Factory Code A: Marysville, Ohio Factory in U.S.A. C: Saitama Factory in Japan (Sayama) Serial Number 000001-: US model 800001-: Canada model


I I a b

a. Transmission Type BAXA: 4-speed Automatic (Ohio) MAXA: 4-speed Automatic (Sayama) P2A8: 5-speed Manual b. Serial Number BAXA: 6000001- (Ohio) MAXA: 2000001- (Sayama) P2A8: 2000001 - (Ohio) P2A8: 2500001 - (Sayama)

Paint Code Code Color B-80P Mystic Blue Pearl B-89P Deep Velvet Blue Pearl G-87P Dark Emerald Pearl NH-578 Taffeta White NH-592P Flamenco Black Pearl NH-612M Regent Silver Metallic Satin Silver Metalic*Note NH-623M RP-25P Black Currant Pearl RP-29P Raisin Pearl R-94 San Marino Red YR-508P Heather Mist Metallic * Note: US model only

COLOR LABEL Examplo:


INT. COLOR

TYPEE

EXT. COLOR B-80P KAS84AOA

PolntCode'-----'

BACK

1-3

General Information Chassis and Paint Codes - 2000 Model Vehicle Identification Number

Engine Number F23A 1 - 3000001

1HGCG554* Y A 000001

I---r-

iifffiTi cdefgh

a

a

b

a. Manufacturer, Make and Type of Vehicle JHM: HONDA MOTOR CO., LTD. HONDA Passenger vehicle 1HG: HONDA OF AMERICA MFG., INC., U.S.A. HONDA Passenger vehicle b. Line, Body and Engine Type CF8: ACCORD/F23A5 CG3: ACCORD COUPE/F23A1, F23A4 CG5: ACCORD/F23A 1 CG6: ACCORD/F23A1, F23A4 c. Body Type and Transmission Type 1: 2-door Coupe/5-speed Manual 2: 2-door Coupe/4-speed Automatic 5: 4-door Sedan/5-speed Manual 6: 4-door Sedan/4-speed Automatic d. Vehicle Grade (Series) US model Canada model 0: EX-SULEV 4: DX, LX 4: DX, LX 5: EX, LX-ULEV 5: EX 6: EX, LX-ULEV 6: EX 7: EX-ULEV, LX-SE 7: LX-SE 8: EX-ULEV 9: LX-SE e. Check Digit f. Model Year Y:2000 g. Factory Code A: Marysville, Ohio Factory in U.S.A. C: Saitama Factory in Japan (Sayama) h. Serial Number 000001-: US model 800001-: Canada model

b

a. Engine Type F23A1: 2.3.e SOHC VTEC Sequential Multiport Fuel-injected engine F23A4: 2.3.e SOHC VTEC Sequential Multiport Fuel-injected engine F23A5: 2.3.e SOHC Sequential Multiport Fuel-injected engine b. Serial Number F23A1, F23A4, F23A5: 3000001- (Ohio) F23A1, F23A4, F23A5: 3500001- (Sc!y'ama)


I-I a

b

a. Transmission Type BAXA: 4-speed Automatic (Ohio) MAXA: 4-speed Automatic (Sayama) P2A8: 5-speed Manual b. Serial Number BAXA: 7000001- (Ohio) MAXA: 3000001 - (Sayama) P2A8: 3000001- (Ohio) P2A8: 3500001- (Sayama)

Paint Code Code B-89P B-92P G-87P NH-578 NH-623M RP-31M R-94 YR-524M

Color Deep Velvet Blue Pearl Nighthawk Black Pearl Dark Emerald Pearl Taffeta White Satin Silver Metallic Signet Silver Metallic San Marino Red Naples Gold Metallic

COLOR LABEL Example: INT. COLOR


1-4

BACK

TVPEE EXT. COLOR

8-S0P KAS84AOA

Paint Code ' - - - - - - '

Chassis and Paint Codes - 2001 Model Vehicle Identification Number 1HG CG5 54* 1 A 000001

IIIIII11 a cdefgh b

a. Manufacturer, Make and Type of Vehicle JHM: HONDA MOTOR CO., LTD. HONDA Passenger vehicle 1HG: HONDA OF AMERICA MFG., INC., U.S.A. HONDA Passenger vehicle 3HG: HONDA DE MEXICO, HONDA Passenger vehicle b. Line, Body and Engine Type CF8: ACCORD/F23AS CG3: ACCORD COUPE/F23A 1, F23A4 CGS: ACCORD/F23A 1 CG6: ACCORD/F23A4 c. Body Type and Transmission Type 1: 2-door Coupe/5-speed Manual 2: 2-door Coupe/4-speed Automatic 5: 4-door Sedan/5-speed Manual 6: 4-door Sedan/4-speed Automatic d. Vehicle Grade (Series) Canada model US model 0: EX-SULEV 4: DX, LX S:EX 4: DX, LX 5: EX, LX-ULEV, LX-A 6: EX 6: EX, LX-ULEV 8: LX 7: EX-ULEV, LX-A, LX-A ULEV 8: EX-ULEV, LX 9: LX-ULEV with Side Airbags e. Check Digit f. Model Vear 1: 2001 g. Factory Code A: Marysville, Ohio Factory in U.S.A. C: Saitama Factory in Japan (Sayama) X: EI Saito Factory in Mexico h. Serial Number 000001-: US model 800001-: Canada model

Engine Number F23A1 ·4000001

I I a b a. Engine Type F23A1: 2.3 ~ SOHC VTEC Sequential Multiport Fuel-injected engine F23A4: 2.3 ~ SOHC VTEC Sequential Multiport Fuel-injected engine F23AS: 2.3 ~ SOHC Sequential Multiport Fuel-injected engine b. Serial Number F23A1, F23A4, F23AS: 4000001- (Ohio) F23A1, F23A4, F23AS: 4S00001- (Sayama) F23A1: 4400001- (EI Saito)


I I a b

a. Transmission Type BAXA: 4-speed Automatic (Ohio) MAXA: 4-speed Automatic (Sayama) P2A8: S-speed Manual b. Serial Number BAXA: 7000001- (Ohio) MAXA: 4000001- (Sayama) P2A8: 4000001- (Ohio) P2A8: 4S00001- (Sayama)

Paint Code Color Code B-92P Nighthawk Black Pearl B-96P Eternal Blue Pearl G-87P Dark Emerald Pearl Taffeta White· Note NH-S78 NH-623M Satin Silver Metallic R-94 San Marino Red R-S07P Firepepper Pearl RP-31M Signet Silver Metallic YR-S24M Naples Gold Metallic • Note: US model only

COLOR LABEL

Example:

INT. COLOR

TVPEE EXT. COLOR

B-80P


KASB4AOA

BACK

1-5

General Information Chassis and Paint Codes - 2002 Model Vehicle Identification Number 1HG CG5 54* 2 A 000001

"rrriTi

a

b

Engine Number F23A1 ·5000001

II 8

cdefgh

a. Manufacturer, Make and Type of Vehicle JHM: HONDA MOTOR CO., LTD. HONDA Passenger vehicle 1HG: HONDA OF AMERICA MFG., INC., U.S.A. HONDA Passenger vehicle b. Line, Body and Engine Type CF8: ACCORD/F23AS CG3: ACCORD COUPE/F23A1, F23A4 CGS: ACCORD/F23A 1 CG6: ACCORD/F23A4 c. Body Type and Transmission Type 1: 2-door Coupe/S-speed Manual 2: 2-door Coupe/4-speed Automatic S: 4-door Sedan/S-speed Manual 6: 4-door Sedan/4-speed Automatic d. Vehicle Grade (Series) Canada model US model 0: EX-SULEV, SE O:SE 4: DX, LX 1: SE S:EX 2:SE 6: EX 3:SE 4: DX, LX 7:SE S: EX, LX-ULEV, LX-A 8: LX 6: EX, LX-ULEV, DX VP 7: EX-ULEV, LX-SE, LX-A ULEV, SE 8: EX-ULEV, LX, SE 9: LX-ULEV e. Check Digit f. Model Year 2:2002 g. Factory Code A: Marysville, Ohio Factory in U.S.A. C: Saitama Factory in Japan (Sayama) h. Serial Number 000001-: US model 800001-: Canada model

b

a. Engine Type F23A 1: 2.3 a SOHC VTEC Sequential Multiport Fuel-injected engine F23A4: 2.3 a SOHC VTEC Sequential Multiport Fuel-injected engine F23AS: 2.3 SOHC Sequential Multiport Fuel-injected engine b. Serial Number

a

Transmission Number BAXA • 8000001

II 8

b

a. Transmission Type BAXA: 4-speed Automatic (Ohio) MAXA: 4-speed Automatic (Sayama) P2A8: S-speed Manual b. Serial Number BAXA: 8000001- (Ohio) MAXA: S000001- (Sayama) P2A8: 4000001- (Ohio) P2A8: 4S00001- (Sayama)

Paint Code Color Code Nighthawk Black Pearl B-92P Eternal Blue Pearl B-96P Noble Green Pearl· G-S08P Taffeta White· NH-S78 Satin Silver Metallic NH-623M San Marino Red· R-94 Firepepper Pearl R-S07P Naples Gold Metallic YR-S24M US model only *:

COLOR LABEL

Example:

INT. COLOR

TYPEE EXT. COLOR

B-80P

Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification. Vehicle Identification Number and Canadian Motor Vehicle Safety Standerd Certification.

1-6

KAS84AOA

BACK

Identification Number Locations

Vehicle Identification Number (VIN)


Transmission Number (Manual) Engine Number

BACK

1-7

General Information Warning/Caution Label Locations CABLE REEL CAUTION ISRS I INSTALLATION OF THE SRS CABLE REEL IS CRITICAL TO THE PROPER OPERATION OF THE SRS SYSTEM. REFER TO THE SERVICE MANUAL FOR DETAILED INSTALLATION INSTRUCTIONS.

DRIVER MODULE DANGER

A DANGER EXPLOSIVE/FLAMMABLE STORAGE TEMPERATURES MUST NOT EXCEED 200°F(93°C). FOR PROPER HANDLING STORAGE AND DISPOSAL PROCEDURES, REFER TO SERVICE MANUAL SRS SUPPLEMENT. FIRST AID IF CONTENTS ARE SWALLOWED,INDUCE VOMITING. FOR EYE CONTACT, FLUSH EYES WITH WATER FOR 15 MINUTES. IN EVERY CASE, GET PROMPT MEDICAL ATTENTION. KEEP OUT OF REACH OF CHILDREN.

AWARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND,IF ACCIDENTALLY DEPLOYED, CAN SERIOUSLY HURT OR KILL YOU. • DO NOT USE ELECTRICAL TEST EQUIPMENT OR PROBING DEVICES. THEY CAN CAUSE ACCIDENTAL DEPLOYMENT. • NO SERVICEABLE PARTS INSIDE. DO NOT DISASSEMBLE. • PLACE AIRBAG UPRIGHT WHEN REMOVED. • FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY.

1-8

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SRS WARNING (HOOD) '98-00 models with driver's and passenger's airbags

FRONT PASSENGER MODULE DANGER

A DANGER

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) THIS VEHICLE IS EQUIPPED WITH DRIVER AND FRONT SEAT PASSENGER AIRBAGS. ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW. TAMPERING WITH, DISCONNECTING, OR USING ELECTRICAL TEST EQUIPMENT ON THE SRS WIRING CAN MAKE THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL FIRING OF THE INFLATOR. J~

EXPLOSIVE/FLAMMABLE STORAGE TEMPERATURES MUST NOT EXCEED 200°F (93°C). FOR PROPER HANDLING STORAGE AND DISPOSAL PROCEDURES REFER TO SERVICE MANUAL SRS SUPPLEMENT. FIRST AID IF CONTENTS ARE SWALLOWED, OBTAIN IMMEDIATE MEDICAL ATTENTION. FOR EYE CONTACT, FLUSH EYES WITH WATER FOR 15 MINUTES. IN EVERY CASE, GET PROMPT MEDICAL ATTENTION. KEEP OUT OF REACH OF CHILDREN.

WARNING

THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDENTALLY DEPLOYED, CAN SERIOUSLY HURT YOU. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY.

AWARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDENTALLY DEPLOYED, CAN SERIOUSLY HURT OR KILL YOU. • DO NOT USE ELECTRICAL TEST EQUIPMENT OR PROBING DEVICES. THEY CAN CAUSE ACCIDENTAL DEPLOYMENT. • NO SERVICEABLE PARTS INSIDE. DO NOT DISASSEMBLE. PLACE AIRBAG UPRIGHT WHEN REMOVED. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY.

SRS WARNING (HOOD) '00-02 models with driver's and passenger's, and front seats side airbags SUPPLEMENTAL RESTRAINT SYSTEM (SRS) THIS VEHICLE IS EQUIPPED WITH DRIVER AND FRONT SEAT PASSENGER, AND FRONT AND SIDE AIRBAGS. ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW. TAMPERING WITH, DISCONNECTING, OR USING TEST EQUIPMENT ON THE SRS WIRING CAN MAKE THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL DEPLOYMENT.

AWARNING ACCIDENTAL DEPLOYMENT CAN SERIOUSLY HURT OR KILL YOU. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY.

. MONITOR NOTICE

STEERING COLUMN NOTICE I NOTICEI TO PREVENT SRS DAMAGE, REMOVE STEERING WHEEL BEFORE REMOVING STEERING SHAFT CONNECTING BOLT.

INOTICEI ISRSI • NO SERVICEABLE PARTS INSIDE. • REFER TO SERVICE MANUAL FOR DETAILED INSTRUCTIONS.

(cant'd)

BACK

1-9

General Information Warning/Caution Label Locations (cont'd) SRS INFORMATION U.S.A. model AIRBAG WARNING FLIP VISOR OVER. SRS WARNING INFORMATION U.S.A. '98 model

h. WARNING DEATH OR SERIOUS INJURY CAN OCCUR. • CHILDREN 12 AND UNDER CAN BE KILLED BY THEAIRBAG. • THE BACK SEAT IS THE SAFEST PLACE FOR CHILDREN. • NEVER PUT A REAR-FACING CHILD SEAT IN THE FRONT. • SIT AS FAR BACK AS POSSIBLE FROM THE AIRBAG. • ALWAYS USE SEAT BELTS AND CHILD RESTRAINTS. • THE SRS MUST BE INSPECTED TEN YEARS AFTER IT IS INSTALLED. • THE DATE OF INSTALLATION IS SHOWN ON THE DRIVER'S DOORJAMB. FRONT PASSENGER AIRBAG WARNING (CHILD SEAT) 49ST '98, '99-02 models

SRS WARNING INFORMATION U.S.A. '99-02 models

i .. WARNING

i .. WARNING CHILDREN CAN BE KILLED OR INJURED BY THE PASSENGER AIRBAG. THE BACK SEAT IS THE SAFEST PLACE FOR CHILDREN 12 AND UNDER. MAKE SURE ALL CHILDREN USE SEAT BELTS OR CHILD SEATS.

DEATH OR SERIOUS INJURY CAN OCCUR. • CHILDREN 12 AND UNDER CAN BE KILLED BY THEAIRBAG. • THE BACK SEAT IS THE SAFEST PLACE FOR CHILDREN. • NEVER PUT A REAR-FACING CHILD SEAT IN THE FRONT. • SIT AS FAR BACK AS POSSIBLE FROM THE AIRBAG. • ALWAYS USE SEAT BELTS AND CHILD RESTRAINTS .

FRONT PASSENGER AIRBAG WARNING (CHILD SEAT) California '98 model

.4l

WARNING

CHILDREN CAN BE KILLED OR INJURED BY THE PASSENGER AIRBAG. MAKE SURE ALL CHILDREN USE SEAT BELTS OR CHILD SEATS.

SRS INFORMATION Canada '98 model (located only driver side sun visor)

SRS INFORMATION Canada '99-02 models (located only driver side sun visor) CAUTION TO AVOID SERIOUS INJURY: • FOR MAXIMUM SAFETY PROTECTION IN ALL TYPES OF CRASHES, YOU MUST ALWAYS WEAR YOUR SEAT BELT. • DO NOT INSTALL REARWARD FACING CHILD SEATS IN ANY FRONT PASSENGER SEAT POSITION. • DO NOT SIT OR LEAN UNNECESSARILY CLOSE TO THE AIRBAG. • DO NOT PLACE ANY OBJECTS OVER THE AIRBAG OR BETWEEN THE AIRBAG AND YOURSELF. SEE THE OWNER'S MANUAL FOR FURTHER INFORMATION AND EXPLANATIONS.

1-10

CAUTION TO AVOID SERIOUS INJURY: • FOR MAXIMUM SAFETY PROTECTION IN ALL TYPES OF CRASHES, YOU MUST ALWAYS WEAR YOUR SEAT BELT. • DO NOT INSTALL REARWARD FACING CHILD SEATS IN ANY FRONT PASSENGER SEAT POSITION. • DO NOT SIT OR LEAN UNNECESSARILY CLOSE TO THE AIRBAG. • DO NOT PLACE ANY OBJECTS OVER THE AIRBAG OR BETWEEN THE AIRBAG AND YOURSELF. • SEE THE OWNER'S MANUAL FOR FURTHER INFORMATION AND EXPLANATIONS • THE SRS MUST BE INSPECTED TEN YEARS AFTER IT IS INSTALLED. • THE DATE OF INSTALLATION IS SHOWN ON THE DRIVER'S DOORJAMB.

BACK

'98-99 models

ENGINE COOLANT INFORMATION

SERVICE INFORMATION (Under-hood Emission Control Labell

SRS WARNING LABEL

'00-02 models

'( ~I

U /) I /

(b

/~

BATTERY CAUTION

TIRE INFORMATION

SIDE AIRBAG INFORMATION Labeled only on models with side airbags o Located on driver's door jamb and passenger's door jamb (not shown) o

SIDEAIRBAG o THIS CAR IS EQUIPPED WITH SIDE AIRBAGS IN THE DRIVER'S AND PASSENGER'S SEAT. o DO NOT LEAN AGAINST THE DOOR. o SEE OWNER'S MANUAL FOR MORE INFORMATION.

BACK

1-11

General Information Under-hood Emission Control Label (1998 Model) Emission Group Identification

Engine and Evaporative Families:

Example:

Engine Family:

VEHICLE EMISSION CON ROLINFORMATION u.

THIS VEHICLE CONFORMS TO

~

5. EPA

REGULATIONS APPLICABLE TO 1998 MODEL YEAR NEW MOTOR VEHICLES.

III

CATALYST

TWC /H025 VAlV'lASH (COLD)

2

(§86p'RJ~~OG~[Sl

FRONT

Ul

I

{H]

(P'A)

HONDA MOTOR CO•• LTD

PAA-AOO

I

i

IIIII abc d

VAlVE

I rM1:ln~ ~ u,(-

EGR/SFi/OBD" CERTlFIEO

IN:O. li±O. Olm~rH",V01' )PAl EX: O. JO±O. 02mm WHNXRCl130AAA

SPARK PLUG GAP 1. 0-1, lmm NO OTHER A.DJUSTMENTS NEEDED.

."~,. f~~ --1

Il:r

W HNX V 02.3 PF1

{7

.

e

a. Model Year W: 1998 b. Manufacturer Subcode

~~~SSUR(

REGULA TOR

HNX:HONDA

I

I

FEDERAL THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS APPLICABLE TO 1998 MODEL YEAR NEW MOTOR VEHICLES.

c. Family Type V:LDV T:LDT

d. Displacement e. Sequence Characters

Evaporative Family: CALIFORNIA TLEV THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1998 NEW TLEV PASSENGER CARS PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED INTO COMMERCE FOR SALE IN THE STATE OF CALIFORNIA.

TIER 1/LEV THIS VEHICLE CONFORMS TO U.S. EPA TIER 1 AND STATE OF CALIFORNIA LEV REGULATIONS APPLICABLE TO 1998 MODEL YEAR NEW MOTOR VEHICLES.

W HNX R 0130 AAA

IIIII

abc d

a. Model Year W: 1998 b. Manufacturer Subcode HNX: HONDA

c. Family Type E: EVAP R: EVAP/ORVR

CALIFORNIA LEV THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1998 NEW LEV PASSENGER CARS PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED INTO COMMERCE FOR SALE IN THE STATE OF CALIFORNIA.

CALIFORNIA ULEV THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1998 NEW ULEV PASSENGER CARS PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED INTO COMMERCE FOR SALE IN THE STATE OF CALIFORNIA.

1-12

e

BACK

d. Canister Work Capacity e. Sequence Characters

Under-hood Emission Control Label (1999 Model) Emission Group Identification


Example:

Engine Family:

. i

VEHICLE EMISSION CONTROL INFORMATION THIS VEHICLE CONFORMS TO U. S. EPA REGULATIONS APPLICABLE 10 1999 MODn YEAR NEW MOTOR VEHICLES.

CATALYST

I

TWC/H02S"72 /EGR/SFI/OBDIIC RT1FIED VALV, LASH IN: O. 2UO. 02m: XHNXV02 lPAl (COLD) u.: O. lO:!.O. 02mm • SPARK PLUG GAP 1.0-1. Imm XHNXROIJOAAA NO OTH[R ADJUSTMENTS HHOlO. 2. 3l

(HJ

(poL)

HONDA MOTOR CO •• lTD

PAA-L12

X HNX V 02.3 PA3

rr-r'l

"~. ~-1

Iii'.

II~~ fRONf

{>-

a. Model Year X: 1999 b. Manufacturer Subcode

~~AE

REGULATOR

23VHGGFG

I

e

abc d

HNX: HONDA

I

c. Family Type V:LDV T:LDT



CALIFORNIA TLEV THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1999 NEWTLEV PASSENGER CARS PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED INTO COMMERCE FOR SALE IN THE STATE OF CALIFORNIA. TIER 1/LEV THIS VEHICLE CONFORMS TO U.S. EPA TIER 1 AND STATE OF CALIFORNIA LEV REGULATIONS APPLICABLE TO 1999 MODEL YEAR NEW MOTOR VEHICLES.

Evaporative Family:

rr-ri,

X HNX R 0130 AAA

abc d

e

a. Model Year X: 1999

b. Manufacturer Subcode HNX: HONDA

c. Family Type

CALIFORNIA LEV THIS VEHICLE CONFORMS TO U.S EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1999 NEW LEV PASSENGER CARS PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED INTO COMMERCE FOR SALE IN THE STATE OF CALIFORNIA.

E: EVAP R: EVAP/ORVR


CALIFORNIA ULEV THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1999 NEW ULEV PASSENGER CARS PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED INTO COMMERCE FOR SALE IN THE STATE OF CALIFORNIA.

BACK

1-13



Example

Engine Family:

VEHICLE EMISSION CONTROL INFORMATION. THIS VEHICLE CONFORMS TO u. S. EPA NLEV AND CLEAN-FUEL VEHICLE ANO CALIFORNIA REGULATIONS APPLICABALE TO GASOLINE FUELED 2000 MODEl YEAR NEW LEV PASSENGER CARS. CERTIFICATION TEST FUEl: EPA UNLEADED GASOLINE

TWC/H09~1:~b!~I!T o. VALVE LASH

IN:

FlED

I~1---1M'4:Jn.~~J'i

(HJ HONDA MOTOR CO .• LTO

(poW) PAS-AD)

ab

cd

.~~~fs;RE

REGUlATOR

FRONT { }

23VHGFFG

I

r i r ie l

_~

r

2UD. Olenm

(COLD) EX: o. lO:!::O. 02mlll YHNXV02. lPAl SPARK PLUG GAP I. 0-1. 1mm YHNX RO IlOAAA NO OTHER ADJUSTMENTS NEEDED. 2.lL

Y HNX V 02.3 PA3

I

FEDERAL THIS VEHICLE CONFORMS TO U.S. EPA NLEV AND CLEAN-FUEL VEHICLE AND CALIFORNIA REGULATIONS APPLICABLE TO GASOLINE FUELED 2000 MODEL YEAR NEW LEV PASSENGER CARS. CERTIFICATION TEST FUEL: EPA UNLEADED GASOLINE

a. Model Year Y: 2000 b. Manufacturer Subcode HNX:HONDA c. Family Type V: LDV T:LDT d. Displacement e. Sequence Characters

Evaporative Family:

CALIFORNIA ULEV THIS VEHICLE CONFORMS TO U.S. EPA NLEV REGULATIONS APPLICABLE TO 2000 MODEL YEAR NEW ULEV PASSENGERS CARS, AND CALIFORNIA REGULATIONS APPLICABLE TO 2000 MODEL YEAR NEW ULEV PASSENGER CARS.

Y HNX R 0130 AM

r i r le l

ab

cd

a. Model Year Y:2000 b. Manufacturer Subcode HNX:HONDA c. Family Type E: EVAP R: EVAP/ORVR d. Canister Work Capacity e. Sequence Characters

1-14

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Example:

Engine Family:

VEHICLE EMISSION CONTROL INFORMATION THIS vEHICLE CON~()AMS TO U.S. EPA Nl~V

REGULATIONS APPLICABLE 10 2001 MODH YEAR N(W ULEV PASSENGER CARS AHO CALIFORNIA

REGULATIONS APPLICABLE TO 20rH MODEL nAIl

/

CATALYST

H02S

VALV"ASH

(2)

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I I FEDERAL THIS VEHICLE CONFORMS TO U.S. EPA NLEV AND CLEAN-FUEL VEHICLE REGULATIONS APPLICABLE TO GASOLINE FUELED 2001 MODEL YEAR NEW LEV PASSENGER CARS. HONDA MOTOA CO .. LTO

1 HNX V 02.3 WB7

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NO OTHER ADJUSTMENTS N~EDEO.

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PURGE

NEW UlfV PASSENGER CARS.

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CALIFORNIA lEV THIS VEHICLE CONFORMS TO U.S. EPA NLEV AND CLEAN-FUEL VEHICLE AND CALIFORNIA REGULATIONS APPLICABLE TO GASOLINE FUELED 2001 MODEL YEAR NEW LEV PASSENGER CARS.

a. Model Year 1: 2001 b. Manufacturer Subcode HNX: HONDA c. Family Type V:LDV T:LDT d. Displacement e. Sequence Characters

Evaporative Family:

1 HNX R 0130 AAF

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CALIFORNIA UlEV THIS VEHICLE CONFORMS TO U.S. EPA NLEV REGULATIONS APPLICABLE TO 2001 MODEL YEAR NEW ULEV PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2001 MODEL YEAR NEW ULEV PASSENGER CARS.

ab

d

a. Model Year 1:2001 b. Manufacturer Subcode HNX: HONDA c. Family Type E: EVAP R: EVAP/ORVR d. Canister Work Capacity e. Sequence Characters

CALIFORNIA SULEV THIS VEHICLE CONFORMS TO CALIFORNIA REGULATIONS APPLICABLE TO 2001 MODEL YEAR NEW LEVII SULEV PASSENGER CARS. THIS VEHICLE MAY ONLY BE INTRODUCED INTO COMMERCE FOR SALE IN CALIFORNIA. CANADIAN TIER 1 THIS VEHICLE CONFORMS TO U.S. EPA NLEV REGULATIONS AND CANADIAN TIER 1 STANDARDS FOR 2001 MODEL YEAR NEW PASSENGER CARS.

BACK

1-15



Example:

Engine Family:

VEHICLE EMISSION CONTROL INFORMATIO.N THIS VEHICLE CONFORMS TO U. S. EPA NLEV REGULATIONS APPLICABLE TO ZDOZ MODEL YEAR NEW LEV PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO ZDOl MODEL YEAR NEW LEV PASSENGER CARS.

CATALYST

TWC I HOU-r'lI 7fo'R/IFI/OBD I CERTIFIED

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a. Model Year

2:2002

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FEDERAL and CANADIAN TIER 1 THIS VEHICLE CONFORMS TO U.S. EPA NLEV REGULATIONS APPLICABLE TO 2002 MODEL YEAR NEW LEV PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2002 MODEL YEAR NEW LEV PASSENGER CARS.

b. Manufacturer Subcode HNX:HONDA c. Family Type V:LDV T:LDT d. Displacement e. Sequence Characters

Evaporative Family:

2 HNX R 0130 AAF

I I I Ie I

ab

cd

a. Model Year

2:2002 b. Manufacturer Subcode HNX: HONDA c. Family Type E: EVAP R: EVAP/ORVR d. Canister Work Capacity e. Sequence Characters

1-16

BACK

Lift and Support Points Floor Jack

Frame Hoist If you are going to remove heavy components such as suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with a tall safety stand. When substantial weight is removed from the rear of the vehicle, the center of gravity can change and cause the vehicle to tip forward on the hoist. 1. Position the hoist lift blocks (A), or safety stands, under the vehicle's front support points (B) and rear support points (e).

1. Setthe parking brake. 2. Block the wheels that are not being lifted. 3. When lifting the rear of the vehicle, put the gearshift lever in reverse (or the automatic transmission in ~ position.) 4. Position the floor jack under the front jacking bracket (A) or rear jacking bracket (B), center the jack lift platform (e) on the jacking bracket, and jack up the vehicle high enough to fit the safety stands under it.

A

c

2. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly supported. 3. Raise the hoist to full height, and inspect the lift points for solid contact with the lift blocks.

Safety Stands To support the vehicle on safety stands, use the same support points (B and e) as for a frame hoist. Always use safety stands when working on or under any vehicle that is supported only by a jack.

c 5. Position the safety stands under the support points and adjust them so the vehicle will be level. 6. Lower the vehicle onto the stands.

BACK

1-17

General Information Towing If the vehicle needs to be towed, call a professional towing service. Never tow the vehicle behind another vehicle with just a rope or chain. It is very dangerous.

If the vehicle cannot be transported by flat-bed, it should be towed with the front wheels off the ground. If due to damage, the vehicle must be towed with the front wheels on the ground, do the following:

There are three popular methods oftowing a vehicle.

Flat-bed Equipment- The operator loads the vehicle on the back of a truck. This is the best way of transporting the vehicle. To accommodate flat-bed equipment, the vehicle is equipped with a towing hook (A) and tie down hooks (8). The towing hook can be used with a winch to pull the vehicle onto the truck, and the tie down hooks can be used to secure the vehicle to the truck.

Manual Transmission • Release the parking brake. • Shift the transmission to Neutral. Automatic Transmission • Release the parking brake. • Start the engine. • Shift to ~ position, then rID position. • Turn off the engine. It is best to tow the vehicle no farther than 50 miles (80 km), and keep the speed below 35 mph (55 km/h).

B

INOTICEI • Improper towing preparation will damage the transmission. Follow the above procedure exactly. If you cannot shift the transmission or start the engine (automatic transmission), the vehicle must be transported on a flat-bed. • Trying to lift or tow the vehicle by the bumpers will cause serious damage. The bumpers are not designed to support the vehicle's weight.

A

Wheel Lift Equipment- The tow truck uses two pivoting arms that go under the tires (front or rear) and lift them off the ground. The other two wheels remain on the ground. Sling-type Equipment- The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspension and the cables lift that end of the vehicle off the ground. The vehicle's suspension and body can be seriously damaged. This method of towing is unacceptable.

1-18

BACK

Parts Marking To deter vehicle theft, certain major components are marked with the vehicle identification number (VIN). Original parts have self-adhesive labels. Replacement body parts have generic self-adhesive labels. The original engine or transmission VIN plate is transferred to a replacement engine or transmission and attached with break-off bolts. NOTE: Be careful not to damage the parts marking labels during body repair. Mask the labels before repairing the part.

BACK

1-19

General Information Revised Component Terms Beginning with '01 models, the following component terms have been changed to conform with the standards in SAE document J 1930. If you find a terms or abbreviation in a '01 manual that is unfamiliar to you, check this list. If a term is not listed below, it did not change.

00 and Earlier Models Meaning Heated Oxygen Sensor (for some models) Brake Switch Clutch Switch Distributor Ignition Rotor Function Sensor Evaporative Emission Control Canister Evaporative Emission Control Canister Vent Shut Valve Evaporative Emission Purge Control Solenoid Valve Exhaust Gas Recirculation Valve Lift Exhaust Gas Recirculation Control Solenoid Valve Exhaust Gas Recirculation Vacuum Control Valve

'01 Model or later

HONDA Abbreviations H02S

Air Fuel Ratio Sensor

01 Rotor

EVAP Control Canister EVAP Control Canister Vent Shut Valve EVAP Purge Control Solenoid Valve EGR Valve Lift Sensor EGR Control Solenoid Valve EGR Vacuum Control Valve

Radiator Fan Control Module Fuel Tank Evaporative Emission Valve ORVR Vent Shut Valve ORVR Vapor Recirculation Tube First Idle Themo Valve Fuel Injector Fuel Injection Air Control Valve Fuel Injection Air Control Solenoid Valve Intake Air Bypass Check Valve

Intake Air Bypass Control Diaphragm

1-20

Meaning

FIA Control Valve FIA Control Solenoid Valve lAB Check Valve

lAB Control Diaphragm

Brake Pedal Position Switch Clutch Pedal Position Switch Distributor Rotor Engine Speed Fluctuation Sensor Evaporative Emission Canister Evaporative Emission Canister Vent Shut Valve Evaporative Emission Canister Purge Valve Exhaust Gas Recirculation Valve Position Exhaust Gas Recirculation Valve Vacuum Control Solenoid Valve Exhaust Gas Recirculation Valve Vacuum Control Solenoid Valve Fan Control Module Fuel Tank Vapor/Liquid Separation Valve Fuel Tank Vapor Control Valve Fuel Tank Vapor Recirculation Tube Idle Air Control Thermal Valve Injector Intake Air Bypass Control Valve Intake Air Bypass Control Themal Valve Intake Manifold Runner Control Vacuum Check Valve Intake Manifold Runner Control Actuator Intake Manifold Runner Control Actuator Wire Intake Manifold Runner Control Actuator Diaghragm Intake Manifold Runner Control Module

BACK

New Abbreviations SAE recommendation AlFSENSOR BPPSwitch

RPM Fluctuation Sensor EVAP Canister EVAP Canister Vent Shut Valve EVAP Canister Purge Valve EGR Valve Position Sensor EGR Valve Vacuum Control Solenoid Valve EGR Valve Vacuum Control Solenoid Valve

lAC Thermal Valve

IMRC Vacuum Check Valve IMRC Actuator IMRC Actuator Wire IMRC Diaphragm IMRC Module

'01 Model or later

00 and Earlier Models Meaning

Intake Air Bypass Control Solenoid Valve Intake Air Bypass Vacuum Tank Intake Air Bypass Valve Body Assembly Breather Chamber Fuel Pressure Regulator Control Solenoid Valve Air Control Valve Check Valve

lAB Control Solenoid Valve lAB Vacuum Tank lAB Valve Body Assembly

Air Control Valve Vacuum Tank Air Control Solenoid Valve

Air Pump Air Control Valve Air Pump Electric Current Sensor Shift/Clutch Pressure Control Solenoid Valve Set Shift Control Solenoid Valve Set Shift/Lock-up Clutch Control Solenoid Valve Assy Shift Control Solenoid Valve A Shift Control Solenoid Valve B Throttle Valve Control Module Lock-up Clutch Control Solenoid Valve Set

Lock-up Clutch Control Solenoid Valve Automatic Transaxle Position Switch Variable Valve Timing and Valve Lift Electronic Control Pressure Switch

Meaning

HONDA Abbreviations

Intake Manifold Runner Control Solenoid Valve Intake Manifold Runner Control Vacuum Intake Manifold Runner Control Valve Oil/Air Separator Pressure Regulator Vacuum Control Solenoid Valve Secondary Air Injection Control Vacuum Check Valve Secondary Air Injection Control Vacuum Reservoir Secondary Air Injection Control Vacuum Control Solenoid Valve Secondary Air Iniection Pump Secondary Air Injection Pump Control Valve Secondary Air Injection Pump Electric Current Sensor Shift Solenoid and Automatic Transaxle Clutch Pressure Control Solenoid Valve Set Shift Solenoid and Torque Converter Clutch Solenoid Valve Set Shift Solenoid and Torque Converter Clutch Solenoid Valve Shift Solenoid Valve A Shift Solenoid Valve B

New Abbreviations SAE recommendation IMRC Solenoid Valve

IMRCVacuum Reservoir IMRCValve

Air Control Vacuum Check Valve Air Control Vacuum Reservoir Air Control Valve Vacuum Control Solenoid Valve Air Pump Air Control Valve Air Pump Electric Current Sensor SS and AfT Clutch Pressure Control Solenoid Valve Set SS and TCC Solenoid Valve Set SS and TCC Solenoid Valve SS Valve A SS Valve B

Throttle Actuator

AfT Gear Position Switch VTEC Pressure Switch

Torque Converter Clutch Solenoid and Automatic Transaxle Clutch Pressure Control Solenoid Valve Set Torque Converter Clutch Solenoid Valve Transmission Range Switch

TCC solenoid and AfT Clutch Pressure Control Solenoid Valve Set

Variable Valve Timing and Valve lift Electronic Control Pressure Switch

VTEC Oil Pressure Switch

BACK

TCC solenoid Valve TR Switch

1-21

BACK

II

Specifications Standards and Service Limits Engine Electrical .................................................... Engine Assembly .................................................. Cylinder Head ........................................................ Engine Block .......................................................... Engine lubrication ................................................ Cooling ................................................................... Fuel and Emissions ............................................... Clutch ..................................................................... Manual Transmission and Differential ................ Automatic Transmission and Differential ........... Steering .................................................................. Suspension ....................................................... ..... Brakes ............... ................. ................... .................. Air Conditioning ....................................................

2-2 2-2 2-3 2-4 2-5 2-6 2-6 2-6 2-7 2-10 2-16 2-16 2-17 2-17

Design Specifications Dimensions ............................................................ Weight (U.S.A.) ...................................................... Weight (CANADA) ................................................. Engine .................................................................... Starter .................................................................... Clutch ..................................................................... Manual Transmission ........................................... Automatic Transmission ...................................... Steering .................................................................. Suspension ............................................................ Wheel Alignment .................................................. Brakes ..................................................................... Tires ........................................................................ Air Conditioning .................................................... Electrical Ratings ...................................................

2-18 2-18 2-18 2-18 2-18 2-18 2-19 2-19 2-19 2-19 2-19 2-19 2-19 2-19 2-20

Body Specifications Illustration .............................................................. 2-21

Standards and Service Limits Engme EI ectnca Item Ignition coil

Measurement Rated voltage Primary winding resistance Secondary winding resistance

Ignition wire Spark plug

Firing order Resistance Type

Gap Ignition timing Alternator belt NOTE: Adjust a new belt to the new belt spec., run the engine for 5 minutes, then readjust it

Deflection with 98 N (10 kgf, 221bs) applied mid-way between pulleys

Tension (measured with belt tension gauge)

to the used belt spec. Alternator

Output

Coil (rotor) resistance Slip ring 0.0. Brush length Brush spring tension Starter for Mrr (DEN SO)

Starter for Arr (MITSUBA)

Qualification

Standard or New

Service Limit

12 V at 68°F (20°C) F23A1 and F23A4 engines: 0.45-0.55 Q F23A5 engine: 0.63-0.77 Q at 68°F (20°C) F23A1 and F23A4engines: 16.8-25.2 kQ F23A5 engine: 12.8- 19.2 kQ 1-3-4-2 at 68°F (20°C) 25kQ max. '98-99 models NGK: ZFR5F-11 DENSO: KJ16CR-L11 '00-01 models NGK: PZFR5F-11 DENSO: PKJ 16CR-L 11 '98-99 models 1.0 - 1.1 mm (0.039 - 0.043 in.) '00-01 models 1.0-1.1 mm (0.039-0.043 in.) 1.3 mm (0.051 in.) At idle (check the Mrr (in neutral): 12±2° BTDC at 700±50 rpm red mark) Arr (in IBl or [lI): 12 ± 2° BTDC at 700 ± 50 rpm WithoutAlC Used belt: 10.5- 12.5 mm (0.41 -0.49 in.) (with AlC, see New belt: 8.0-10.0 mm (0.31 -0.39 in.) "Compressor belt" in the AlC table) WithoutAlC Used belt: 290-440 N (30-45 kgf, 66-99Ibs) (with AlC, see New belt: 540-740N (55-75kgf, 120-170Ibs) "Compressor belt" in the AlC table) At 13.5Vand normal engine temperature at 68°F (20°C)

F23A 1 engine: 80 A F23A4 engine: 90 A F23A5 engine: 80 A 2.8-3.0kQ 14.4 mm (0.57 in.) 10.5 mm (0.41 in.) 2.9-3.5 N (0.66-0.79Ibs)

Output Commutator mica depth Commutator runout Commutator 0.0. Brush length Brush spring tension (new) Output Commutator mica depth

1.2kW 0.5-0.8 mm (0.020-0.031 in.) 0.02 mm (0.001 in.) max. 29.9-30.0 mm (1.177-1.181 in.) 15.0- 15.5 mm (0.59-0.61 in.) 14-20 N (1.4-2.0 kgf, 4.0-5.3Ibs) 1.4kW 0.4-0.6 mm (0.016-0.020 in.)

Commutator runout

0.02 mm (0.001 in.) max.

Commutator 0.0. Brush length Brush spring tension (new)

28.0-28.1 mm (1.102-1.106 in.) 15.8- 16.2 mm (0.62-0.64 in.) 16-18 N (1.6-1.8 kgf, 3.5-4.0 Ibs)

14.0 mm (0.55 in.) 1.5 mm (0.06 in.)

0.2 mm (0.008 in.) 0.05 mm (0.002 in.) 29.0 mm (1.142 in.) 10.0 mm (0.39 in)

0.2 mm (0.008 in.) 0.05 mm (0.002 in.) 27.5 mm (1.083 in.) 11.0 mm (0.43 in.)

Engme A ssem blIV Item Compression

2-2

Measurement Pressure check at 200 rpm with wide open throttle. (See Design Specs for ratio.)

Qualification Standard or New Minimum 930 kPa (9.5 kgf/cm', 135 psi) Maximum 200 kPa (2.0 kgf/cm', 28 psi) variation

BACK

Service Limit

---

Cylinder Head Measurement

Item Head

Camshaft

Standard or New

Qualification

Service Limit 0.05 mm (0.002 in.)

Warpage Height

--

End play

0.05-0.15 mm (0.002-0.006 in.)

0.5 mm (0.02 in.)

Camshaft-to-holder oil clearance

0.050-0.089 mm (0.0020-0.0035 in.)

0.15 mm (0.006 in.)

Total runout Cam lobe height

99.95-100.05 mm (3.935-3.939 in.)

0.03 mm (0.001 in.) max. VTEC intake, 37.775 mm (1.4872 in.) primary VTEC intake, mid 39.725 mm (1.5640 in.) VTEC intake, 34.481 mm (1.3575 in.)

--

0.04 mm (0.002 in.)

---

--

secondary

Valves

Clearance (cold) StemO.D.

Stem-to-guide clearance

Valve seats

Width

VTEC exhaust 38.366 mm (1.5105 in.) Intake 38.339 mm (1.5094 in.) Exhaust 37.716 mm (1.4849 in.) Intake 0.24-0.28 mm (0.009-0.011 in.) Exhaust 0.28- 0.32 mm (0.011- 0.013 in.) 5.485-5.495 mm (0.2159-0.2163 in.) Exhaust 5.450-5.460 mm (0.2146-0.2150 in.) Intake 0.020-0.045 mm (0.0008-0.0018 in.) Exhaust 0.055-0.080 mm (0.0022-0.0031 in.) Intake

Intake Exhaust

Stem installed height

Intake Exhaust

Valve springs

Free length

Valve guides

1.0.

Installed height

VTEC intake VTEC exhaust Intake 53.66 mm (2.113 in.) Exhaust 55.58 mm (2.188 in.) Intake 5.515-5.530 mm (0.2171-0.2177 in.) Exhaust 5.515-5.530 mm (0.2171-0.2177 in.) Intake 21.20-22.20 mm (0.835-0.874 in.) Exhaust

Rocker arms

Arm-to-shaft clearance

1.25-1.55mm (0.049-0.061 in.) 1.25-1.55 mm (0.049-0.061 in.) 46.75-47.55 mm (1.841-1.872 in.) 46.68-47.48 mm (1.838-1.869 in.) 51.08 mm (2.011 in.) 55.58 mm (2.188 in.)

20.63-21.63 mm (0.812-0.852 in.) Intake 0.026 - 0.067 mm (0.0010-0.0026 in.) Exhaust 0.018-0.054 mm (0.0007-0.0021 in.)

BACK

--

---

--5.455 mm (0.2148 in.) 5.420 mm (0.2134 in.) 0.08 mm (0.003 in.) 0.12 mm (0.005 in.) 2.00 mm (0.079 in.) 2.00 mm (0.079 in.) 47.80 mm (1.882 in.) 47.73 mm (1.879 in.)

----5.55 mm (0.219 in.) 5.55 mm (0.219 in.)

--

-0.08 mm 10.003 in.) 0.08 mm (0.003 in.)

2-3

Standards and Service Limits Englne 81 ock Item

Block

Measurement Warpage of deck

Bore diameter

Qualification

Aorl B or II

Bore taper Reboring limit Piston

Skirt 0.0. at 16.0 mm (0.63 in.) from bottom of skirt Clearance in cylinder Ring groove width

Ring-to-groove clearance

2.805-2.825 mm (0.1104-0.1112 in)

2.85 mm (0.112 in.) 0.13 mm (0.005 in.)

Connecting rod

0.13 mm (0.005 in.) 0.60 mm (0.024 in.)

0.20-0.70 mm (0.008-0.028 in.)

0.80 mm (0.031 in.)

0.0.

0.70 mm (0.028 in.)

Pin-to-piston clearance

21.962-21.965 mm (0.8646-0.8648 in.) 21.954 mm (0.8643 in.) -0.0050- +0.0010 mm 0.004 mm (0.0002 in.)

Pin-to-rod clearance

(-0.00020-+0.00004 in.) 0.005-0.014 mm (0.0002-0.0006 in.)

0.Q19 mm (0.0007 in.)

Small-end bore diameter

21.970-21.976 mm (0.8650-0.8652 in.)

--

48.0 mm (1.89 in.)

--

Large-end bore diameter

Nominal

End play installed on crankshaft Crankshaft

0.030-0.055 mm (0.0012-0.0022 in.)

Top 0.20-0.35 mm (0.008-0.014 in.) Second 0.40-0.55 mm (0.016-0.022 in.) Oil

Piston pin

86.010-86.020 mm (3.3862-3.3866 in.) 86.070 mm (3.3886 in.) 86.000-86.010 mm (3.3858-3.3862 in.) 86.070 mm (3.3886 in.) -0.05 mm (0.002 in.)

Top 0.035-0.060 mm (0.0014-0.024 in.) Second

Ring end gap

Service Limit 0.10 mm (0.004 in.)

--0.25 mm (0.01 in.) No letter 85.980-85.990 mm (3.3850-3.3854 in.) 85.970 mm (3.3846 in.) Letter B 85.970-85.980 mm (3.3846-3.3850 in.) 85.960 mm (3.3842 in.) 0.020--0.040 mm (0.0008-0.0016 in.) 0.05 mm (0.002 in.) Top 1.220-1.230 mm (0.0480-0.0484 in.) 1.25 mm (0.049 in.) Second 1.220-1.230 mm (0.0480-0.0484 in.) 1.25 mm (0.049 in) Oil

Piston rings

Standard or New 0.07 mm (0.003 in.) max.

Main journal diameter

No.1 journal

0.15-0.30 mm (0.006-0.012 in.)

0.40 mm (0.061 in.)

54.980-55.004 mm (2.1646-2.1655 in.)

--

No.2 journal No.4 journal No.3 journal No.5 journal Rod journal diameter

54.976-55.000 mm (2.1644-2.1654 in.) - 54.992-55.Q16 mm (2.1650-2.1660 in.) - 44.976-45.000 mm (1.7707-1.7717 in.) - 0.005 mm (0.0002 in.) max.

0.006 mm (0.0002 in.) 0.006 mm (0.0002 in.)

End play

0.005 mm (0.0002 in.) max. 0.10-0.35 mm (0.004-0.014 in.)

Runout

0.03 mm (0.001 in.) max.

0.45 mm (0.018 in.) 0.04 mm (0.002 in.)

Rod/main journal taper Rod/main journal out-of-round

0.021-0.045 mm (0.0008-0.0018 in.)

0.050 mm (0.0020 in.)

0.021-0.045 mm (0.0008-0.0018 in.) No.3 journal 0.025-0.049 mm (0.0010-0.0019 in.) No.4 journal 0.021-0.045 mm (0.0008-0.0018 in.)

0.050 mm (0.0020 in.) 0.055 mm (0.0022 in.)

No.5 journal

0.009-0.033 mm (0.0004-0.0013 in.)

0.040 mm (0.0016 in.)

No.1 journal No.2 journal No.3 journal No.4 journal

0.025-0.049 mm (0.0010-0.0019 in.) 0.025-0.049 mm (0.0010-0.0019 in.) 0.021-0.045 mm (0.0008-0.0018 in.)


Crankshaft

Main bearing-to-journal oil clearance

No.1 journal

bearings

F23A 1 (1000001-, 2000001-,3000001-,

No.2 journal

4000001- ), F23A4 (1000001 -, 2000001 -,3000001 -, 4000001-), F23A5 (1000001 -,2000001 -,3000001 -,

0.050 mm (0.0020 in.)

4000001-), F23A 1 (3400001 - , 4400001 - ), F23A4 (3400001 - , 4400001- ) engines Main bearing-to-journal oil clearance F23A 1 (3500001 -,4500001), F23A4 (3500001 -,4500001), F23A5 (3500001 - , 4500001) engines Main bearing-to-journal oil clearance F23A1 (2500001 -), F23A4 (2500001 -) engines

No.5 journal No.1 journal No.2 journal No.3 journal No.4 journal No.5 journal

Rod bearing clearance

2-4

BACK

0.013-0.037 mm (0.0005-0.0015 in.) 0.009-0.033 mm (0.0004-0.0013 in.)

0.040 mm (0.0016 in.)

0.013-0.037 mm (0.0005-0.0015 in.) 0.021-0.045 mm (0.0008-0.0018 in.)

0.045 mm (0.0018 in.) 0.050 mm (0.0020 in.)

0.025-0.049 mm (0.0010-0.0019 in.) 0.013-0.037 mm (0.0005-0.0015 in.)

0.055 mm (0.0022 in.) 0.045 mm (0.0018 in.)

0.009-0.033 mm (0.0004-0.0013 in.) 0.021-0.049 mm (0.0008-0.0019 in.)

0.040 mm (0.0016 in.) 0.060 mm (0.0024 in.)

Item Balancer shafts

Measurement

Journal diameter

Qualification

No.1 journal,

Standard or New 42.722- 42.734 mm

front shaft

(1.6820-1.6824 in.)

No.1 journal,

20.938 - 20.950 mm

rear shaft

(0.8243-0.8248 in.)

No.2 journal, front and rear

38.712-38.724 mm

shafts No.3 journal, front and rear

Service limit 42.71 mm (1.681 in.)

20.92 mm (0.824 in.) 38.70 mm (1.524 in.)

(1.5241-1.5246 in.) 34.722-34.734 mm (1.3670-1.3675 in.)

34.71 mm (1.367 in.)

0.005 mm (0.0002 in.)

---

shafts Journal taper

Front shaft 0.10-0.40 mm

End play

(0.004-0.016 in.) Rear shaft 0.04-0.15 mm

--

(0.002-0.006 in.) Total runout Shaft-to-bearing oil clearance

No.1 journal, front shaft

0.02 mm (0.001 in.)

0.03 mm (0.001 in.)

0.066-0.098 mm

0.12 mm (0.005 in.)

(0.0026-0.0039 in.)

No.3 journal, front and rear shafts No.1 journal,

Balancer shaft

1.0.

bearings

0.050-0.075 mm

0.09 mm (0.004 in.)

rear shaft

(0.0020-0.0030 in.)

No.2 journal, front and rear

0.076-0.108 mm (0.0030-0.0043 in.)

0.13 mm (0.005 in.)

shafts No.1 journal,

42.800-42.820 mm

42.83 mm (1.686 in.)

front shaft

(1.6850-1.6858 in.)

No.1 journal,

21.000-21.013 mm

rear shaft

(0.8268- 0.8273 in.)

No.2 journal,

38.800-38.820 mm (1.5276-1.5283 in.)

38.83 mm (1.529 in.)

34.800-34.820 mm (1.3701-1.3709 in.)

34.83 mm (1.371 in.)

front and rear shafts No.3 journal, front and rear

21.02 mm (0.828 in.)

shafts

Engme Lub" ricat"Ion Measurement

Item

Engine oil

Qualification

Capacity

Standard or New

Service Limit

5.6 A (5.9 US qt, 4.9 Imp qtl for engine overhaul 4.3 A (4.5 US qt, 3.8 Imp qt) for oil change, including filter

Oil pump

Relief valve

Inner-to-outer rotor clearance Pump housing-to-outer rotor clearance

4.0 A (4.2 US qt, 3.5 Imp qt) for oil change, without filter 0.20 mm (0.008 in.) 0.02 - 0.16 mm (0.001 - 0.006 in.) 0.10-0.19 mm (0.004-0.007 in.) 0.21 mm (0.008 in.)

Pump housing-to-outer rotor axial

0.02-0.07 mm (0.001-0.003 in.)

clearance Oil pressure with oil temperature at 176°F (80°C)

at idle at 3,000 rpm

BACK

0.12 mm (0.005 in.)

70 kPa (0.7 kgf/cm', 10 psi) min. 340 kPa (3.5 kgf/cm2, 50 psi) min.

2-5

Standards and Service Limits C00 rmg Measurement

Item

Radiator

Coolant capacity (Includes engine, heater, hoses, and reservoir)

Reservoir Radiator cap Thermostat

Coolant capacity Opening pressure Opening temperature

Radiator fan switch A

Valve lift at fully open Thermoswitch "ON" temperature Thermoswitch "OFF" temperature

Qualification

Standard or New

I

Service Limit

MIT: engine 7.0/1 (7.4 US qt, 6.2 Imp qt) overhaul MIT: coolant 5.5/1 (5.8 US qt, 4.8 Imp qt) change NT: engine 6.911 (7.3 US qt, 6.1 Imp qt) overhaul NT: coolant 5.411 (5.7 US qt, 4.8 Imp qt) change 0.611 (0.6 US qt, 0.5 Imp qt) 93-123 kPa (0.95-1.25 kgf/cm', 14-18 psi) Begins to open 169-176°F (76-80°C) Fully open

194°F (90°C) 8.0 mm (0.31 in.) min. 196-203°F (91-95°C) Subtract 5-15°F (3-8°C) from actual "ON" temperature

Fuel and Emissions Measurement

Item

Fuel pressure regulator Fuel tank Engine idle

Pressure with regulator vacuum hose disconnected Capacity Idle speed with headlights and radiator fan off Fast idle

Qualification

Standard or New

I

Service Limit

320-370 kPa (3.3-3.8 kgf/cm', 47-54 psi) 64.811 (17.1 US gal, 14.3 Imp gal) MIT in neutral 700±50rpm NT in [t!I or[fl 700±50rpm MIT in neutral 1,400±50 rpm NT in [t!I or[fl 1,400±50 rpm

IdleCO%

0.1 max.

Clutch Item

Clutch pedal

Flywheel Clutch disc

Measurement

Height Stroke Play Disengagement height Runout on clutch mating surface Rivet head depth Rivet head thickness

Pressure plate

Warpage Height of diaphragm spring fingers

Qualification

feeler gauge and special tool

2-6

Standard or New

190 mm (7.5 in.) 141-151 mm (5.6-5.9 in.) 9-15 mm (0.4-0.6 in.) from the floor 96 mm (3.8 in.) min. 0.05 mm (0.002 in.) max. 1.650-1.225 mm (0.065-0.089 in.) 8.5-9.1 mm (0.33-0.36 in.) 0.03 mm (0.001 in.) max. Measure with 0.6 mm (0.02 in.) max.

from the floor

BACK

Service Limit

--

---

-0.15 mm (0.006 in.) 0.8 mm (0.03 in.) 6.0 mm (0.24 in.) 0.15 mm (0.006 in.) 0.8 mm (0.03 in.)

Manual Transmission and Differential Measurement

Item

Transmission oil

Capacity

Mainshaft

End play

Service Umit Standard or New Qualification Use Honda MTF Forfluid change: 1.94 (2.0 US qt, 1.7 Imp qt) For overhaul: 2.0 4 (2.1 US qt, 1.81mp qt) Adjust 0.10-0.16 mm (0.004-0.006 in.)

27.977 - 27.990 mm

Diameter of ball bearing contact area

(1.1000 in.)

37.984-38.000 mm (1.4954-1.4961 in.)

37.930mm (1.4933 in.)

27.987 - 28.000 mm (1.1018-1.1024 in.)

27.940mm (1.1000 in.)

Runout

0.02 mm (0.001 in.) max.

0.05 mm (0.002 in.)

1.0.

43.009 - 43.025 mm

43.080mm

Diameter of needle bearing contact area Diameter of ball bearing contact area

Mainshaft 3rd and 4th gears

End play

Mainshaft 5th

0.30 mm (0.012 in.) 32.3 mm (1.27 in.) 30.8 mm (1.21 in.)

1.0.

4th gear 30.92-30.97 mm (1.217-1.219 in.) 43.009-43.025 mm (1.6933-1.6939 in.) 0.06-0.21 mm (0.002-0.008 in.)

43.080mm (1.6961 in.)

30.92-30.97 mm (1.217-1.219 in.)

0.30 mm (0.012 in.) 30.8 mm (1.21 in.)

area

38.000-38.015 mm (1.4961-1.4967 in.)

37.950mm (1.4941 in.)

Diameter of ball bearing and needle

24.987 - 25.000 mm

24.940mm

bearing contact area

(0.9837-0.9843 in.)

(0.9819 in.)

Diameter of 1st gear contact area

39.984-40.000 mm (1.5742-1.5748 in.)

39.930mm (1.5720 in.)

Runout

0.02 mm (0.001 in.) max.

0.05 mm (0.002 in.)

1.0.

46.009 - 46.025 mm

46.08 mm (1.814 in.)

Thickness Diameter of needle bearing contact

(1.8114-1.8120 in.) End play Thickness

Countershaft 2nd

(1.6961 in.)

0.06-0.21 mm (0.002-0.008 in.) 3rd gear 32.42-32.47 mm (1.276-1.278 in.)

End play

Countershaft 1st gear

(1.6933-1.6939 in.) Thickness

gear

Countershaft

27.940mm

(1.1015-1.1020 in.)

1.0.

gear

0.06-0.23 mm (0.002-0.009 in.)

0.23 mm (0.009 in.)

32.95-33.00 mm (1.297-1.299 in.)

--

47.009-47.025 mm

47.08 mm (1.854 in.)

(1.8507-1.8514 in.) End play

0.10-0.15 mm (0.004-0.006 in.)

Thickness

28.92-28.97 mm (1.139-1.141 in.)

Countershaft 2nd gear spacer

1.0.

36.48-36.49 mm (1.4362-1.4366 in.)

36.50 mm (1.437 in.)

collar

0.0.

41.989 - 42.000 mm (1.6531-1.6535 in.)

41.94 mm (1.651 in.)

29.07 - 29.09 mm

--

Length

0.18 mm (0.007 in.)

--

(1.1445-1.1453 in.) (cont'd)

BACK

2-7

Standards and Service Limits Manual Transmission and Differential (cont'd) Item

Mainshaft 4th

Measurement

Qualification

1.0.

Standard or New 31.002-31.012 mm

0.0.

37.989-38.000 mm

and 5th gears spacercoilar

Service Limit

31.06 mm (1.223 in.)

(1.2205-1.2209 in.) 37.94 mm (1.494 in.)

(1.4956-1.4961 in.) Length

A

) . I] ," , .' , L__ J , +

t

I

Reverse idler

56.45-56.55 mm

--

(2.222-2.226 in.) B 26.03 - 26.08 mm

26.01 mm (1.024 in.)

(1.025-1.027 in.)

1.0.

20.016-20.043 mm

gear

20.09 mm (0.7909 in.)

(0.7880-0.7891 in.) Gear-to-reverse gear shaft clearance

0.036-0.084 mm

0.160 mm (0.0063 in.)

(0.0014-0.0033 in.) Synchro ring

Ring-to-gear clearance (ring pushed

0.85-1.10 mm

against gear)

(0.033-0.043 in.)

Dual cone

Outer synchro ring-to-synchro cone

Ring pushed

0.5-1.0 mm

synchro

clearance

against gear

(0.02-0.04 in.)

Synchro cone-to-gear clearance

Ring pushed

0.5-1.0mm

against gear

(0.02-0.04 in.)

Outer synchro ring-to-gear clearance Shift fork

Ring pushed

0.95-1.68 mm

against gear

(0.037-0.066 in.)

Finger thickness

6.2-6.4mm


--

(0.24-0.25 in.) Fork-to-synchro sleeve clearance

0.35-0.65 mm

1.0 mm (0.039 in.)

(0.014-0.026 in.) Reverse shift

Pawl groove width

13.0-13.3 mm

fork

--

(0.51-0.52 in.) Fork-to-reverse idler gear clearance

0.5-1.1 mm

1.8 mm (0.07 in.)

(0.02-0.04 in.) Groove width

atA

~, Fork-to-5th/reverse shift shaft

at B 7.4-7.7 mm

--

--

(0.29-0.30 in.)

atA

clearance

0.05-0.35 mm

0.5 mm (0.02 in.)

(0.002-0.014 in.) A

/~ Shift arm

7.05-7.25 mm (0.278-0.285 in.)

A I

at B 0.4-0.8mm

1.0 mm (0.04 in.)

(0.02-0.03 in.)

1.0.

15.973-16.000 mm

--

(0.6289-0.6299 in.) Shift arm-to-shaft clearance

0.005-0.059 mm

--

(0.0002-0.0023 in.) Shift fork diameter at contact area

12.9-13.0 mm

--

(0.508-0.512 in.) 0.2-0.5 mm

Shift arm-to-shift fork shaft clearance

(0.008-0.020 in.)

2-8

BACK

0.6 mm (0.024 in.)

Measurement

Item

Select lever

Standard or New

Qualification

Shaft outer diameter

15.941 - 15.968 mm

Shaft arm cover clearance

0.032-0.102 mm

Service Umit

--

(0.6276-0.6287 in.)

--

(0.0013-0.0040 in.) Shift lever

15.941-15.968 mm

0.0.

--

(0.6276-0.6287 in.) 0.012-0.122 mm

Transmission housing clearance

--

(0.0005-0.0048 in.) Interlock

16.00-16.05 mm

Bore diameter

--

(0.630 ~ 0.632 in.) 0.032-0.109 mm

Shift arm clearance

--

(0.0013-0.0043 in.) MIT differential

Pinion shaft contact area 1.0.

18.000-18.018 mm

--

(0.7087 -0.7094 in.)

carrier Carrier-to-pinion shaft clearance

0.017-0.047 mm

0.1 mm (0.004 in.)

(0.0007 - 0.0019 in.) Oriveshaft and intermediate shaft

28.005-28.025 mm

contact area 1.0.

(1.1026-1.1033 in.) 0.025-0.066 mm

Carrier-to-driveshaft clearance

-0.12 mm (0.005 in.)

(0.0010- 0.0026 in.) Carrier-to-intermediate shaft clearance

0.055-0.091 mm

0.15 mm (0.006 in.)

(0.0022-0.0036 in.)

MIT differential

Tapered roller bearing starting torque

1.4-2.5 N·m

(preload)

(14-26 kgf·cm. 12-23Ibf·in)

Backlash

0.05~0.15

pinion gear

mm

Adjust

--

(0.002-0.006 in.)

1.0.

18.042- 18.066 mm

--

(0.7103-0.7113 in.) Pinion gear-to-pinion shaft clearance

0.055-0.095 mm

0.15 mm (0.006 in.)

(0.0022 - 0.0037 in.)

BACK

2-9

Standards and Service Limits Automatic Transmission and Differential Item ATF (Automatic

Measurement Capacity

Qualification

Standard or New

Honda ATF-Zl

Transmission

Service Limit

For fluid change: 2.52 (2.6 US qt, 2.2 Imp qt) For overhaul: 6.1 2 (6.4 US qt, 5.4 Imp qt)

Fluid) ATF pressure

Line pressure

At 2,000 rpm in

[HJ or [f] position 4th clutch pressu re

At 2,000 rpm in

3rd clutch pressure

At 2,000 rpm in

2nd clutch pressure

At 2,000 rpm in

1st clutch pressure

At 2,000 rpm in

~ position ~ position

00 position [I] position Stall speed

Check with vehicle on level ground

B50-910 kPa

BOO kPa

(B.7 ···9.3 kgf/cm', 120 - 130 psi)

(B.2 kgf/cm', 120 psi)

B40-920 kPa

790 kPa

(B.6 ·-9.4 kgf/cm', 120- 130 psi)

(B.l kgf/cm', 120 psi)

B40-920 kPa

790 kPa

(8.6-- 9.4 kgf/cm', 120- 130 psi)


B40-920 kPa

790 kPa

(B.6-9.4 kgf/cm', 120- 130 psi)


B40-920 kPa

790 kPa

(B.6-9.4 kgf/cm', 120- 130 psi)

(B.l kgf/cm', 120 psi) 2,400-2,700 rpm

F23A 1/F23A4 engines

2,350-2,650 rpm

F23A5 engine Clutches

Clutch end plate-to-top disc clearance

1.15- 1.35 mm

1st

(0.045-0.053 in.) 2nd

0.7-0.9 mm

3rd

0.6-0.Bmm

(0.02B-0.035 in.) (0.024-0.031 in.) 0.4-0.6 mm

4th Clutch return spring free length

-

43.7 mm (1.72 in.)

3rd,4th

33.5 mm (1.32 in.)

31.5 mm (1.24 in.) --

1st

2.0 mm (0.079 in.)

When discolored

2nd

2.3 mm (0.091 in.)

When discolored

3rd

2.6 mm (0.102 in.)

When discolored

4th

2.3 mm (0.091 in.)

Clutch disc thickness

1.94 mm (0.076 in.)

2-10

When discolored

Mark 1 3.10 mm (0.122 in.)

When discolored

Mark 2 3.20 mm (0.126 in.)

When discolored

3.30 mm (0.130 in.)

When discolored

Mark 4 3.40 mm (0.134 in.)

When discolored

Mark3

3rd and 4th clutch end plate thickness

(0.016-0.024 in.)

45.7 mm (1.BO in.)

Clutch plate thickness

1st and 2nd clutch end plate thickness

-

1st, 2nd

Mark 6

2.60 mm (0.102 in.)

When discolored

Mark 7

2.70 mm (0.106 in.)

When discolored

MarkB

2.BO mm (0.110 in.)

When discolored

Mark9

2.90 mm (0.114 in.)

When discolored

MarkO

3.00 mm (0.1 lB in.)

When discolored

Mark 1 2.10 mm (0.OB3 in.)

When discolored

Mark2

2.20 mm (0.OB7 in.)

When discolored

Mark3

2.30 mm (0.091 in.)

When discolored

Mark4

2.40 mm (0.094 in.)

When discolored

Mark 5 Mark6

2.50 mm (0.09B in.) 2.60 mm (0.102 in.)

When discolored

Mark7

2.70 mm (0.106 in.)

When discolored

MarkB

2.BO mm (0.110 in.)

When discolored

Mark9

2.90 mm (0.114 in.)

When discolored

BACK

When discolored

Measurement

Qualification

Stator shaft needle bearing contact 1.0.

Torque converter

Item

Valve body

Standard or New

Service Limit

27.000-27.021 mm (1.0630-1.0638 in.) When worn or damaged

side ATF pump side ATF pump gear-to-body clearance

Drive gear 0.210-0.265 mm (0.0083-0.0104 in.) Driven gear 0.070-0.125 mm (0.0028-0.0049 in.)

0.07 mm (0.003 in.)

--

--


ATF pump driven gear 1.0. Reverse shift fork

29.000-29.021 mm (1.1417-1.1426 in.) When worn or damaged 0.03-0.05 mm (0.001-0.002 in.)

ATF pump gear thrust clearance

ATF pump driven gear shaft 0.0.

13.980-13.99 mm (0.5504-0.5508 in.)

Fork finger thickness

5.60-6.00 mm (0.220-0.236 in.)

When worn or damaged 5.40 mm (0.213 in.) When worn or damaged

Park gear and pawl

--

Shift fork shaft bore 1.0.

14.000-14.010 mm (0.5512-0.5516 in.)

Shift fork shaft valve bore 1.0.

37.000-37.039 mm (1.4567-1.4582 in.) 37.045 mm (1.4585 in.)

Sealing ring contact 1.0.

32.000-32.013 mm (1.2598-1.2604 in.) 32.050 mm (1.2618 in.)

Accumulator body


35.000-35.025 mm (1.3780-1.3789 in.) 35.05 mm (1.3799 in.)

Stator shaft


Mainshaft

Diameter of needle bearing contact

Servo body Regulator valve body

area

29.000-29.021 mm (1.1417-1.1426 in.) 29.050 mm (1.1437 in.) at stator shaft


at3rd gear 55.975-55.991 mm (2.2037-2.2044 in.) When worn or damaged at 4th gear collar

33.975-33.991 mm (1.3376-1.3382 in.) When worn damaged

1.0. of 3rd gear 1.0. of 4th gear


End play of 3rd gear

0.03-0.31 mm (0.001-0.012 in.)

--

End play of 4th gear

0.10-0.22 mm (0.004-0.009 in.)

--

41 x 72 mm thrust shim thickness

Thrust washer thickness


No.1

6.35 mm (0.2500 in.)

When worn or damaged

No.2

6.40 mm (0.2520 in.)


No.3

6.45 mm (0.2539 in.)


No.4

6.50 mm (0.2559 in.)


No.5

6.55 mm (0.2579 in.)


No.6 6.60 mm (0.2598 in.)


27x47 x5mm

Length of 4th gear collar 4th gear collar flange thickness Sealing ring thickness

32 mm sealing

5.00 mm (0.197 in.)


49.40-49.50 mm (1.9449-1.9448 in.)

--

4.35-4.50 mm (0.171-0.177 in.)


1.85-1.95 mm (0.073-0.077 in.)

1.800 mm (0.071 in.)

1.85-1.95 mm (0.073-0.077 in.)

1.800 mm (0.071 in.)

ring 29 mm sealing ring Width of sealing ring groove

2.025-2.060 mm (0.080-0.081 in.)

2.080 mm (0.082 in.)

5.97-5.98 mm (0.2350-0.2354 in.)

5.95 mm (0.2343 in.)

Clutch feed pipe 0.0.

3rd clutch 4th clutch

11.47-11.48 mm (0.4516-0.4520 in.)

11.45 mm (0.4508 in.)

Clutch feed pipe bushing 1.0.

3rd clutch

6.018-6.030 mm (0.2369-0.2374 in.)

6.045 mm (0.2380 in.)

4th clutch

11.500-11.518 mm (0.4528-0.4535 in.) 11.530 mm (0.4539 in.)

(cont'd)

BACK

2-11

Standards and Service Limits Automatic Transmission and Differential (cont'd) Item Countershaft

Measurement Diameter of needle bearing contact area

Qualification Standard or New at 4th gear 33.975-33.991 mm (1.3376-1.3382 in.) at 2nd gear 39.979- 40.000 mm (1.5740-1.5748 in.) at park gear 41.964-41.980 mm (1.6521-1.6528 in.) at left end

1.0. of 4th gear

40.000- 40.016 mm (1.5748-1.5754 in.) 50.000-50.016 mm (1.9685-1.9691 in.) 46.000-46.016 mm (1.8110-1.8116 in.)

1.0. of idler gear 1.0. of reverse gear

0.00-0.33 mm (0.000-0.013 in.) 0.04-0.28 mm (0.002-0.011 in.) 0.015-0.045 mm (0.0006-0.0018 in.) 0.10-0.25 mm (0.004-0.010 in.) 50.42-50.46 mm (1.985-1.987 in.) 1.99-2.02 mm (0.078-0.080 in.) 55.87 - 55.90 mm (2.1996- 2.2008 in.)

End play of 1st gear End play of 4th gear End play of idler gear End play of reverse gear Length of distance collar Cotter thickness Reverse selector hub 0.0.

2-12

36.005-36.015 mm (1.4175-1.4179 in.)

BACK

Service Umit When worn or damaged When worn or damaged When worn or damaged When worn or damaged When worn or damaged When worn or damaged When worn or damaged

--

-----When worn or damaged

Measurement

Item Secondary shaft


Qualification

Service Limit When worn or

37.978-37.993 mm (1.4952-1.4958 in.)

damaged

at 2nd gear

33.986-33.999 mm

When worn or

(1.3380-1.3385 in.)

damaged

area

1.0. of 1st gear 1.0. of 2nd gear

44.000-44.016 mm

When worn or

(1.7323-1.7329 in.)

damaged

40.000-40.016 mm

When worn or

(1.5748-1.5754 in.)

damaged

0.07-0.15 mm (0.003-0.006 in.) 0.04-0.12 mm (0.002-0.005 in.)

---

No.1

6.85 mm (0.270 in.)

When worn or

No.2

6.90 mm (0.272 in.)

When worn or

No.3

6.95 mm (0.274 in.)

When worn or

NO.4

7.00 mm (0.276 in.)

End play of 1st gear End play of 2nd gear 38 x 56.5 mm splined washer thickness

Standard or New

at 1st gear

damaged damaged damaged When worn or damaged No.5

7.05 mm (0.278 in.)

When worn or

NO.6

7.10 mm (0.280 in.)

When worn or

No.1

4.90 mm (0.193 in.)

When worn or

No.2

4.95 mm (0.195 in.)

When worn or

No.3

5.00 mm (0.197 in.)

When worn or

No.4

5.05 mm (0.199 in.)

When worn or

No.5

5.10 mm (0.201 in.)

When worn or

No.6

5.15 mm (0.203 in.)

When worn or

No.7

5.20 mm (0.205 in.)

When worn or

1.99-2.02 mm (0.078-0.080 in.)

--

damaged damaged 37 x 55 mm thrust shim thickness

damaged damaged damaged damaged damaged damaged damaged Cotter thickness Sealing ring thickness

1.890-1.95 mm (0.074-0.077 in.)

1.800 mm (0.071 in.)

Width of sealing ring groove

2.025-2.060 mm (0.080-0.081 in.)

2.080 mm (0.082 in.)


7.97-7.98 mm (0.3138-0.3142 in.)

7.95 mm (0.3130 in.)


8.000-8.015 mm (0.3150-0.3156 in.)

8.030 mm (0.3161 in.)

14.985 -15.000 mm

When worn or

Reverse idler


gear

area

at reverse idler

(0.5900-0.5906 in.)

damaged

1.0.

gear shaft

20.007 - 20.020 mm

When worn or

(0.7877-0.7882 in.)

damaged

End play

0.20-0.55 mm (0.008-0.022 in.)

--

1.0. of reverse idler gear shaft holder 1.0. of transmission housing of reverse

14.800-14.824 mm

When worn or

(0.5827 - 0.5836 in.)

damaged --

14.800-14.818 mm (0.5827-0.5834 in.)

idler gear shaft contact area

(cont'd)

BACK

2-13

Standards and Service Limits Automatic Transmission and Differential (cont'd) Item

Measurement

Qualification

Standard or New Wire Diameter

Main valve body

Lock-up control valve spring

0.7mm (0.028 in.)

6.6mm

Free Length 42.9mm

(0.260 in.)

(1.689 in.)

Lock-up shift valve spring

0.9mm (0.035 in.)

7.6mm

63.0mm (2.480 in.)

22.4

(0.299 in.)

Shift valve E spring

0.7mm (0.028 in.)

6.6mm (0.260 in.)

32.2mm (1.268 in.)

13.4

Shift valve D spring

0.7mm (0.028 in.)

6.6mm

35.7mm (1.406 in.)

17.2

springs (see page 14-160).

Shift valve C spring

6.6mm (0.260 in.)

49.1 mm (1.933 in.)

21.7

(0.031 in.) Modulator valve spring

1.6mm (0.063 in.)

10.4mm (0.409 in.)

33.5mm (1.319 in.)

9.8

Reverse CPC valve spring

0.7mm

6.1 mm (0.240 in.)

17.8mm (0.701 in.)

7.9

6.6mm (0.260 in.)

35.7mm (1.406 in.)

17.2

8.4mm (0.331 in.)

38.2mm

14.0

(0.043 in.) 0.6mm (0.024 in.)

5.8mm

14.5 mm

(0.228 in.)

(0.571 in.)

1.6mm

9.2mm

44.0mm

(0.063 in.)

(0.362 in.) 14.7 mm (0.579 in.)

(1.732 in.) 77.4mm (3.047 in.)

15.2

35.4mm (1.394 in.)

30.3mm (1.193 in.)

1.92

(0.177 in.) 0.9mm

6.6mm (0.260 in.)

39.8mm (1.567 in.)

20.4

(0.035 in.) 0.65mm

6.6mm (0.260 in.)

34.8mm (1.370 in.)

15.6

(0.026 in.)

7.1 mm (0.280 in.)

40.4mm (1.591 in.)

16.9 16.9

0.7mm

Servo control valve spring

(0.028 in.) Torque converter check valve spring

1.1 mm

Cooler check valve spring

body springs (see page 14163).

(0.260 in.)

No. of Coils 14.2

0.8mm

(0.028 in.)

Regulator valve

0.0.

Regulator valve spring B Regulator valve spring A

1.9mm (0.075 in.) 4.5mm

Stator reaction spring Relief valve spring Lock-up timing valve spring

(1.504 in.) 6.8 12.5

Servo body

Shift valve B spring

springs (see page 14-164).

0.8mm (0.031 in.)

Shift valve A spring

0.8mm

7.1 mm

40.4mm

(0.031 in.)

(0.280 in.)

(1.591 in.)

0.7mm

6.1mm (0.240 in.)

17.8mm (0.701 in.)

7.9

(0.028 in.) CPC valve B spring

0.7mm (0.028 in.)

6.1mm (0.240 in.)

17.8mm (0.701 in.)

7.9

3rd accumulator spring

3.8mm

19.6mm

59.8mm

7.8

(0.150 in.)

(0.772 in.)

(2.354 in.)

4th accumulator spring

3.8mm (0.150 in.)

19.6mm (0.772 in.)

59.8mm (2.354 in.)

7.8

1st accumulator spring B

2.5mm (0.098 in.)

49.5mm (1.949 in.)

8.5

1st accumulator spring A

2.6mm (0.102 in.)

12.8mm (0.504 in.) 19.6mm

69.7mm

10.8

(0.772 in.)

(2.744 in.)

CPC valve A spring

Accumulator body springs (see page 14165).

2-14

2nd accumulator spring B

2.7mm (0.106 in.)

14.8mm (0.583 in.)

51.0 mm (2.008 in.)

9.6

2nd accumulator spring A

2.6mm (0.102 in.)

21.6mm (0.850 in.)

73.2mm (2.882 in.)

10.0

BACK

Item

AfT differential

Measurement

Qualification

carrier Carrier-to-pinion shaft clearance Driveshaft shaft contact area 1.0. Carrier-to-driveshaft clearance Tapered roller bearing starting torque (preload)

AfT differential pinion gear

Backlash 1.0. Pinion gear-to-pinion shaft clearance

Standard or New

18.010-18.028 mm (0.7091 -0.7098 in.) 0.023-0.057 mm (0.001-0.002 in.) 28.025- 28.045 mm (1.103-1.104 in.) 0.045-0.086 mm (0.002-0.003 in.)

Pinion shaft contact area 1.0.

For new 2.7-3.9 N·m bearing (28-40 kgf·cm, 24-35Ibf·in) For used 2.5-3.6 N·m bearing (25-37 kgf·cm, 22-·32Ibf·in) 0.05-0.15 mm (0.002-0.006 in.) 18.042-18.066 mm (0.7103-0.7113 in.) 0.055-0.095 mm

Service Limit

-0.1 mm (0.004 in.) -0.12 mm (0.005 in.) Adjust Adjust --

-0.12 mm (0.005 in.)

(0.002-0.004 in.)

BACK

2-15

Standards and Service Limits

s teenng Item Steering wheel

Measurement Rotational play measured at outside edge Starting load measured at outside edge

Qualification Standard or New With engine 0- 10 mm (0-0.39 in.) running With engine running

30 N (3.1 kgf, 6.8 Ibs)

Service Umit

--

--

Gearbox

Angle of rack guide screw loosened from locked position

20° Max.

Pump

Output pressure with shut-off valve closed Capacity

7,200-7,800 kPa (73-80 kgf/cm', 1,040- 1,140 psi)

Power steering fluid Power steering

Deflection with 98 N (10 kgf, 221bs)

pump belt NOTE: Adjust a new belt to the

applied mid-way between pulleys Tension (measured with belt tension gauge)

Use Honda For fluid change: 0.411 (0.42 US qt, 0.35 Imp qt) Power Steering For system overhaul: 1.1 II (1.16 US qt, 0.97 Imp qt) Fluid Used belt: 13.0-16.0 mm (0.51-0.63 in.) New belt: 11.0-12.5 mm (0.43-0.49 in.) Used belt: 390-540 N (40-55 kgf, 88- 121 Ibs) New belt: 740-880 N (75-90kgf, 165-198Ibs)

new belt spec, run the engine for 5 minutes, then readjust it to the used belt spec.

s uspenslon Item Wheel alignment

Measurement Camber Caster Total Toe Front wheel turning angle

Aluminum wheel

Runout

Steel wheel

Runout

Wheel bearings

End play

2-16

Qualification Standard or New Front 0000'± 1° Rear -0030'± 1° Front 2°48'±1° Front 0±2 mm (0±1/16 in.) Rear IN 2+2 (1/16+ 1/16 in.) Inside wheel Outside wheel Axial Radial Axial Radial Front Rear

BACK

38°32'±2° 31°03' (Reference) 0-0.7 mm (0-0.03 in.) 0-0.7 mm (0-0.03 in.) 0- 1.0 mm (0-0.04 in.) 0-1.0 mm (0-0.04 in.) 0-0.05 mm (0-0.002 in.) 0-0.05 mm (0-0.002 in.)

Service Umit


Brakes Measurement

Item

Parking brake

Distance travelled when pulled with

lever

196 N (20 kgf, 44 Ibs) of force

Brake pedal

Standard or New

Qualification

Disc brake

6-9 clicks

Drum brake

4-7 clicks

MiT

Pedal height (Carpet removed)

Service Umit

144 mm (5 11/16 in.)

NT 148 mm (513/16 in.) Free play

1-5 mm (1/16-3/16 in.)

Master cylinder

Piston-to-pushrod clearance

0-0.4 mm (0-0.02 in.)

Brake disc

Thickness

Front

22.9-23.1 mm (0.90-0.91 in.)

Rear

9.9 -1 0.1 mm (0.39 - 0.40 in.)

21.0 mm (0.83 in.) 8.0 mm (0.31 in.)

Parallelism

-Rear - Front and rear - -

Thickness

Front

10.5 -11.5 mm (0.41- 0.45 in.)

Rear

8.9 - 9.1 mm (0.350 - 0.358 in.)

1.6 mm (0.06 in.)

219.9-220.0 mm

221 mm (8.700 in.)

0.10 mm (0.004 in.)

Front

Runout

0.10 mm (0.004 in.) 0.015 mm (0.0006 in.)

Brake pads Brake drum

I.D.

Brake shoes

Lining thickness

1.6 mm (0.06 in.)

(8.657 -8.661 in.) 2.0 mm (0.08 in.)

4.5 mm (0.18 in.)

" A"Ir Con d"Itlomng Measurement

Item

Qualification

Standard or New

Refrigerant

Type

HFC-134 a (R-134 a)

Capacity or system

600-650 g (21-23 oz)

Refrigerant oil

Type Capacity of components

DEN SO: ND-OIL 8 (P/N 38897-PR7-A01AH or 38899-PR7-A01) Condenser

25 mil (5/6 fI

Evaporator

40 mil (1 1/3 fI

Each line and

OZ,

0.9 Imp oz)

OZ,

10 mil (1/3 fl

OZ,

10 mil (113 fl

OZ,

1.4 Imp OZ)

0.41mp

OZ)

hose Receiver Compressor

160 mil (5 1/3 fl

0.4 Imp oz) OZ,

5.6 Imp oz)

Compressor (DENSO)

Starter coil resistance Pulley-to-pressure plate clearance

0.5±0.15 mm (0.02±0.006 in.)

Alternator-com-


Used belt: 7.0-9.0 mm (0.28-0.35 in.)

pressor belt

applied mid-way between pulleys

New belt: 4.0-6.0 mm (0.16-0.24 in.)

NOTE: Adjust a

Tension (measured with belt tension

Used belt: 490-590 N (50-60 kgf, 110-130 Ibs)

new belt to the

gauge)

New belt: 1,030-1,130 N (105-115 kgf, 231-254Ibs)

at 68°F (20°C)

3.4-3.8 Q

new belt spec., run the engine for 5 minutes, then readjust it to the used belt spec.

BACK

2-17

Design Specifications Item DIMENSIONS

Measurement Overall length

aualification

Specification

4-door 2-door

Overall width Overall height Wheelbase Track

WEIGHT (U.S.A.)

4,795 mm (188.8 in.) 4,745 mm (186.8 in.) 1,785 mm (70.3 in.)

4-door

1,445 mm (56.9 in.)

2-door

1,395 mm (54.9 in.)

4-door

2,715 mm (106.9 in.)

2-door

2,670 mm (105.1 in.)

Front

1,555 mm (61.2 in.)

Rear

1,535 mm (60.4 in.)

Ground clearance

158 mm (6.2 in.)

Seating capacity

Five

4-door Sedan: Gross Vehicle Weight Rating (GVWR)

OX (99-00)

3,9901bs

OX (01)

4,0351bs

LX (98-02) EX (98-00) EX (01-02)

4,0801bs

2-door Coupe:

LX (98-00)

3,9451bs

Gross Vehicle Weight Rating (GVWR)

LX (01-02)

3,9901bs

EX (98-02)

4,0351bs

WEIGHT

4-door sedan:

OX (98-00)

1,810 kg

(CANADA)


DX(Ol)

1,830 kg

LX(98-02) EX(98-00)

ENGINE

EX (01-02)

1,850 kg

2-door Coupe:

LX (98-00)

1}90kg


LX (01-02)

1,810 kg

EX (98-02)

Type

F23A 1 and F23A4

1,830 kg Water-cooled, 4-stroke SOHC VTEC gasoline engine

engines F23A5 engine

Water-cooled, 4-stroke SOHC gasoline engine

Cylinder arrangement

Inline 4-cylinder, transverse

Bore and stroke

86.0 x 97.0 mm (3.39 x 3.82 in.)

Displacement Compression ratio

2,254 em' (mlA) (138 cu in.) F23A 1 and F23A4

9.3

engines F23A5 engine Valve train

F23A 1 and F23A4

8.8 Belt driven, SOHC VTEC 4 valves per cylinder

engines F23A5 engine Lubrication system Oil pump displacement

at 6,000 engine rpm

Water pump displacement

at 6,000 engine rpm

Fuel required STARTER

53.7IA (56.7 US qt, 47.3 Imp qt)/minute 150 IA (159 US qt, 132 Imp qt)/minute UNLEADED gasoline with 86 pump octane number or higher

Type Normal output

Belt driven, SOHC 4 valves per cylinder Forced, wet sump, with trochoid pump

Gear reduction MIT

1.2kW

AJT 1.4kW Nominal voltage

12 V

Hour rating

30 seconds

Direction of rotation CLUTCH

Clutch

Clockwise as viewed from gear end MIT

Single plate dry, diaphragm spring

AJT Torque converter Clutch friction material surface

MIT

area

2-18

BACK

217 em' (33.6 sq in)

Measurement

Item MANUAL

Type

TRANSMISSION

Primary reduction

Synchronized, 5-speed forward, 1 reverse Direct 1:1 1st 3.285

Gear ratio

2nd

Final reduction Type

TRANSMISSION

Primary reduction

1.193

4th

0.903

5th

0.685

Reverse

3.000

Type

2nd

1.427

3rd

0.931

4th

0.620

Type Gear ratio

16.09

Turns, lock-to-Iock

3.11

Type Shock absorber Camber

ALIGNMENT

380 mm (15.0 in) Front

Front Rear

0° - 0°30'

Caster

Front

2°48'

Total toe

Front

Omm(Oin.)

Type of service brake

Front Rear without ASS Rear with ABS

Type of parking brake Pad friction surface area Shoe friction surface area TIRES

Independent double wishbone, coil spring with stabilizer Five-link double wishbone

Front and rear Telescopic, hydraulic, nitrogen gas-filled

Rear BRAKES

4.466

Overall ratio

Rear WHEEL

1.863 Single helical gear Power-assisted rack and pinion

Type

Steering wheel diameter SUSPENSION

4.062 Electronically controlled automatic, 4-speed forward, 1 reverse Direct 1:1

Reverse

STEERING

Single helical gear

1st 2.528

Gear ratio

Final reduction

1.807

3rd

Gear ratio AUTOMATIC

Specification

Qualification

CONDITIONING

Compressor

Power-assisted self-adjusting solid disc 49 cm' x 2 (7.6 sq in x 2)

Rear

28cm' x 2 (4.3 sq in x 2)

Rear

74 cm' x 2 (11.5 sq in x 2)

OX

P195nO R14 90S

LX and EX

P195/65 R15 89H

Size of spare tires Cooling capacity

Power-assisted self-adjusting ventilated disc Power-assisted self-adjusting solid drum Mechanical actuating, rear wheels

Front

Size offront and rear tires

AIR

In 2 mm (1/16 in.)

T125nO 015 95M 5,240 Kcal/h (20,800 BTU/h) Type/manufacturer

Swash plate/DENSO

Number of cylinders

10

Capacity Maximum speed Lubricant

177.7 mA/rev. (10.84 cu in/rev.) 7,600 rpm 160 mA (51/3 fl oz)

capacity Lubricant type

NO-OIL 8 (P/N 38897-PR7-A01AH or 38899-PR7-A01)

Condenser

Type

Corrugated fin

Evaporator

Type

Corrugated fin

BACK

2-19

Design Specifications (cont'd) Item

AIR

Measurement

Blower

CONDITIONING

Qualification

Type

Specification

Sirocco fan

Motor input 230W/12 V Speed control Maximum capacity Temperature control Compressor clutch

4-speed 520 m'/h (18,300 cu ft/h) Air-mix type

Type Electrical power

Dry, single plate, Poly-V belt drive 40 W maximum at 12 V

consumption at 6BoF (20°C) Refrigerant

Type Quantity

ELECTRICAL

Battery

RATINGS

Starter Alternator

HFC-134 a (R-134 a) 600-650 g (21-23 oz) 12 V-52 AH/S hours

DENSO

12V-1.2kW

MITSUBA

12V-1.4kW

F23A1 and

12 V-BOA

F23AS engines F23A4 engine Fuses

Under-hood fuse/

12V-90A 100A, 50 A, 40 A, 30A, 20 A, 1S A

relay box Under-dash driver's 30 A, 1SA,10A, 7.SA fuse/relay box Under-dash

30 A, 20 A, 10 A, 7.S A

passenger's fuse/ relay box Light bulbs

Headlight high

12V-60W

beam Headlight low

12V-S1 W

beam Front turn signal!

12 V -24 W/2.2 CP (candlepower)(two filaments)

Front side marker lights Front parking lights

12 V-3 CP

Rear turn signal

12V-21 W

lights Brake/Taillights

12 V-21/SW

Inner taillight

12 V-3 CP

High mount

12 V-21 W

brake light Back-up lights

12V-21 W

License plate light

12 V-3 CP

Ceiling light

12V-7W

Trunk lights

12V-5W

Door courtesy

12 V-2 CP

lights Vanity mirror lights Glove box light Spotlights Gauge lights Indicator lights Panel and pilot

12V-1.1W 12 V-3.4 W 14 V-4 CP 14 V-1.4 W, 3.0 W, 3.4 W 12V-LED, 14V-0.56W, 0.7 W, 1.4W 14 V-0.S6W, 0.B4W

lights Heater control panel lights

2-20

BACK

14V-1.12W,1.4W

Body Specifications

4-door sedan Unit: mm (in.)

III

III

N

~

... en ........

......

(cant'd)

BACK

2-21

Body Specifications (cont'd) 2-door coupe Unit: mm (in.)

o o

....

CI

CD

.. III

....

N ..

C'!

P"

~ CI

-+U------lI---lI!III--II-l-ll----I- ~ 1::

jg ~

P"

2-22

BACK

P"

Maintenance Lubricants and Fluids ...... ..... ......... ......... ... ....... 3-2 Maintenance Schedule for Normal Conditions (1998-2000 Models) Listed by DistancefTime ............................................... 3-4

Maintenance Schedule for Severe Conditions (1998-2000 Models) Listed by DistancefTime ............................................... 3-6

Maintenance Schedule for Normal and Severe Conditions (1998-2000 Models) Listed by Maintenance Item ........................................ 3-8

Maintenance Schedule for Normal Conditions (2001-2002 Models) Listed by DistancefTime ............................................... 3-10

Maintenance Schedule for Severe Conditions (2001-2002 Models) Listed by DistancefTime ............................................... 3-12


Lubricants and Fluids

For details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work I Over hau,I Insta II· . d .rn each section. . graced ures (suc h as A ssem blIVIIR eassem blry, R eplacement, atlon, etc. ) contarne NO. LUBRICATION POINTS LUBRICANT Engine 1 Honda Motor oil. API Service Grade: Use SJ "Energy Conserving" grade oil. The oil container may also display the API Certification seal shown below. Make sure it says "For Gasoline Engines." SAE Viscosity: See chart below. Transmission Manual Honda Manual Transmission Fluid (MTF)" , 2 Honda ATF-Z1 (ATF)'2 Automatic Transmission Brake line (includes ABS line) Honda DOT 3 Brake Fluid"3 3 Clutch line Honda DOT 3 Brake Fluid"3 4 Power steering gearbox Steering grease PIN 08733-B070E 5 Release fork (manual transmission) Super High Temp Urea Grease (PIN 08798-9002) 6 Shift and select cable ends (manual 7 transmission) Throttle cable end (dashboard lower panel hole) Silicone grease 8 Throttle cable end (throttle link) 9 Multi-purpose grease 10 Brake master cylinder push rod Clutch master cylinder push rod 11 12 Pedal linkage 13 Battery terminals 14 Fuel fill lid 15 Rear brake shoe linkage Honda White Lithium Grease 16 Hood hinges and hood latch 17 Trunk hinges and latch 18 Door hinges, upper and lower 19 Door opening detent 20 Caliper piston boot, caliper pins and boots Silicone grease Brake line joints (front and rear wheelhouse) Rust preventives 21 22 Power steering system Honda Power Steering Fluid"' 23 Air conditioning compressor Compressor oil: DEN SO: NO-OIL 8 (PIN 38897-PR7-A01 AH or 38899-PR7-A01) For refrigerant: HFC-134 a (R-134 a) API CERnRCAnON SEAL

Recommended Engine Oil Engine oil viscosity for ambient temperature ranges

For '98-00 models

I

-I

-20

20

For '01-02 models

=.;1

40

&0

I

I

I

I

-30

·20

-to

to

I I:

80

100""

I

20

10

I

40"

1111 ·20 ,

-30

0

rIIII

5W-20

20

40

60

80

'OO·F

!

,

!

,

,

,

-20

·,0

0

,0

20

30

!

4O·C

*1: Always use Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because it does not contain the proper additives. *2: Always use Honda ATF-Z1 (ATF). Using a non-Honda ATF can affect shift quality. *3: Always use Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system. *4: Always use Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmission fluid can cause increased wear and poor steering in cold weather.

3-2

BACK

NOTE: Lubricate all hinges, latches, and locks once a year. In corrosive areas, more frequent lubrication is necessary. We recommend Honda White Lithium Grease.

@

@ @

®cv@®®

®

@

®

@

\

./

®

@CD@

® @

@

®

®

®

@ @

@

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BACK

3-3

Maintenance Schedule for Normal Conditions (1998-2000 Models) Listed by Distance/Time This two-page maintenance schedule outlines the minimum required maintenance. Service at the indicated time or distance, whichever comes first. Use the Maintenance Schedule for Severe Conditions if the vehicle meets any of the qualifiers listed in the severe conditions schedule or if the vehicle is normally driven in Canada.

o o o

Do items in A. 7 ,500 mil 12,000 km/15,000 mil 24,000 km/ 1 year Do items in A and B. 22,500 mi/36,OOO km/ Do items in A. 30,000 mil 48,000 km/2 years Replace spark plugs for '98-99 models. Use NGK (ZFR5F-11) or DENSO (KJ16CR-L 11). Gap: 1.0-1.1 mm (0.039-0.043 in.) (see page 4-26). Do: item in A. Band C. Do items in A. 37 ,500 mi/60.000 km/45,000 mil 72,000 km/3 years Replace coolant (see page 10-10) Capacity: MIT: 5.511 (5.B US qt, 4.8 Imp qt), AfT: 5.411 (5.7 US qt, 4.8 Imp qt). Use Honda All Season Antifreeze/Coolant Type 2. Replace brake fluid. Use Genuine Honda DOT 3 Brake Fluid. Fill to between marks on reservoir. Do items in A and B. 52,500 mil 84.000 km/Do items in A, 60,000 mi/96,000 km/4 years Replace spark plugs for '98-99 models. Use NGK (ZFR5F-11) or DENSO (KJ16CR-L 11). Gap: 1.0-1.1 mm (0.039-0.043 in.) (see page 4-26). Do: item in A, Band C. 67,500 mi/108,000 km/ Do items in A. 75,000 mil120,000 km/ 5 years Replace coolant (see page 10-10) Capacity: MIT: 5.511 (5.B US qt, 4.8 Imp qt), AfT: 5.411 (5.7 US qt, 4.8 Imp qt). Use Honda All Season Antifreeze/Coolant Type 2. Do items in A and B. 82,500 mi/132,000 km/Do items in A. 90,000 mi/144,000 km/6 years Replace spark plugs for '98-99 models. Use NGK (ZFR5F-11) or DENSO (KJ16CR-L 11). Gap: 1.0 -1.1 mm (0.039 - 0.043 in.) (see page 4-26). Replace transmission fluid. MIT: 1.9 II (2.0 US qt, 1.7 Imp qt) Use Honda MTF (see page 13-3). AfT: 2.5 II (2.6 US qt, 2.2 Imp qt) Use Honda ATF-Z1 (see page 14-113). Replace brake fluid. Use Honda DOT 3 Brake Fluid. Fill to between marks on reservoir. Do items in A, B, and C. Do items in A. 97,500 mi/156,OOO km/105,000 mi/168,000 km/7 years Inspect valve clearance (cold) (see page 6-14) Intake: 0.24 - 0.28 mm (0.009 - 0.011 in.) Exhaust: 0.28 - 0.32 mm (0.011 - 0.013 in.) Replace spark plugs for '98-99 models. Use NGK (ZFR5F-11) or DENSO (KJ16CR-L11). Gap: 1.0-1.1 mm (0.039-0.043 in.) (see page 4-26). Replace spark plugs for '00 model (see page 4-26). Use NGK (PZFR5F-11) or DENSO (PKJ16CR-L11). Gap: 1.0-1.1 mm (0.039-0.043 in.) Replace timing belt and balancer belt (Removal: (see page 6-23), Installation: (see page 6-26)) and inspect water pump (see page 10-9). Check idle speed. Should be 700±50 rpm in neutral (Automatic transmission in IJ!l or If) position) (see page 11-110). Replace coolant (see page 10-10). Capacity: MIT: 5.511 (5.B US qt, 4.Blmp qt), AfT: 5.44 (5.7 US qt, 4.8 Imp qt). Use Honda All Season Antifreeze/Coolant Type 2. Do items in A and B. 112,500 mil181 ,000 km/Do items in A. 120,000 mi/193,000 km/8 years Replace spark plugs for '98-99 models. Use NGK (ZFR5F-11) or DENSO (KJR16CR-L11). Gap: 1.0-1.1 mm (0.039-0.043 in.) (see page 4-26). Do the items in A, B, and C.

o o

o o o

o o o o o o o o

o o o o o o o

o

o

o o

o

o

o o

3-4

BACK

Do the items in parts A, B, and C as required for mileage/time interval listed. A

D D

Replace engine oil (see page 8-5). - Capacity with filter change: 4.3 11 (4.5 US qt, 3.8 Imp qt) Rotate tires. Follow the pattern shown in the Owner's Manual -Check tire inflation and condition.

B

D D D D

D D D D

D D D

Replace engine oil filter (see page 8-6). Inspect front and rear brakes (see page 19-10). • Check pads and discs for wear (thickness), damage, and cracks. • Check calipers for damage, leaks, and tightness of mount bolts. Check parking brake adjustment. Should be fully applied within 6 to 9 clicks (disc brake) or within 4 to 7 clicks (drum brake). Inspect tie rod ends, steering gearbox, and boots (see page 17-8). • Check rack grease and steering linkage. • Check boots for damage and leaking grease. • Check fluid line for damage and leaks. Inspect suspension components. • Check bolts for tightness. • Check condition of ball joint boots for deterioration and damage. Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3). Inspect brake hoses and lines (including ABS). - Check the master cylinder, proportioning control valve, and ABS modulator for damage and leakage. Check all fluid levels and condition offluids; check for leaks. If necessary, add ATF (see page 14-113) or MTF (see page 13-3), engine coolant, brake fluid, and windshield washer fluid. Inspect cooling system hoses and connections. • Check for damage, leaks, and deterioration. • Check for proper fan operation. Inspect exhaust system* . Check catalytic converter heat shield, exhaust pipe, and muffler for damage, leaks, and tightness (see page 9-5). Inspect fuel lines and connections*. Check for loose connections, cracks and deterioration; retighten loose connections and replace damaged parts (see page 11-118).

C

D Replace air cleaner element. D Inspect and adjust drive belts.

D

• Look for cracks and damage, then check belt deflection by pushing on it (about 22 Ibs) midway between the pulleys. - Alternator belt: 10.5-12.5 mm (0.41-0.49 in.)(see page 4-40) - PIS pump belt: 13.0-16.0 mm (0.51-0.63 in.) (see page 17-12) - AlC compressor belt: 7.0-9.0 mm (0.28-0.35 in) (see page 4-39) Replace the air conditioning filter (see page 21-26). • Replace it twice as often (at 15,000 mile interval) if the vehicle is driven mostly in urban areas that have high concentrations of soot in the air from industry and diesel-powered vehicles. • Replace it whenever airflow from the climate control system is less than normal.

According to state and federal regulations, failure to do the maintenance items marked with asterisk ( * ) will not void customer's emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability.

BACK

3-5

Maintenance Schedule for Severe Conditions (1998-2000 Models) Listed by Distance/Time Service at the indicated distance or time, whichever comes first. Use this schedule if the vehicle is driven MAINLY in Canada or in any of the following conditions; if only OCCASIONALLY driven in these conditions, use the Normal Conditions schedule (see page 3-4). Severe Driving Conditions • Less than 5 miles (8 km) per trip or, in freezing temperatures, less than 10 miles (16 km) per trip • In extremely; hot weather (over 90°F/32°C) • Extensive idling or long periods of stop-and-go driving • Trailertowing • On muddy, dusty, or de-iced roads • Driving in mountainous conditions

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3,750 mil 6,000 km/ Replace oil and filter. 7,500 mil 12,000 km/6 months Do items in A. 11 ,250 mil 18,000 km/ Replace oil and filter. 15,000 mil 24,000 km/ 1 year Clean air cleaner element with low pressure air. Do items in A and B. 18,750 mil 30,000 km/ Replace oil and filter. 22,500 mil 36,000 km/ 1 1/2 years: Do items in A. 26,250 mil 42,000 km/ Replace oil and filter 30,000 mil 48,000 km/ 2 years: Replace spark plugs for '98-99 models. Use NGK (ZFR5F-ll) or DENSO (KJ16CR-L 11). Gap: 1.0-1.1 mm (0.039-0.043 in.) (see page 4-26). Do items A, B, and C. 33,750 mil 54,000 km/ Replace oil and filter. 37 ,500 mil 60,000 km/2 1/2 years: Do items in A. 41,250 mil 66,000 km/ Replace oil and filter. 45,000 mil 72,000 km/ 3 years: Clean air cleaner element with low pressure air. Replace coolant (see page 10-10). Use Honda All Season Antifreeze/Coolant Type 2. Capacity: MIT: 5.5 .Q (5.8 US qt, 4.8 Imp qt), AfT: 5.4 .Q (5.7 US qt, 4.8 Imp qt). Replace brake fluid (see page 19-7). Use Genuine Honda DOT 3. Fill to between marks on reservoir. Do items in A and B. 48,750 mil 78,000 km/Replace oil and filter. 52,500mi/ 84,000 km/3 1/2 years: Do items in A. 56,250 mil 90,000 km/Replace oil and filter. 60,000 mil 96,000 km/ 4 years: Replace spark plugs for '98-99 models. Use NGK (ZFR5F-11) or DENSO (KJ16CR-L 11). Gap: 1.0-1.1 mm (0.039-0.043 in.) (see page 4-26). Replace timing belt and balancer belt (Removal: (see page 6-23), Installation: (see page 6-26)) and inspect the water pump for '98-99 models (see page 10-9) ifthe vehicle is regularly driven in weather over 110°F (43°C) or under -20°F (-29°C); If not, replace the belts at 105,000 miles. Do items in A, Band C. Replace oil and filter. 63,750 mi/102,000 km/Do items in A. 67,500 mi/108,000 km 4 1/2 years: Replace oil and filter. 71 ,250 mi/114,000 km 75,000mi/120,000 km/5 years: Clean air cleaner element with low pressure air. Replace coolant (see page 10-10). Use Honda All Season Antifreeze/Coolant Type 2. Capacity: MIT: 5.5 .Q (5.8 US qt, 4.8 Imp qt), AfT: 5.4 .Q (5.7 US qt, 4.8 Imp qt) Do items in A, and B. 78,750 mi/126,000 km/Replace oil and filter. Do items in A. 82,500 mi/132,000 km/5 1/2 years 86,250 mi/138,000 km/Replace oil and filter. 90,000 mi/144,000 km/ 6 years: Replace spark plugs for '98-'99 models. Use NGK (ZFR5F-11) or DENSO (KJ16CR-L 11). Gap: 1.0-1.1 mm (0.039-0.043 in.) (see page 4-26). Replace brake fluid (see page 19-7). Use Honda DOT 3 Brake Fluid. Fill to between marks on reservoir. Do items in A, Band C. Replace oil and filter. 93,750 mi/150,000 km/Do items in A. 97,500 mi/156,000 km/6 1/2 years: 101,250 mi/162,000 km/Replace oil and filter.

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3-6

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105,000 mi/168,OOO km/7 years: Clean air cleaner element with low pressure air. Inspect valve clearance (cold) (see page 6-14) Intake: 0.24-0.28 mm (0.009-0.011 in.) Exhaust: 0.28-0.32 mm (0.011-0.013 in.) D Replace spark plugs for '00 model. Use NGK (PZFR5F-11) or DENSO (PKJ16CR-L11). Gap: 1.0-1.1 mm (0.039-0.043 in.) (see page 4-26). D Replace timing belt and balancer belt (Removal: (see page 6-23), Installation: (see page 6-2611 and inspect the water pump (see page 109) only if the belts were not replaced at 60,000 miles. D Check idle speed* (see page 11-110).: 700 ± 50 rpm in neutral (Automatic transmission in !HI or [fJ position) D Replace coolant (see page 10-10). Use Honda All Season Antifreeze/Coolant Type 2. Capacity: MIT: 5.5 II (5.8 US qt, 4.8 Imp Qt), AfT: 5.4 II (5.7 US Qt, 4.8 Imp Qt). D Do items in A, B. D Replace oil and filter. 108,750 mi/174,OOO km/D Do items in A. 112,500 mi/180,OOO km/7 1/2 years: 116,250 mi/186,OOO km/D Replace oil and filter. 120,000 mi/192,OOO km/ 8 years: D Replace spark plugs for '98-'99 models. Use NGK (ZFR5F-11) or DENSO (KJ16CR-L11). Gap: 1.0 -1.1 mm (0.039 - 0.043 in.) (see page 4-26). D Do items A, B, and C.

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Do the items in parts A, B, and C as required for mileage/time interval. A

D Replace engine oil and filter (see page 8-5). - Capacity with filter change: 4.3 f! (4.5 US Qt, 3.8 Imp Qt) D Inspect front and rear brakes, every 6 months if vehicle is driven less than 7,500 mile per year (see page 19-10).

D D

D D

• Check pads and discs for wear (thickness), damage, and cracks. • Check calipers for damage, leaks, and tightness of mount bolts. Rotate tires, if the vehicle has been driven the distance listed. Follow the pattern shown in the Owner's Manual. (Check tire inflation and condition.) Inspect tie rod ends, steering gearbox, and boots (see page 17-8). • Check rack grease and steering linkage. • Check boots for damage and leaking grease. • Check fluid lines for damage and leaks. Inspect suspension components. • Check bolts for tightness. • Check condition of ball joint boots for deterioration and damage. Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3).

B

D Check parking brake adjustment. - Should be fully applied within 6 to 9 clicks (disc brake) or within 4 to 7 clicks (drum brake). D Lubricate locks, hinges and latches with Honda white lithium grease. D Inspect brake hoses and lines (including ABS). Check the master cylinder, proportioning control valve, and ABS modulator for damage and

D D D D D

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leakage (see page 19-30). Check fluid levels and condition offluids; check for leaks. If necessary, add ATF (see page 14-113) or MTF (see page 13-3), engine coolant, brake fluid, and windshield washer fluid. Inspect cooling system hoses and connections. • Check for damage, leaks, and deterioration. • Check for proper fan operation. Inspect exhaust system. * Check catalytic converter heat shield, exhaust pipe, and muffler for damage, leaks, and tightness (see page 9-5). Inspect fuel lines and connections. * Check for loose connections, cracks and deterioration; retighten loose connections and replace damaged parts (see page 11-118). Check all lights. Check function of all interior and exterior lights, and the positions of the headlights (see page 22-95). Inspect the vehicle underbody. Check the paint for damage, scratches, stone chipping, and dents.

C

D D

D D

Replace air cleaner element (see page 11-133). Inspect and adjust drive belt. Look for cracks and damage, then check tension by pushing on each belt (about 22 Ibs) midway between the pulleys: • Alternator belt: 10.5-12.5 mm (0.41-0.49 in) (see page 4-40). • PIS pump belt: 13.0-16.0 mm (1/2-5/8 in) (see page 17-12). • AlC compressor belt: 7.0-9.0 mm (0.28-0.35 in) (see page 4-391. Replace air conditioning filter, every 15,000 miles if vehicle is driven mostly where air has high concentration of soot from industry and diesel-powered vehicles; also replace it anytime airflow is less than usual (see page 21-26). Replace transmission fluid. Use Genuine Honda MTF or ATF. • MIT: 1.9 II (2.0 US Qt, 1.7 Imp Qt) • AfT: 2.5 II (2.6 US qt, 2.2 Imp Qt)

According to state and federal regulations, failure to do the maintenance items marked with asterisk (*) will not void customer's emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability.

BACK

3-7

Maintenance Schedule for Normal and Severe Conditions (1998-2000 Models) Listed by Maintenance Item Service at the indicated distance or time, whichever comes first. • If driven in normal conditions, do items with a dot (.). • If driven in severe conditions (see page 3-6) or normally driven in Canada, do the circle (0) and dot (.) items. Service at the indicated distance or time, whichever comes fi rst.

miles x 1000

3.75

7.5

11.25

15

18.75

22.5

26.25

30

33.75

37.5

km x 1000

6

12

18

24

30

36

42

48

54

60

years

-

1/2

-

1

-

11/2

-

2

-

21/2

Replace engine oil

Normal Conditions: Every 7,500 miles (12,OOOkm) or 1 year Severe Conditions: Every 3,750 miles (6,000 km) or 6 months

Replace engine oil filter

Normal Conditions: Every other oil change Severe Conditions: Every oil change

0

Clean air cleaner element Replace air cleaner element Inspect valve clearance Replace spark plugs

Adjust only if noisy. '98-99 models '00 model

Replace timing belt, balancer belt NOTE', and inspect water pump

• •

'98-99 models '00 model

•

Inspect and adjust drive belts Inspect idle speed* Replace engine coolant

0

Replace transmission fluid

0

Inspect front and rear brakes Replace brake fluid Check parking brake adjustment Replace air conditioning filter NOTE'

0

0

Lubricate locks, hinges, and latches Rotate tires (Check tire inflation and condition at least once a month)

• 0

Inspect tie-rod ends, steering gearbox, and boots Inspect suspension components

0

Inspect driveshaft boots

0

Inspect brake hoses and lines (including ASS) Inspect all fluid levels and condition of fluids Inspect cooling system hoses and connections Inspect exhaust system* Inspect fuel lines and connections*

• • • • • • • • • 0

Check lights and controls

0

Inspect vehicle under body

3-8

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BACK

• • • • • • • • • • • •

0

0

• 0

0 0

0

0

• 0 0 0

41.25

45

48.75

52.5

56.25

60

63.75

67.5

71.25

75

78.75

82.5

86.25

90

93.75

97.5

101.25

105

108.75

112.5

116.25

120

66

72

78

84

90

96

102

108

114

120

126

132

138

144

150

156

162

168

175

181

187

193

-

3

-

31/2

-

4

-

41/2

-

5

-

51/2

-

6

-

61/2

-

7

-

71/2

-

8

Normal Conditions: Every 7,500 miles (12,OOOkm) or 1 year Severe Conditions: Every 3,750 miles (6,000 km) or 6 months Normal Conditions: Every other oil change Severe Conditions: Every oil change

0

0

0

• •

• •

Adjust only if noisy.

•

0

• •

• • •

0

•

• •

• • • • • • • • • •

0

0

0

• • • • • • • • •

•

0

• 0 0 0

0

0

0

0

• •

0

0

• 0 0 0

• • • • • • • • • 0

0

• • • • • • • • • • • • • •

0

0

0 0

0

0

• • • • • • •

0

• 0

•

• • • • • • • • • • • •

0

0

0

0

0

0

•

• •

• 0 0 0

•

• • • • • • • 0

• 0 0 0

0

NOTE: 1 If the vehicle is regularly driven in very hot or cold weather, over 110'F (43'C) or under - 20'F (- 29'C), replace this belt every 60,000 miles; If not, replace it at 105,000 miles. 2 Replace the air conditioning filter every 15,000 miles if the vehicle is driven mostly where air has a high concentration of soot from industry and diesel-powered vehicle; also replace it anytime airflow is less than usual. * According to state and federal regulations, failure to do the maintenance items marked with an asterisk (*) will not void customer's emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability.

BACK

3-9

Maintenance Schedule for Normal Conditions (2001-2002 Models) Listed by Distance/Time This two-page maintenance schedule outlines the minimum required maintenance. Service at the indicated time or distance, whichever comes first. Use the Maintenance Schedule for Severe Conditions if the vehicle meets any of the qualifiers listed in the severe conditions schedule or if the vehicle is normally driven in Canada. 7,500 mi/12,OOO km/D Do items in A. 15,000 mi/24,OOO km/1 year D Do items in A and B. 22,500 mi/36,OOO km/ D Do items in A. 30,000 mil 4B,OOO km/2 years D Do item in A, B, and C. 37,500 mil 60,000 km/ D Do items in A. / /3 years D Do items in D. 45,000 mil 72,000 km/3 years D Do items in A and B. 52,500 mi/B4,OOO km/ D Do items in A. 60,000 mi/96,OOO km/4 years D Do item in A, B, and C. 67,500 mi/10B,OOO km/ D Do items in A. 75,000 mi/120,OOO km/5 years D Do items in A and B. 82,500 mi/132,OOO km/D Do items in A. -/-/6years D Do items in D. 90,000 mi/144,OOO km/6 years D Do items in A, B, and C. 97 ,500 mi/156,OOO km/D Do items in A. 105,000 mi/168,OOO km/7 years D Inspect valve clearance (cold) (see page 6-14) Intake: 0.24-0.28 mm (0.009- 0.011 in.) Exhaust: 0.2B-0.32 mm (0.011-0.013 in.) D Replace spark plugs for '01 model (see page 4-26). Use NGK (PZFR5F-11) or DENSO (PKJ16CR-L 11). Gap: 1.0-1.1 mm (0.039-0.043 in.) D Replace timing belt and balancer belt (Removal: (see page 6-23), Installation: (see page 6-26)) and inspect water pump (see page 10-9). D Check idle speed. Should be 700±50 rpm in neutral (Automatic transmission in [NJ or ~ position) (see page 11-110). D Do items in A and B. 112,500 mi/1BO,OOO km/D Do items in A. D Do items in A, Band C. 120,000 mi/192,OOO km/ B years 120,000 mil192,OOO km/6 years D Replace manual transmission fluid. Use Honda MTF (see page 13-3). Capacity: 1.911 (2.0 US qt, 1.7 Imp qt) 120,000 mi/192,OOO km/ 6 years, then every 90,000 mi/144,OOO km/5 years D Replace automatic transmission fluid. Use Honda ATF-Z1 (ATF). Capacity: 2.511 (2.6 US qt, 2.2 Imp qt) 120,000 mil192,OOO km/ 10 years, then every 60,000 mil96,OOO km or 5 years D Replace engine coolant (see page 10-10). Use Honda All Season Antifreeze/Coolant Type 2. Capacity: M{(: 5.511 (5.8 US qt, 4.8 Imp qt), AfT: 5.411 (5.7 US qt. 4.Blmp qt).

3-10

BACK

Do the items in parts A, B, C and D as required for mileage/time interval listed.

A

D Replace engine oil (see page 8-5). - Capacity with filter change: 4.3 II (4.5 US qt, 3.8 Imp qt) D Rotate tires. Follow the pattern shown in the Owner's Manual - Check tire inflation and condition. B

D D

D D

D D D D D

D D

Replace engine oil filter (see page 8-6). Inspect front and rear brakes (see page 19-10). • Check pads and discs for wear (thickness), damage, and cracks. • Check calipers for damage, leaks, and tightness of mount bolts. • Check brake lining for cracking, glazing, wear, and contamination. • Check wheel cylinders for leaks. Check parking brake adjustment. Should be fully applied within 6 to 9 clicks (disc brake) or within 4 to 7 clicks (drum brake). Inspect tie rod ends, steering gearbox, and rack boots for damage and leaking grease and fluid (see page 17-8). • Check steering linkage for looseness. • Check boots for damage and leaking grease. Inspect suspension components. • Check bolts for tightness. • Check condition of ball joint boots for deterioration and damage. Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3). Inspect brake hoses and lines (including ABS). - Check the master cylinder, proportioning control valve, and ABS modulator for damage and leakage. Check all fluid levels and condition offluids; check for leaks. If necessary, add Honda ATF-Z1 (see page 14-113) or MTF (see page 13-3), engine coolant, brake fluid, and windshield washer fluid. Inspect cooling system hoses and connections. • Check for damage, leaks, and deterioration. • Check for proper fan operation. Inspect exhaust system* . Check catalytic converter heat shield, exhaust pipe, and muffler for damage, leaks, and tightness (see page 9-5). Inspect fuel lines and connections*. Check for loose connections, cracks and deterioration; retighten loose connections and replace damaged parts (see page 11-118).

c

D D

D

Replace air cleaner element. Inspect and adjust drive belts. • Look for cracks and damage, then check belt deflection by pushing on it (about 22 Ibs) midway between the pulleys. - Alternator belt: 10.5-12.5 mm (0.41-0.49 in.) (see page 4-40) - PIS pump belt: 13.0-16.0 mm (0.51-0.63 in.) (see page 17-12) - AlC compressor belt: 7.0-9.0 mm (0.28-0.35 in) (see page 4-39) Replace the dust and pollen filter (see page 21-26). • Replace it twice as often (at 15,000 mile interval) if the vehicle is driven mostly in urban areas that have high concentrations of soot in the airfrom industry and diesel-powered vehicles. • Replace it whenever airflow from the climate control system is less than normal.

D

D

Replace brake fluid every 3 years (Independent of distance), Use Genuine Honda DOT 3 Brake Fluid. Fill to between marks on reservoir. (see page 19-7).

According to state and federal regulations, failure to do the maintenance items marked with asterisk( * ) will not void customer's emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability.

BACK

3-11

Maintenance Schedule for Severe Conditions (2001-2002 Models) Listed by Distance/Time Service at the indicated distance or time, whichever comes first. Use this schedule if the vehicle is driven MAINLY in Canada or in any of the following conditions; if only OCCASIONALLY driven in these conditions, use the Normal Conditions schedule (see page 3-10). Severe Driving Conditions • Less than 5 miles (8 km) per trip or, in freezing temperatures, less than 10 miles (16 km) per trip • In extremely; hot weather (over 90°F/32°C) • Extensive idling or long periods of stop-and-go driving • Trailer towing • On muddy, dusty, or de-iced roads • Driving in mountainous conditions

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3,750 mil 6,000 km/Do items in A. 7,500 mil 12,000 km/Do items in A, B. 11,250 mil 18,000 km/Do items in A. 15,000 mil 24,000 km/l year Clean air cleaner element with low pressure air. Do items in A, Band C. 18,750 mil 30,000 km/Do items in A. 22,500 mil 36,000 kml Do items in A, B. 26,250 mil 42,000 km/Do items in A. 30,000 mil 48,000 km/2 years Do items in A, B, C and 0 . 33,750 mil 54,000 km/Do items in A. 37,500 mil 60,000 km/Do items in A and B. 41,250 mil 66,000 km/Do items in A. -1-/3years Do items in E. 45,000 mil 72,000 km/3 years Clean air cleaner element with low pressure air. Do items in A, B, and C. 48,750 mil 78,000 km/Do items in A. 52,500mi/84,000 km/Do items in A, B. 56,250 mil 90,000 km/Do items in A. 60,000 mil 96,000 km/3 years Replace manual transmission fluid. Use Honda MTF (see page 13-3). Capacity:l.9.Q (2.0 US qt, 1.7 Imp qt) 60,000 mil 96,000 km/3 years, then every 30,000 mi/48,000 km/2 years Replace automatic transmission fluid. Use Honda ATF-Zl (ATF) (see page 14-113). Capacity:2.5 II (2.6 US qt, 2.21 Imp qt) 60,000 mil 96,000 kml 4 years: Replace timing belt and balancer belt (Removal: (see page 6-23l.lnstallation: (see page 6-26)) and inspect the water pump (see page 109) if the vehicle is regularly driven in weather over 110°F (43°C) or under - 20°F (- 29°C); If not, replace the belts at 105,000 miles. Do items in A, B, C and D. 63,750 mill 02,000 kml Do items in A. 67,500 mi/l08,000 kml Do items in A, B. 71,250 mi/114,000 km/Do items in A. 75,000mi/120,000 km/5 years Clean air cleaner element with low pressure air. Do items in A, Band C. 78,750 mi/126,000 kml 0 Do items in A. 82,500 mi/132,000 kml 0 Do items in A, B. 86,250 mi/138,000 km/0 Do items in A. 90,000 mi/144,000 km/5 years, then every 30,000 mi/48,000 km/2 years Replace automatic transmission fluid. Use Honda ATF-Zl (ATF) (see page 14-113). -1-/6 years 0 Do items in E. 90,000 mi/144,000 km/6 years: 0 Do items in A, B, C, and D. 93,750 mi/150,000 kml 0 Do items in A. 97,500 mi/156,000 km/· 0 Do itemsin A, B. 101,250 mi/162,000 kml 0 Do items in A. 105,000 mi/168,000 km/7 years: Clean air cleaner element with low pressure air. Inspect valve clearance (cold) (see page 6-14) Intake: 0.24-0.28 mm (0.009-0.011 in.) Exhaust: 0.28-0.32 mm (0.011-0.013 in.) Replace spark plugs for '01 model. Use NGK (PZFR5F-ll) or DENSO (PKJ16CR-L 11). Gap: 1.0-1.1 mm (0.039-0.043 in.) (see page 4-26). Replace timing belt and balancer belt (Removal: (see page 6-23), Installation: (see page 6-26)) and inspect the water pump (see page 109) only if the belts were not replaced at 60,000 miles. Check idle speed* (see page 11-110).: 700 ± 50 rpm Do items in A, Band C.

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3-12

BACK

108,750 mi/174,000 km/D Do items in A. 112,500 mi/180,000 km/D Do items in A, B. 116,250 mi/186,000 km/ D Do items in A. 120,000 mi/192,000 km/ 8 years: D Replace timing belt and balancer belt (Removal: (see page 6-23), Installation: (see page 6-26)) and inspect the water pump (see page 10-9) only if the belts were not replaced at 60,000 miles. D Do items A, B, C and D. 120,000 mi/192,000 km/ 10 years, then every 60,000 mi/96,000 km or 5 years D Replace engine coolant (see page 10-10). Use Honda All Season Antifreeze/Coolant Type 2. • Capacity: MIT: 5.5 A(5.8 US at. 4.8 Imp at), A/T: 5.4 A(5.7 US at. 4.8 Imp at) 120,000 mi/192,000 km/ 6 years D Replace manual transmission fluid. Use Honda MTF (see page 13-3). Capacity: 1.9 A(2.0 US at, 1.7 Imp at) 120,000 mi/192,000 km/ 7 years, then every 30,000 mi/48,OOO km/ 2 years D Replace automatic transmission fluid. Use Honda ATF-Z1 (ATF). Capacity: 2.5 A (2.6 US at, 2.2 Imp at) Do the items in parts A, B, C, D and E as required for mileage/time interval. A

D

Replace engine oil and filter (see page 8-5). - Capacity with filter change: 4.3 A (4.5 US qt, 3.8 Imp qt)

B

D

D D

D D

Inspect front and rear brakes, every 6 months if vehicle is driven less than 7,500 mile per year (see page 19-10). • Check pads and discs for wear (thickness), damage, and cracks. • Check calipers for damage, leaks, and tightness of mount bolts. • Check brake lining for cracking, glazing, wear, and contamination. • Check wheel cylinders for leaks. Rotate tires, if the vehicle has been driven the distance listed. Follow the pattern shown in the Owner's Manual. (Check tire inflation and condition.) Inspect tie-rod ends, steering gearbox, and rack boots for damage and leaking grease and fluids (see page 17-8). • Check steering linkage for looseness. • Check boots for damage and leaking grease. • Check fluid lines for damage and leaks. Inspect suspension components. • Check bolts for tightness. • Check condition of ball joint boots for deterioration and damage. Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3).

c

D D D

D D D D D D

Check parking brake adjustment. - Should be fully applied within 6 to 9 clicks (disc brake) or within 4 to 7 clicks (drum brake). Lubricate door locks and hinges with Honda white lithium grease. Inspect brake hoses and lines (including ABS). Check the master cylinder, proportioning control valve, and ABS modulator for damage and leakage (see page 19-30). Check fluid levels and condition of fluids; check for leaks. If necessary, add Honda ATF-Z1 (see page 14-113) or MTF (see page 13-3), engine coolant, brake fluid, and windshield washer fluid. Inspect cooling system hoses and connections. • Check for damage, leaks, and deterioration. • Check for proper fan operation. Inspect exhaust system. * Check catalytic converter heat shield, exhaust pipe, and muffler for damage, leaks, and tightness (see page 9-5). Inspect fuel lines and connections. * Check for loose connections, cracks and deterioration; retighten loose connections and replace damaged parts (see page 11-118). Check all lights. Check function of all interior and exterior lights, and the positions of the headlights (see page 22-95). Inspect the vehicle underbody. Check the paint for damage, scratches, stone chipping, and dents.

D

D

D

D

Replace air cleaner element (see page 11-133). Inspect and adjust drive belt. Look for cracks and damage, then check tension by pushing on each belt (about 22 Ibs) midway between the pulleys: • Alternator belt: 10.5-12.5 mm (0.41-0.49 in) (see page 4-40). • PIS pump belt: 13.0-16.0 mm (1/2-5/8 in)(see page 17-12). • AlC compressor belt: 7.0-9.0 mm (0.28-0.35 in) (see page 4-39). Replace dust and pollen filter, every 15,000 miles if vehicle is driven mostly where air has high concentration of soot from industry and diesel-powered vehicles; also replace it anytime airflow is less than usual (see page 21-26).

E

D

Replace brake fluid every 3 years (Independent of distance), Use Genuine Honda DOT 3. Fill to between marks on reservoir. (see page 19-7).

According to state and federal regulations, failure to do the maintenance items marked with asterisk (*) will not void customer's emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability.

BACK

3-13

Maintenance Schedule for Normal and Severe Conditions (2001-2002 Models) Listed by Maintenance Item Service at the indicated distance or time, whichever comes first . • If driven in normal conditions, do items with a dot (.) . • If driven in severe conditions (see page 3·12) or normally driven in Canada, do the circle (0) and dot (.) items. Service at the indicated distance or time, whichever comes first.

miles x 1000

3.75

7.5

11.25

15

18.75

22.5

26.25

30

33.75

37.5

km x 1000

6

12

18

24

30

36

42

48

54

60

years

-

1/2

-

1

-

11/2

-

2

-

21/2

Replace engine oil

Normal Conditions: Every 7,500 miles (12,OOOkm) or 1 year Severe Conditions: Every 3,750 miles (6,000 km) or 6 months


Normal Conditions: Every other oil change Severe Conditions: Every oil change

0

Clean air cleaner element Replace air cleaner element Inspect valve clearance


•

Replace spark plugs Replace timing belt, balancer belt NOTE', and inspect water pump

•



3-14

Normal Conditions: At 120,000 miles (192,000 km) or 10 years, then every 60,000 miles (96,000 km) or 5 years Severe Conditions: At 120,000 miles (192,000 km) or 10 years, then every 60,000 miles (96,000 km) or 5 years Manual Transmission

Normal Conditions: Every 120,000 miles (192,000 km) or 6 years Severe Conditions: Every 60,000 miles (96,000 km) or 3 years

Automatic Transmission

Normal Conditions: At 120,000 miles (192,000 km) or 6 years, then every 90,000 miles (144,000 km) or 5 years Severe Conditions: At 60,000 miles (96,000 km) or 3 years, then every 30,000 miles (48,000 km) or 2 years

BACK

41.25

45

48.75

52.5

56.25

60

63.75

67.5

71.25

75

78.75

82.5

86.25

90

93.75

97.5

101.25

105

108.75

112.5

116.25

120

66

72

78

84

90

96

102

108

114

120

126

132

138

144

150

156

162

168

175

181

187

193

-

3

-

31/2

-

4

-

41/2

-

5

-

51/2

-

6

-

61/2

-

7

-

71/2

-

8

Normal Conditions: Every 7,500 miles (12,000km) or 1 year Normal Conditions: Every other oil change

Severe Conditions: Every 3,750 miles (6,000 km) or 6 months

Severe Conditions: Every oil change

0

0

0

•

•


0

•

•

Normal Conditions: At 120,000 miles (192,000 km) or 10 years, then every 60,000 miles (96,000 km) or 5 years Severe Conditions: At 120,000 miles (192,000 km) or 10 years, then every 60,000 miles (96,000 km) or 5 years

• • • •

• 0

• •

Normal Conditions: Every 120,000 miles (192,000 km) or 6 years Severe Conditions: Every 60,000 miles (96,000 km) or 3 years Normal Conditions: At 120,000 miles (192,000 km) or 6 years, then every 90,000 miles (144,000 km) or 5 years Severe Conditions: At 60,000 miles (96,000 km) or 3 years, then every 30,000 miles (48,000 km) or 2 years

(cont'd)

BACK

3-15

Maintenance Schedule for Normal and Severe Conditions (2001-2002 Models) Listed by Maintenance Item (cont'd) Service at the indicated distance or time. whichever comes first.

miles x 1000 km x 1000 years

3.75

7.5

11.25

15

18.75

22.5

26.25

30

33.75

37.5

6

12

18

24

30

36

42

48

54

60

-

1/2

-

1

-

11/2

-

2

-

21/2

0

Inspect front and rear brakes Replace brake fluid Check parking brake adjustment Replace air conditioning filter NOTE 2

0 Every 3 years

Rotate tires (Check tire inflation and condition at least once a month)

• 0

Inspect tie-rod ends. steering gearbox. and boots Inspect suspension components

0


0

Inspect brake hoses and lines (including ABS) Inspect all fluid levels and condition of fluids Inspect cooling system hoses and connections Inspect exhaust system* Inspect fuel lines and connections*

• • • • • • • • • 0


0

Inspect vehicle underbody

BACK

• • • • • • • • • • • •

0

0

0

Lubricate locks. hinges. and latches

3-16

• •

• 0

0 0

0

0

• 0

0 0

41.25

45

48.75

52.5

56.25

60

63.75

67.5

71.25

75

78.75

82.5

86.25

90

93.75

97.5

101.25

105

108.75

112.5

116.25

120

66

72

78

84

90

96

102

108

114

120

126

132

138

144

150

156

162

168

175

181

187

193

-

3

-

31/2

-

4

-

41/2

-

5

-

51/2

-

6

-

61/2

-

7

-

71/2

-

8

• •

0

0

0

0

• 0 0 0

0

0

•

• • • • • • • • • • • •

0

0

•

0 Every 3 years

•

0

0

• • • • • • • • •

• • • • • • • • • • • •

0

• 0

0 0

• • •

• • • • • 0

0

0 0 0

0

• • 0

0

0

•

0

•

• • • • • • • • • • • •

•

0

0

• 0 0 0

• • •

• • • • 0

• 0 0 0

0

NOTE:

1 If the vehicle is regularly driven in very hot or cold weather, over 110'F (43'C) or under -20'F (- 29'C), replace this belt every SO,OOO miles; If not, replace it at 105,000 miles. 2 Replace the dust and pollen filter every 15,000 miles if the vehicle is driven mostly where air has a high concentration of soot from industry and diesel-powered vehicle; also replace it anytime airflow is less than usual. * According to state and federal regulations, failure to do the maintenance items marked with an asterisk (*) will not void customer's emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability.

BACK

3-17

BACK

Engine Electrical Engine Electrical Special Tools ................................ 4-2 Starting System Component Location Index Circuit Diagram ............................ Starter Circuit Troubleshooting ...................... Clutch Interlock Switch Test ....... Starter Solenoid Test .................. Starter Performance Test ............ Starter Replacement ................... Starter Overhaul .......................... Ignition System Component Location Index ........ Circuit Diagram ............................ Ignition Timing Inspection .......... Distributor Replacement ............. Distributor Overhaul ................... Ignition Control Module (lCM) Input Test ............. ..................... Ignition Coil Test .......................... Ignition Wire Inspection and Test .................................... Spark Plug Inspection ................. Charging System Component Location Index ........ Circuit Diagram ............................ Charging Circuit Troubleshooting ...................... Alternator Replacement .............. Alternator Overhaul .................... Aiternator-AIC Compressor Belt Inspection and Adjustment ..... Alternator Belt Inspection and Adjustment ...............................

4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10

4-17 4-18 4-19 4-19 4-21 4-23 4-24 4-25 4-26

4-27 4-28 4-29 4-32 4-33 4-39 4-40

Cruise Control Component Location Index ........ Circuit Diagram ............................ Symptom Troubleshooting Index ......................................... Cruise Control Communication Circuit Troubleshooting (AfT) ......•...... Control Unit Input Test ................ Main Switch Test/Replacement .................... Set/Resume/Cancel Switch Test/Replacement .................... Clutch Pedal Position Switch Test ............................................ Brake Pedal Position Switch Test ............................................ Actuator Solenoid Test ............... Actuator Test ................................ Actuator/Solenoid/Cable Replacement ............................ Actuator Cable Adjustment ........

4-41 4-42 4-43

4-45 4-46 4-48 4-48 4-49 4-49 4-50 4-51 4-52 4-54

Engine Mount Control System Component Location Index ........ 4-55 Circuit Diagram ............................ 4-56 Troubleshooting .......................... 4-57

r--:'II L::.I

Engine Electrical Special Tools Tool Number Descri~tion Vacuum Pump/Gauge, 0-30 in.Hg A973X-041-XXXXX 07JGG-001010A Belt Tension Gauge *® Driver Attachment, 52 x 55 mm 077 46-0010400 ® G) Driver 077 49-00 10000 *Included In the Belt TensIon Gauge Set, T/N 07JGG-001000A

Number

Qty

CD

1 1 1 1

I CD

4-2

0

!

®

®

BACK

.')';,

111

G)

Starting System Component Location Index

UNDER-DASH DRIVER'S FUSEfRELA V BOX

REAR SIDE

CLUTCH INTERLOCK

TRANSMISSION RANGE SWITCH (AfT) Test, page 14-138 Replacement, page 14-139

SWITCH (MfT) Test, page 4-6 Switch Position Adjustment, page 12-4 STARTER Starter Circuit Troubleshooting, page 4-5 Solenoid Test, page 4-7 Performance Test, page 4-8 Replacement, page 4-9 Overhaul, page 4-10

BACK

4-3

Starting System Circuit Diagram

UNDER·HOOD FUSE/RELAY BOX

IGNITION SWITCH

BATTERY

+ >----t-- BlK ---1.......ar"'\..O----+--WHT ~T ST No.4t (tOOA)

No.42 (SOA)

ST HOT in START (III) BlKlWHT

)

~L ____________ ~

STARTER CUT RELAY

DRIVER'S UNDER·DASH FUSE/RELAY

BOX

NO.t3 (7.SA)

~

BlK/RED

PCM PGM·FI MAIN RELAY BlKlWHT

-.----.

(AfT)

B

BlUIWHT

(MIT)

S

B

S

(MIT) I ,

' L

~: ,•

B

,,

(AfT) I : TRANSMISSION RANGE SWITCH

l_ ~ _ ~ L_-I---__ ~ (Permanent magnet type)

I GtOt

4-4

BACK

J

~~~andlm~O~)

STARTER (Field winding type)

STARTER

CLUTCH INTERLOCK SWITCH

~

r--:'I I.!!!!.I Starter Circuit Troubleshooting NOTE: • Air temperature must be between 59° and 100°F (15° and 38°C) during this procedure. • After this test, or any subsequent repair, reset the ECM/PCM to clear any codes (see page 11-3). • The battery must be in good condition and fully charged.

4. Check the battery condition. Check electrical connections atthe battery, the negative battery cable to body, engine ground cables, and the starter for looseness and corrosion. Then try starting the engine again.

Did the starter crank the engine? YES- Repairing the loose connection fixed the problem. The starting system is OK.•

Recommended Procedure: • Use a starter system tester. • Connect and operate the equipment in accordance with the manufacturer's instructions.

NO - Go to step 5. 5. Make sure the transmission is in neutral, then disconnect the BLK/WHT wire (A) from the starter solenoid (B). Connect a jumper wire from the battery positive terminal to the solenoid terminal.

Alternate Procedure 1. Hook up the following equipment: • Ammeter, 0-400 A • Voltmeter, 0 - 20 V (accurate within 0.1 volt) • Tachometer, 0-1200 rpm

[1J A

A

B

Did the starter crank the engine? YES-Go to step 6. 2. Remove the No. 46 (15A) fuse from the under-dash fuse/relay box. 3. With the shift lever in I!!I or ~ (AfT), or the clutch pedal depressed (MIT), turn the ignition switch to start (III).

NO- Remove the starter and repair or replace as necessary. 6. Check the following items in the order listed until you find the open circuit.

Did the starter crank the engine normally? YES- The starting system is OK.•

NO -If the starter will not crank the engine at all, go to step 4. If it cranks the engine erratically or too slowly, go to step 7. If it won't disengage from the flywheel or torque converter ring gear when you release the key, check for the following until you find the cause.

• Check the BLK/WHT wire and connectors between the driver's under-dash fuse/relay box and the ignition switch, and between the driver's under dash fuse/relay box and the starter. • Check the ignition switch (see page 22-56). • Check the transmission range switch and connector (AfT) or the clutch interlock switch (see page 4-6) and connector(MIT). • Substitute a known-good starter relay.

• Solenoid plunger and switch malfunction • Dirty drive gear or damaged overrunning clutch (cont'd)

BACK

4-5

Starting System Starter Circuit Troubleshooting (cont'd)

Clutch Interlock Switch Test

7. Check the engine speed while cranking the engine.

1. Disconnect the clutch interlock switch 2P connector.

Is the engine speed above 100 rpm? YES-Go to step 8. NO- Replace the starter, or remove and disassemble the starter, and check for the following until you find the cause. • • • •

Excessively worn starter brushes Open circuit in commutator brushes Dirty or damaged helical spline or drive gear Faulty drive gear clutch

8. Check the cranking voltage and current draw.

Is cranking voltage no less than 8.5 volts (with AlT) or 8.0 volts (with MIT), and current draw no more than 380 amps (with AlT) or 280 amps (with MIT)? YES- Go to step 9.

2. Remove the clutch interlock switch (A).

NO- Replace the starter, or remove and disassemble the starter, and check for the following until you find the cause.

3. Check for continuity between the terminals according to the table. 1

2

0

-0

Clutch Interlock Switch \ PRESSED RELEASED

9. Remove the starter and inspect its drive gear and the flywheel or torque converter ring gear for damage. Replace any damaged parts.•

4-6

Terminal

\

• Open circuit in starter armature commutator segments • Starter armature dragging • Shorted armature winding • Excessive drag in engine

BACK

4. If necessary, replace the switch or adjust the clutch padal height (see page 12-4).

~ ~ Starter Solenoid Test 1. Check the hold-in coil for continuity between the S terminal and the armature housing (ground). There should be continuity. • If there is continuity, go to step 2. • If there is no continuity, replace the solenoid.

MIT:

M

s A/T:

s

2. Check the pull-in coil for continuity between the S terminal and M terminal. There should be continuity. • If there is continuity, the solenoid is OK. • If there is no continuity, replace the solenoid.

BACK

4-7

Starting System Starter Performance Test 1. Disconnect the wires from the S terminal and the M terminal.

5. Disconnect the battery from the starter body. Ifthe pinion retracts immediately, it is working properly.

2. Make the connections as described below using as heavy a wire as possible (preferably equivalent to the wire used for the vehicle). To avoid damaging the starter, never leave the battery connected for more than 10 seconds.

5

12V

BATTERY

3. Connect the battery as shown. Be sure to disconnect the starter motor wire from the solenoid. If the starter pinion moves out, it is working properly.

s 6. Clamp the starter firmly in a vise. 12V

BATTERY

7. Connect the starter to the battery as described in the diagram below, and confirm that the motor starts and keeps rotating.

4. Disconnect the battery from the M terminal. If the pinion does not retract, the hold-in coil ofthe solenoid is working properly . --------

.

5

BATTERY

12V 12V

BATTERY 8. If the electric current and motor speed meet the specifications when the battery voltage is at 11.5 V, the starter is working properly.

Specifications: Maker

4-8

BACK

Electric current

Motor speed

DENSO

90 A or less

3,000 rpm or more

MITSUBA

80 A or less

2,600 rpm or more

~ ~ Starter Replacement 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons.

A/T: 10x 1.25 mm 44 N·m (4.5 kgf·m, 33 Ibf·ftl

2. Disconnect the battery negative cable, then disconnect the positive cable. 3. Remove the engine wire harness and radiator lower hose from the bracket on the starter motor. 4. Disconnect the starter cable (A) from the B terminal on the solenoid, then disconnect the BLK/WHT wire (B) from the S terminal.

_~' 0 \ ~ A-

MIT: 8x 1.25 mm

10x 1.25 mm 44N·m (4.5 kgf·m, 33 Ibf·ttl

8x 1.25mm 9 N·m (0.9 kgf·m, 7 Ibf·ftl

5. Remove the two bolts holding the starter, then remove the starter. 6. Install the stater in the reverse order of removal. Make sure the crimped side of the ring terminal (A) is facing out.

~ ~10X1.25mm

44 N·m (4.5 kgf.m, 33 Ibf·ttl

A

7. Connect the battery positive cable and negative cable to the battery. 8. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 9. Retest starter performance.

BACK

4-9

Starting System Starter Overhaul Disassembly/Reassembly - M/T

BRUSH HOLDER

BRUSH

HARNESS

BRA~

STEEL BALL When reassembling, install steel ball from clutch side.

MOLYBDENUM DISULFIDE

ARMATURE

MOLYBDENUM DISULFIDE OVERRUNNING CLUTCH ASSEMBLY ROLLER BEARINGS and CAGE Prevent rollers from being scattered and lost.

• -$;jijjjffl MOLYBDENUM DISULFIDE

4-10

BACK

r--:'I

~

DisassemblyIReassembly - AfT

END COVER

MOLYBDENUM DISULFIDE STARTER SOLENOID

GEAR HOUSING GEAR HOUSING COVER OVERRUNNING CLUTCH ASSEMBLY

(cant'd)

BACK

4-11

Starting System Starter Overhaul (cont'd) Armature Inspection and Test

5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.

1. Remove the starter (see page 4-91. Commutator Diameter Standard (New): MIT: 29.9-30.0 mm (1.177-1.181 in.) A/T: 28.0 mm-28.1 mm (1.102-1.106 in.) Service Limit: MIT: 29.0 mm (1.142 in.' AIT: 27.5 mm (1.083 in.'

2. Disassemble the starter as shown at the beginning of this procedure. 3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.

4. Check the commutator (AI surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with # 500 or # 600 sandpaper (8).

6. Measure the commutator (AI runout.

A

• Ifthe commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments . • If the commutator runout is not within the service limit, replace the armature. Commutator Runout Standard (New): 0.02 mm (0.001 in.' max. Service Limit: 0.05 mm (0.002 in.'

A

4-12

BACK

r--:'I

~

7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or V-shaped (0).

9. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attracted to the core or vibrates while the core is turned, the armature is shorted. Replace the armature. B

Commutator Mica Depth Standard (New): MIT: 0.5-0.8 mm (0.020-0.031 in.) A/T: 0.4-0.5 mm (0.016-0.020 in.' Service Limit: MIT: 0.2 mm (0.008 in.' AfT: 0.15 mm (0.006 in.)

A

10. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If continuity exists, replace the armature.

8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.

c

t

B

\A

(cont'd)

BACK

4-13

Starting System Starter Overhaul (cont'd) Starter Brush Inspection

Starter Brush Holder Test

11. Measure the brush length. If it is not within the service limit, replace the armature housing assembly (MfT), or the brush holder assembly (AIT).

14. Check that there is no continuity between the (+) brush holder (A) and (-) brush holder (8). If there is no continuity, replace the brush holder assembly.

Brush Length Standard (New):

MIT:

MIT: 15.0-15.5 mm (0.59-0.61 in.) A/T: 15.8-16.2 mm (0.62-0.64 in.) Service Limit: MIT: 10.0 mm (0.39 in.) AIT: 11.0 mm (0.43 in.)

A

B

A/T: Starter Field Winding Test (MIT)

B

12. Check for continuity between the brushes (A). If there is no continuity, replace the armature housing (B).

13. Check for continuity between each brush (A) and the armature housing (B). If there is continuity, replace the armature housing.

4-14

BACK

B

r--:'I

~

15. Insert the brush (A) into the brush holder, and bring the brush into contact with the commutator, then attach a spring scale (B) to the spring (e). Measure the spring tension at the moment the spring lifts off the brush. If the spring tension is not within specification, replace the spring.

17. Install the armature in the housing, and install the brush holder. Next, pry back each brush spring again, and push the brush down until it seats against the commutator, then release the spring against the end of the brush.

Spring Tension: MIT: 13.7 -19.6 N (1.4 - 2.0 kgf, 3.07 - 4.41 Ibf) AfT: 15.7-17.7 N (1.6-1.8 kgf, 3.53-3.97Ibf)

18. Install the starter end cover (A) to retain the brush holder (B). B

16. Pry back each brush spring with a screwdriver, then position the brush about halfway out of its holder, and release the spring to hold it there. NOTE: To seat new brushes, slip a strip of # 500 or # 600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.

(cont'd)

BACK

4-15

Starting System Starter Overhaul (cont'd) Solenoid Plunger Inspection (MIT)

Overrunning Clutch Inspection

19. Check the contact points (A) and the point contacting face (B) of the starter solenoid plunger (C) for burning, pitting or any other defects. If surfaces are rough, recondition them with a strip of # 500 or # 600 sandpaper.

20. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly. 21. Rotate the overrunning clutch (A) both ways. Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it locks in both directions, replace it. A

L

B

22. If the starter drive gear (B) is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged. 23. Reassemble the starter in reverse order of disassembly.

4-16

BACK

~ ~

Ignition System Component Location Index

-----DISTRIBUTOR Replacement, page 4-19 Overhaul, page 4-21 Ignition Control Module (lCM) Input Test, page 4-23 Ignition Coil Test, page 4-24 Ignition Timing Inspection, page 4-19

SPARK PLUG Inspection, page 4-26 IGNITION WIRES Inspection and Test, page 4-25

BACK

4-17

Ignition System Circuit Diagram UNDER·HooD FUSE/RELAY BOX

IGNITION SWITCH

BATIERY

~

&-

No.4l (100A)

BlK

No.42 (SOA)

-+--<:r-U"':"--C"\..l>-+--WHT

~ No.6 (15A)

r

DRIVER'S UNDER·DASH FUSEIRELAY BOX

ECMlPCM

BlKIYEl

YEUGRN

DISTRIBUTOR

F23Al , F23A4engines: WHTlBlK F23A5 engine: WHTIBLU BLKlYEl VEUGRN

IGNITION CONTROL MODULE (ICM) ) ( Has buih~n noise condenser CVPSENSOR

VEL

BLK

~~

IGNITION WIRES

SPARK PLUGS

ECWPCM

CYP SENSOR: Cylinder posHion sensor

4-18

BACK

Ignition Timing Inspection

Distributor Replacement

1. Check the idle speed, and adjust it if necessary (see page 11-110).

Removal 1. Disconnect the connector(A) from the distributor.

2. Connect the Honda PGM tester to the Data Link Connector (DLC), and follow the tester's prompts in the"SCS" menu (see the Honda PGM Tester Operator's Manual).

F23A1, F23A4 engines:

3. Start the engine. Hold the engine at 3,000 rpm with no load (NT in [HJ or [fl, MIT in neutral) until the radiator fan comes on, then let it idle. 4. Connect the timing light to the No.1 ignition wire, then point the light toward the pointers (A) on the timing belt cover.Check the ignition timing in no load conditions: headlights, blower fan, rear window defogger, and air conditioner are not operating. Ignition Timing: MIT: 12°±2° BTDC (RED mark (B)) during idling in neutral A/T: 12° ±2° BTDC (RED mark (B)) during idling in [fl or [HJ

B F23A5 engine:

A

B

5. If the ignition timing is incorrect, replace the ECM/ PCM. (Ignition timing is not adjustable.) 6. Disconnect the Honda PGM Tester and the timing light.

2. Disconnect the ignition wires from the distributor cap. 3. Remove the distributor mounting bolts (8) then remove the distributor (C) from the cylinder head.

(cont'd)

BACK

4-19

Ignition System Distributor Replacement (cont'd) Installation

5. Connect the ignition wires to the distributor cap as shown.

1. Bring the No.1 piston to compression stroke TOC. F23A1, F23A4 engines:

2. Coat a new a-ring (A) with engine oil, then install it. F23A 1, F23A4 engines:

No.4

No.3

No.1

CYLINDER MARK

A

d'

V'"

No.2

No.1

C 22 N·m (2.2 kgf·m, 16 Ibf·ft)

F23A5 engine:

F23A5 engine:

No.3

~

.

&"

No.1

CYLINDER MARK

C 22 N·m (2.2 kgf.m, 16Ibf·ft)

No.1

3. Slip the distributor into position. NOTE: The lugs on the end of the distributor and their mating grooves in the camshaft end (B) are both offset to eliminate the possibility of installing the distributor 1800 out of time.

No.2

6. Connect the connector to the distributor. 7. Check the ignition timing (see page 4-19).

4. Install the mounting bolts (C), and tighten them.

4-20

No.4

BACK

Distributor Overhaul- F23A1, F23A4 Engines

~

CAP SEAL Check for damage.

/

DISTRIBUTOR HOUSING Check for cracks and damage.

IGNITION COIL

/ O-RING Replace.

~'

CYPSENSOR Do not disassemble.

YEL/GR~! BLK/YEl WHT/BLK

~

~~ I

DISTRIBUTOR ROTOR

IGNITION CONTROL MODULE (lCM)

BACK

4-21

Ignition System Distributor Overhaul - F23A5 Engine

DISTRIBUTOR ROTOR

_I

/


/ ~..?-?o___

/

O-RING Replace.

/

DISTRIBUTOR HOUSING Check for cracks and damage.

CVPSENSOR Do not disassemble.

~YEL/GRN

a

~J~

/~ IGNITION CONTROL MODULE (ICM)

I~

~ -1llJ

BlK/VEl

~

BACK

IGNmONCOIL

,/

o~ ~(/?),.,..

WHT/BLU

4-22

DISTRIBUTOR CAP Check for cracks, wear, damage, and fouling. Clean or replace.

~

r:-:'I

~

Ignition Control Module (ICM) Input Test NOTE: • Ifthe Malfunction Indicator Lamp (MIL) comes on, refer to the Fuel and Emission System (see page 11-3). • Perform an input test for the Ignition Control Module (lCM) after finishing the fundamental tests for the ignition system and the fuel and emissions systems. • The tachometer should operate normally if the ICM is OK. 1. Remove the distributor cap, the distributor rotor, and the leak cover.

3. Turn the ignition switch ON (II). Check for voltage between the BLK/YEL wire and body ground. There should be battery voltage. • If there is no battery voltage, check the BLK/YEL wire between the ignition switch and the ICM. • Ifthere is battery voltage, go to step 4. 4. Turn the ignition switch ON (II). Check for voltage between the WHT/BLK (WHT/BLU for the F23A5 engine) wire and body ground. There should be battery voltage.

2. Disconnect the wires from the ICM (A). • If there is no battery voltage, check: - ignition coil. - WHT/BLK (WHT/BLU for the F23A5 engine) wire between the ICM and ignition coil. • If there is battery voltage, go to step 5.

F23A1, F23A4 engines:

A

5. Disconnect the Engine Control Module (ECM)/ Powertrain Control Module (PCM) connector B (25 P), and check for continuity on the YEL/GRN wire between the ICM and ECM/PCM connector terminal B13. There should be continuity. 6. Check for continuity on the YEL/GRN wire to body ground. There should be no continuity. 7. If all the tests are normal, replace the ICM and reconnect the ECM/PCM connector B (25P).

F23A5 engine:

A

BACK

4-23

Ignition System Ignition Coil Test 1. Turn the ignition switch OFF, and remove the distributor cap.

3. Using an ohmmeter, measure resistance between the terminals. Replace the coil if the resistance is not within specifications.

2. Disconnect the BLK/YEL and WHT/BLK (WHT/BLU for the F23A5 engine) wires from terminals A (+) and B (-) respectively.

Primary Winding Resistance (Between the A and B terminals): F23A1, F23A4 engines: 0.45-0.55 Q 0.63-0.77 Q F23A5 engine: Secondary Winding Resistance (Between the A and Secondary Winding terminals) 16.8 - 25.2 k Q F23A 1, F23A4 engines: F23A5engine: 12.8-19.2kQ

F23A1, F23A4 engines: A

F23A5 engine:

B

4-24

NOTE: Resistance will vary with the coil temperature; specifications are at 68°F (20°C).

BACK

r--:'I

~

Ignition Wire Inspection and Test 1. Carefully remove the ignition wires by pulling on the rubber boots. Do not bend the wires; you might break them inside. 2. Check the condition of the ignition wire terminals. If any terminal is corroded, clean it, and if it is broken or distorted, replace the ignition wire. t:ll--_--'".L~ ~

L------g

Check for broken, corroded, and bent terminals.

3. Connect ohmmeter probes, and measure resistance while flexing and moving the wire. Do not bend the wires, you might break them inside. Ignition Wire Resistance: 25 k Q max. at 68°F (20 D e)

r. 0 "' I.

0+-------- g

'-----'

4. If resistance exceeds 25 k Q, replace the ignition wire.

BACK

4-25

Ignition System Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator.

2. Check the electrode gap. '98-99 models: • Adjust the gap with a suitable gapping tool.

Burned or worn electrodes may be caused by: • Advanced ignition timing • Loose spark plug • Plug heat range too hot • Insufficient cooling

Electrode Gap Standard (New): 1.0 -1.1 mm (0.039 - 0.043 in.) • Replace the plug if the center electrode is rounded (A).

Fouled plug may be caused by: • Retarded ignition timing • Oil in combustion chamber • Incorrect spark plug gap • Plug heat range too cold • Excessive idling/low speed running • Clogged air cleaner element • Deteriorated ignition coil or ignition wires Worn or deformed

Damaged gasket

Spark Plugs NGK: ZFR5F-11 DENSO: KJ16CR-L 11 1.1 mm (0.043 in.)

. Improper gap f • Oil-fouling

Carbon deposits ll .• Cracked center electrode insulator

-------~==t

o~~cc -+ ~ ••

-:::=.:::-:=:----=-

.-----------

A

~ -.~~--~-

--..=::-=:::'-~

=---

~--

------

'00-02 models: • Replace the spark plug if the gap is out of specification. Electrode Gap Standard (New): 1.0-1.1 mm (0.039-0.043 in.) 1.3 mm (0.05 in.) Sercive Limit: • Replace the pi ug if the center electrode is rounded (A). Spark Plugs NGK: PZFR5F-11 DENSO: PKJ16CR-L 11 3. Apply a small quantity of anti-seize compound to the plug threads, and screw the plugs into the cylinder head finger-tight. Torque them to 18 N·m (1.8 kgf·m, 13Ibf·ft).

4-26

BACK

r--:'I

~

Charging System Component Location Index

CHARGING SYSTEM INDICATOR (In the gauge assembly)

Test, page 22-57

ALTERNATOR-A/C COMPRESSOR BELT

Inspection and Adjustment, page 4-39 ALTERNATOR

Troubleshooting, page 4-29 Replacement, page 4-32 Overhaul, page 4-33 UNDER-HOOD FUSE/RELAY BOX (Has built-in ELECTRICAL LOAD DETECTOR (ELD) UNIT) BATTERY

Test, page 22-51

BACK

4-27

Charging System Circuit Diagram UNDER-HOOD FUSE/RELAY BOX BATTERY

~

&-

BlK -

No.4l (100A) .....
U_+----WHT

IGNITION SWITCH

BlKlYEl

DRIVER'S UNDER-DASH FUSE/RELAY BOX

No.6 (15A)

BlKlYEl

GRNlRED

BlKIYEl

BLKIYEL

+

~Jfr¥~~

LIGHT SULB (1.4W)

i~ BLK ALTERNATOR

B

H

I I

~

A~

A

"

:-

A

"

BLKlYEL

Ic

IIG

I

I

WHTIBLU

I

L

I

~~

VOLTAGE REGULATOR

~

FIELD WINDING

RECTIFIER

~~

WHTIGRN

~"

. . :l

A~

11

"~~

~

A"

BLK

1

-'

G202

4-28

BACK

...

INTEGRATED CONTROL UNIT

Y

WHT/BLU

I

r--:'I

I.!::J Charging Circuit Troubleshooting 8. Connect the alternator 4P connector terminal No.3 to body ground with jumper wire. Turn the ignition switch ON (II).

If the charging system indicator does not come on or does not go off, or the battery is dead or low, test the following items in the order listed below: Battery (see page 22-57) Charging system indicator Alternator/regulator circuit Alternator control system

ALTERNATOR 4P CONNECTOR

2

Charging System Indicator Test 3

Wire side of female terminals

4

1. Turn the ignition switch ON (II). LIWHT/BLUI

Does the charging system indicator come on? YES - Go to step 2.

=

NO - Go to step 6.

Does the charging system indicator come on ? 2. Start the engine. YES- Go to step 9.

Does the charging system indicator go off? NO- Turn the ignition switch OFF. Check for a blown No.6 (15A) fuse and a blown charging system light bulb. If the fuse and bulb are OK, repair the open in the BLK/VEL and WHT/BLU wire to the indicator bulb .•

YES-Charging system indicator circuit is OK.•

NO- Go to step 3. 3. Turn the ignition switch OFF.

9. Measure the voltage at the No.1 terminal of the alternator 4P connector with the ignition switch ON

4. Disconnect the alternator 4P connector from the alternator.

(II). ALTERNATOR 4P CONNECTOR

5. Turn the ignition switch ON (II).

Does the charging system indicator come on? YES- Turn the ignition switch OFF, and repair the short in the WHT/BLU wire. Ifthe WHT/BLU wire is shorted to ground, the voltage regulator in the alternator may be damaged .•

3

v

4


IG IBLK/YELI

NO - Go to step 9.

6. Turn the ignition switch OFF.

=

7. Disconnect the alternator 4P connector from the alternator.

Is there battery voltage? YES- Go to alternator and regulator circuit test.•

NO-- Repair open in the BLK/VEL wire between the alternator and the under-dash driver's fuse relay box.•

(cont'd)

BACK

4-29

Charging System Charging Circuit Troubleshooting (cont'd) Alternator and Regulator Circuit Test

9. Raise the engine speed to 2,000 rpm, and hold it there.

1. Be sure the battery is sufficiently charged and in good condition (see page 22-51).

Is the voltage less than 13.5 V?

2. Connect a VAT-40 (or equivalent tester), and turn the selector switch to position 1 (starting).

YES - Repai r the alternator components (see page 4-33) .•

VOLT

LOAD ADJUSTER (CARBON PILE)

SELECTOR =..,...,.,,==~.,..=~

FULL FIELD TESTER LEAD (BLU)

/'

NO-Go to step 10.

_VOLTMETER NEGATIVE LEAD (BLK)

10. Apply a load with the VAT-40 until the battery voltage drops to between 12 -13.5 V. Is the amperage 75 A or more? YES- The charging system is OK.• NO-Gotostep 11.

I

NEGATIVE TESTER CABLE (BLK) POSITIVE TESTER CABLE (RED) B TERMINAL WIRE

11. With the engine speed still at 2,000 rpm, full-field the alternator. Attach the probe to the VAT-40 fullfield test lead, and insert the probe into the full field access hole at the back of the alternator. Switch the field selector to the "A (Ground)" position momentarily, and check the amperage reading. Because voltage will rise quickly when the alternator is full-fielded, do not allow the voltage to exceed 18 V: it may damage the electrical system. REGULATOR (Located inside the end cover)

3. Shift to neutral or park, and start the engine. Hold the engine at 3,000 rpm, with no load until the radiator fan comes on, then let it idle. 4. Raise the engine speed to 2,000 rpm, and hold it there. Is the voltage over 15.1 V?

FULL FIELD ACCESS HOLE

YES- Repair the voltage regulator .• NO-Go to step 5.

END COVER

5. Release the accelerator pedal, and let the engine idle. 6. Make sure all accessories are turned off. Turn the selector switch to position 2 (charging).

Is the alternator output 75 A or more? YES - Replace the voltage regulator..

7. Remove the inductive pick-up, and zero the ammeter.

NO - Go to alternator control system test.•

8. Place the inductive pick-up over the B terminal wire of the alternator so that the arrow points away from the alternator.

4-30

BACK

~ ~ Alternator Control System Test

7. Check for continuity between the ECM/PCM connector terminal C2 and body ground.

1. Check proper operation of the Electrical Load Detector (ELD) by confirming with the Malfunction Indicator Lamp (MIL) is off and there is no DTC for ELD failure (see page 11-3).

ECM/PCM CONNECTOR C (31PI

ALTC (WHT/GRNI

2. Disconnect the 4P connector from the alternator. 3. Start the engine and turn the headlights (high beam) ON.

=

4. Measure voltage between the 4P connector terminal No.2 and the positive terminal ofthe battery.


BATIERV

Is there continuity? YES- Repair short to ground in the wire between the alternator and ECM/PCM .• NO-Check that the terminals are firmly seated at the connectors. If OK, substitute a known-good ECM/PCM, and recheck. (see page 11-3). If prescribed voltage is now available, replace the original ECM/PCM .•

2 ALTERNATOR 13+4 -1 4P CONNECTOR


8. Turn the headlight and ignition switch OFF.

Is there 1 V or less?

9. Disconnect the ECM/PCM connector C (31 Pl.

YES-Goto step 8.

10. Check for continuity between the ECM/PCM connector terminal C2 and alternator 4P connector terminal No.2.

NO-Go to step 5.

5. Turn the headlight and ignition switch OFF. ALTC (WHTIGRN)

6. Disconnect the Engine Control Module (ECM)/ Powertrain Control Module (PCM) connector C (31 Pl.

ECM/PCM CONNECTOR C (31P)



Is there continuity? YES- Repair the alternator (see page 4-33) .• NO-Repair open in the wire between the alternator and ECM/PCM .•

BACK

4-31

Charging System Alternator Replacement 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons.

4. Remove the adjusting bolt (A), locknut (S), and mounting bolt (C), then remove the alternator belt and alternator.

2. Disconnect the negative battery cable, then disconnect the positive cable. 3. Disconnect the 4P connector (A) and SLK wire (S) from the alternator.

B

8x 1.25mm 22 N·m (2.2 kgf·m, 16lbf·ftl 8 N·m (0.8 kgf·m, 6lbf·ftl

5. Install in the reverse order of removal. A

6. Adjust the alternator belt tension (see page 4-40) or the alternator-AiC belt tension (see page 4-39). 7. Enter the anti-theft code for the radio, then enter the customer's radio station presets.

4-32

BACK

r--:'I I..!::..I Alternator Overhaul Exploded View

SPACER RING

A \

BEARING RETAINER

REAR BEARING

~@ ,

(jJ

I ROTOR

VOLTAGE REGULATOR

JOE 'REcnFER, ASSEMBLV

BRUSH ASSEMBLV

END COVER

t

BRUSH HOLDER INSULATOR

(cont'd)

BACK

4-33

Charging System Alternator Overhaul (cont'd) 5. Remove the washer nut (A) and insulator (8) from the "8" terminal. then remove the end cover (C) and dust seal (D) .

Special Tools Required • Driver 07749-0010000 • Driver attachment. 52 x 55 mm 07746-0010400

NOTE: Refer to the Exploded View as needed during this procedure. 1. Test the alternator and regulator before you remove them (see step 1 on page 4-30). 2. Remove the alternator (see page 4-32). 3. If the front bearing needs replacing. remove the pulley locknut with a 10 mm wrench (A) and a 22 mm wrench (8). If necessary. use an impact wrench.

C@[O

/\

A

B

6. Remove the brush holder.

4. Remove the three flange nuts (A) and the screw (8) from the alternator. then remove the plate terminal (C).

4-34

BACK

r--:'I

~

7. Remove the voltage regulator.

9. Remove the four flange nuts.

10. Remove the rear housing (A) and washer (8). 8. Remove the four screws (A), then remove the rectifier (8) and rubber seal (C).

A

~/

c-----·@

(cont'd)

BACK

4-35

Charging System Alternator Overhaul (cont'd) 11. If you are not replacing the front bearing and/or rear bearing, go to step 18. Remove the rotor from the stator drive end housing.

14. With a hammer and commercially available tools shown, install a new rear bearing in the rotor shaft.

12. Inspect the rotor shaft for galling, and inspect the bearing journal surface in the stator housing for seizure marks .

15. Remove the front bearing retainer plate.

• If either the rotor or stator housing is damaged, replace the alternator. • If both the rotor and the stator housing are OK, go to step 13. 13. Remove the rear bearing using a puller as shown.

4-36

BACK

~ ~

16. Support the stator housing in a vise, and drive out the front bearing with a brass drift (A) and hammer.

Rectifier Test 18. Check for continuity in each direction, between the B terminal (A) and P terminals (B), and between the E terminal (C) and P terminals (B) of each diode pair. All diodes should have continuity in only one direction. Because the rectifier diodes are designed to allow current to pass in one direction, and the rectifier is made up of eight diodes (four pairs). you must test each diode in both directions for continuity with an ohmmeter that has diode checking capability: a total of 16 checks .

A

• If any diode failed, replace the rectifier assembly. (Diodes are not available separately.) • If all the diodes are OK, go to step 19.

A"-....

17. With a hammer and the special tools, install a new front bearing in the stator housing.

B, 07746-0010400

A

.n.

~1.

~

.

B',

.... B,

1- B, B, B.

~~

~~

-, ~

..

~~

c

(cont'd)

BACK

4-37

Charging System Alternator Overhaul (cont'd) Alternator Brush Inspection

Stator Test

19. Measure the length of both brushes (A) with a vernier caliper (B).

22. Check that there is continuity between each pair of leads (A) . • If there is continuity, go to step 23. • If there is no continuity, replace the alternator .

• If either brush is shorter than the service limit, replace the brush assembly. • If brush length is OK, go to step 20.

~_ _ _--:::::=::::=;;O/A

Alternator Brush Length: Standard (New): 10.5 mm (0.41 in.) 1.5 mm (0.06 in.) Service Limit:

B

23. Check for no continuity between each lead and the coil core (B). • If there is no continuity, go to step 24. • If there is continuity, replace the alternator. Rotor Slip Ring test 20. Check that there is continuity between the slip rings

24. Reassemble the alternator in reverse order of disassembly, and note these items:

(A).

• Be careful not to get any grease or oil on the slip rings . • If you removed the pulley, tighten its locknut to 111 N·m (11.3 kgf·m, 81.7 Ibf·ft) when you reinstall it.

• If there is continuity, go to step 21. • If there is no continuity, replace the alternator. C

J

25. Reinstall the alternator, and adjust its belt tension (see page 4-39).

A

21. Check that there is no continuity between each slip ring (A) and the rotor (B) and the rotor shaft (C) . • If there is no continuity, go to step 22 . • Ifthere is continuity, replace the alternator.

4-38

BACK

r--:'I

~

Alternator-A/C Compressor Belt Inspection and Adjustment Deflection Method

Special Tools Required 8elttension gauge 07JGG-001010A

Inspection

Belt Tension Gauge Method 1. Apply a force of 98 N (10 kgf, 22Ibf), and measure the deflection atthe mid point (A) between the alternator and crankshaft pulley.lfthe belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2.

Inspection 1. Remove the three bolts from the left end of the splash shield, and pull it back as needed.

Deflection: Used Belt: 7.0-9.0 mm (0.28-0.35 in.) New Belt: 4.0-6.0 mm (0.16-0.24 in.)

2. Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. If the belt needs adjustment, goto step 3.

Tension: Used Belt: New Belt:

B

10x1.25mm 44 N·m 14.5 kgf·m, 33 Ibf·ftl

490-590 N (50-60 kgt, 110-130 Ibt) 1,030-1,130 N (105-115 kgf, 2312541bt) A 10x1.25mm 44 N·m (4.5 kgf·m, 33 Ibf·ftl

C 8x 1.25 mm 22 N·m (2.2 kgf.m, 16lbf.ftl B 8x 1.25 mm 22 N·m (2.2 kgf·m, 16lbf·ftl

Adjustment

Adjustment

2. Loosen the mounting bolt (8) and locknut (C).

3. Loosen the mounting bolt (A) and locknut (8). 4. Turn the adjusting bolt (C) to obtain the proper belt tension, then retighten the locknut and mounting bolt. 5. Recheck the belt tension. 6. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification.

3. Turn the adjusting bolt (0) to obtain the proper belt tension, then retighten the locknut and mounting bolt. 4. Recheck the belt tension. 5. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification. 6. Check the power steering pump belt adjustment (see page 17-12).

7. Check the power steering pump belt adjustment (see page 17-12).

BACK

4-39

Charging System Alternator Belt Inspection and Adjustment Deflection Method

Special Tools Required Belttension gauge 07JGG-001010A

Inspection

Belt Tension Gauge Method Inspection 1. Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. If the belt needs adjustment, goto step 2. Tension: Used Belt: New Belt:

1. Apply a force of 98 N (10 kgf. 22Ibf). and measure the deflection at the mid point (A) between the alternator and crankshaft pulley. Ifthe belt is worn or damaged. replace it. If the belt needs adjustment. go to step 2. Deflection: Used Belt: 10.5-12.5 mm (0.41-0.49 in.) New Belt: 8.0-10.0 mm (0.31-0.39 in.) B 10x1.25mm 44 N·m 14.5 kgf·m. 33 Ibf·tt)

290 - 440 N (30 - 45 kgt, 66 - 99 Ibt) 540-740 N (55-75 kgf, 120-170 Ibt)

A 10x 1.25 mm 44 N·m 14.5 kgf.m. 33lbf·tt)

c - - -__ ~~~~

/ /

....:..-:-..

# \::\ A

'.

C 8x1.25mm 22 N·m 12.2 kgf·m. 16lbf·tt)

Adjustment 2. Loosen the mounting bolt (A) and locknut (B).

Adjustment

3. Turn the adjusting bolt (C) to obtain the proper belt tension. then retighten the locknut and mounting bolt. 4. Recheck the belt tension. 5. If you installed a new belt, run the engine for 5 minutes. then readjust the belt to the used belt specification.

2. Loosen the mounting bolt (B) and locknut (C). 3. Turn the adjusting boltlD) to obtain the proper belt tension, then retighten the locknut and mounting bolt. 4. Recheck the belt tension.

6. Check the power steering pump belt adjustment (see page 17-12).

5. If you installed a new belt. run the engine for 5 minutes. then readjust the belt to the used belt specification. 6. Check the power steering pump belt adjustment (see page 17-12).

4-40

BACK

r--:'I

~

Cruise Control Component Location Index

CRUISE CONTROL INDICATOR (Built into gauge assembly) Bulb Locations. page 22-59

CLUTCH PEDAL POSITION SWITCH (MIT) Test. page 4-49 Clutch Pedal Adjustment. page 12-4 BRAKE PEDAL POSITION SWITCH Test. page 4-49 Pedal Height Adjustment. page 19-5

TRANSMISSION RANGE SWITCH (Am Test. page 14-138

BACK

ACTUATOR Test. page 4-51 Solenoid Test. page 4-50 Relacement. page 4-52

4-41

Cruise Control Circuit Diagram

--&

DRIVER'S UNDER·DASH FUSE/RELAY BOX

IGNITION SWITCH

UNDER·HOOD FUSE/RELAY BOX BATTERY

HI----'-Cr'\..J>----r-WHT

BAT

_+-..._____. ~ NO.9 ~

BLKlYEL

IGI IGI HOT in ON (II) and START (III)

(7.5A)

COMBINATION LIGHT SWITCH

Y

No.6 (15A)

REDIBLK

YEL

lTGRNlBLU BLUIRED

~

MAIN SWITCH

WHTIYEL 2 LTGRN

SET

SETI RESUME/ CANCEL RE· SUME SWITCH

3

2

lTf~N

2

SWITCH

4

3

5

GRY

LTGRNlRED

2

6

YY

LT GRN/BLK

BLUIWHT

BLU/GRN

7

12

8

CRUISE CONTROL UNIT 14

9

BRNlBLK BRNIWHT

DASH LIGHTS BRIGHTNESS CONTROLLER

• VEHICLE SPEED SENSOR (VSS) 'PCM CABLE • GAUGE REEL ASSEMBLY PCM

h-----~!

I

BRAKE LIGHTS

BRN

BlK

GAUGE ASSEMBLY

LT GRN

13 100.-......- - - - -.... 3

BlK

CRUISE CONTROL ACTUATOR

BLK

I I

I

G401

GSOI

G302

BACK

DIMMING CIRCUIT CRUISE INDICATOR LIGHT (1.2W)

A/T : TRANSMISSION RANGE SWITCH (ON: (2],~,~J MIT : ClLlTCH PEDAL POSITION SWITCH (ON : Pedal released)

4-42

REDlBlK

HORN SWITCH

HORN

BAAl
5 RED

1 BLK

r--:'I I..:!!.I Symptom Troubleshooting Index NOTE: • The numbers in the table show the troubleshooting sequence . • Before troubleshooting. - check the No.9 (7.5A) and No.6 (15A) fuses in the driver's under-dash fuse/relay box, and the No. 47 (20A) fuse in the under-hood fuse/relay box. - check that the horn sounds. - check the tachometer to see if it works properly. Symptom

Cruise control cannot be set

Diagnostic procedure

1. 2. 3. 4. 5. 6.

Check main switch (see page 4-48) Check SET/RESUME/CANCEL switch (see page 4-48) Check brake pedal position switch and mounting (see page 4-49) Check clutch pedal position switch and mounting (MIT) (see page 4-49) Check transmission range switch (AfT) (see page 14-138) Check control unit (see page 4-46)

Cruise control can be set but indicator light does not go on

Check control unit (see page 4-46)

Cruise speed is noticeably higher or lower than what was set Excessive overshooting or undershooting when trying to set speed Speed fluctuation on a flat road with cruise control set Vehicle does not decelerate or accelerate accordingly when SET/ RESUME/CANCEL button is pushed Cruise control does not cancel when clutch pedal is pushed (MIT) Cruise control does not cancel when shift lever is moved to position

1. 2. 3. 1. 2. 3. 1. 2. 3. 1. 2.

Check vehicle speed sensor (VSS) (see page 22-69) Check actuator and vent line for the actuator (see page 4-51) Check control unit (see page 4-46) Check actuator and vent line for the actuator (see page 4-51) Check vehicle speed sensor (VSS) (see page 22-69) Check control unit (see page 4-46) Check vehicle speed sensor (VSS) (see page 22-69) Check actuator (see page 4-51) Check control unit (see page 4-46) Check SET/RESUME/CANCEL switch (see page 4-48) Check control unit (see page 4-46)

1.

Check clutch pedal position switch and mounting (see page 4-49) Check control unit (see page 4-46) Check transmission range switch (see page 14-138) Check control unit (see page 4-46)

rm

2. 1. 2.

Also check for

• Poor ground: G302, G401, or G501 • Open circuit, loose or disconnected terminals: LTGRN, LTGRN/RED, GRY, LTBLU, BLU/WHT • Poor ground: G302, G401, or G501 • Open circuit, loose or disconnected terminals: YEL, BLU/BLK

Open circuit, loose or disconnected terminals: LTGRN/RED, LTGRN/BLK Short to ground in the LT BLU wire Short to ground in the LT BLU wire

(AfT)

Set speed is not cancelled when brake pedal is pushed

1. 2.

Check brake pedal position switch and mounting (see page 4-49) Check control unit (see page 4-46)

Open circuit, loose or disconnected terminals: WHT/BLK

(cont'd)

BACK

4-43

Cruise Control Symptom Troubleshooting Index (cont'd) Symptom Set speed, does not cancel when main switch is pushed OFF

Set speed, does not cancel when CANCEL button is pushed

Set speed will not resume when RESUME button is pushed (with main switch on, when set speed is temporarily cancelled by pressing the brake pedal) The transmission shifts down slower than normal when going up a hill with the cruise control on

1.

2. 1.

2.

1.

2.

1.

Diagnostic procedure Check main switch (see page 4-48) Check control unit (see page 4-46)

Check SET/RESUME/CANCEL switch (see page 4-48) Check control unit (see page 4-46)

Check SET/RESUME/CANCEL switch (see page 4-48) Check control unit (see page 4-46)

Troubleshoot the cruise control communication circuit (see page 4-45)

(AfT)

4-44

BACK

Also check for -Shorted main switch or short to power in the LT GRNwire. Open circuit, loose or disconnected terminals: LTGRN/REO, LTGRN/BLK Open circuit, loose or disconnected terminals: LTGRN/BLK

Open circuit, loose or disconnected terminals, or short to ground: BLU/ GRN

~ ~ Cruise Control Communication Circuit Troubleshooting (AfT) 1. Start the engine. 2. Turn on the cruise control main switch, then drive the vehicle to speeds over 2S mph (40 km/h) with the cruise control.

8. Connect a voltmeter between cruise control unit 14P connector terminal No.8 and body ground. Test-drive the vehicle at speeds over 2Smph (40km/h) with the cruise control set, and watch the voltmeter. CRUISE CONTROL UNIT 14P CONNECTOR

Does the cruise control operate?

..-YES-Go to step 3. NO-Check the cruise control unit (see page 4-46) or cruise control actuator.•

1

2

3

V

5

6

7

8

9

10

11

12

13

14

BLU/GRN


'Y.

4. Disconnect Powertrain Control Module (PCM) connector A (32P) and cruise control unit connector.

= Wire side of female terminals

S. Check for continuity between the PCM connector terminal AS and body ground.

Is there about 1 V?

PCM CONNECTOR A 132P)

YES-Go to step 9.

BLU/GRN I

V

2

3

4

12 13 14 15

/

/

5

6

17

18 19 20 21

25 26 27

2B 29 30

8

V

9 10

/

NO- Replace the cruise control unit.•

/

23 24

9. Connect a voltmeter between PCM connector terminal AS and body ground. Drive the vehicle at speeds over 2Smph (40km/h) with the cruise control set, and watch the voltmeter.

32 "-


'Y.


=

BLU/GRN t

V

Is there continuity?

2

3

4

12 13 14 15

YES-Repair a short in the wire between the PCM connector terminal AS and the cruise control unit connector terminal No.8.•

5

V

6

/

17 18 19 20 21

25 26 27

2B 29 30

9 10

8

V

/

1/

23 24 32 ~


'Y.

NO-Goto step 6. 6. Reconnect PCM connector A (32P) and cruise control unit connector.

Is there about 1 V? 7. Turn the ignition switch ON (II). YES-Check for loose connections ofthe BLU/GRN wire between the cruise control unit and the PCM. If necessary replace the PCM and recheck. (see page 11-3).• NO-Repair open in the wire between the AS terminal and the cruise control unit connector terminal No.8.•

BACK

4-45

Cruise Control Control Unit Input Test SRS components are located in this area. Review the SRS components locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-28). 1. Remove the driver's dashboard lower cover (see page 20-84). 2. Disconnect the 14P connector from the control unit. 3. Inspect the connector and socket terminals to be sure they are all making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system . • If the terminals look OK, go to step 4.

14P CONNECTOR

CRUISE CONTROL UNIT

BRN/BLK


4. With the 14P connector disconnected, make these input tests.

4-46

Cavity

Wire

Test condition

Test: Desired result

9

BRN/WHT

Under all conditions

1

BRN


11

BRN/BlK


2

GRY

Ignition switch ON (II), main switch ON and brake pedal depressed, then released

Check for resistance to ground: There should be 80-120 Q. Check for resistance to ground: There should be 40-60 Q. Check for resistance to ground: There should be 70 -11 0 Q. Check for voltage to ground: There should be 0 V with the pedal depressed and battery voltage with the pedal released.

3

BlK


Check for continuity to ground: There should be continuity.

BACK

Possible cause if result is not obtained • Faulty actuator solenoid • Poor ground (G401) • An open in the wire • Short to ground

• Faulty brake pedal position switch • An open in the wire • Open in cruise control main switch • Blown No.6 (15A) fuse in the driver's under-dash fuse/relav box • Poor ground (G401) • An open in the wire

~ ~

Cavity

Wire

5

WHT/BLK

6


Test condition Brake pedal depressed, then released

Check for voltage to ground: There should be battery voltage with the pedal depressed, and o V with the pedal released.

LT GRN/RED

Set button pushed

7

LTGRN/BLK

Resume button pushed

10

BLU/BLK

Ignition switch ON (II)

Check for voltage to ground: There should be battery voltage. When testing terminal No.6, there should be no voltage on terminal No.7. Check for voltage to ground: There should be battery voltage. When testing terminal No.7, there should be no voltage on terminal No.6. Attach to ground: Cruise indicator light in the gauge assembly should comes on.

12

BLU/WHT

13

LTGRN

Ignition switch ON (II) and main switch ON; raise the front of the vehicle, and rotate one wheel slowly while holding the other wheel Ignition switch ON (II) and main switch ON

14

LTBLU

A/T: Shift lever in 2, ~ or ~

MIT: Clutch pedal released

8

BLU/GRN

Check for voltage between the BLU/WHT (+) and BLK (-) terminals: Cycles about 0 V - 5 V (2.5 V average). Check for voltage to ground: There should be battery voltage.

Check for continuity to ground: There should be continuity. NOTE: There should be no continuity when the clutch pedal is depressed or when the sift lever is in other positions.

Reconnect the 14P Check for voltage to ground: connector to the control There should be about. 1 V. unit, then start the engine, main switch ON and drive the vehicle to speed over 25 mph (40 km/h) with the cruise control set

Possible cause if result is not obtained • Blown No. 47 (20A) fuse in the under-hood fuse/ relay box • Faulty brake pedal position switch • An open in the wire • Blown No. 47 (20A) fuse in the under-hood fuse/ relay box • Faulty horn relay • Faulty set/resume/cancel switch • Faulty cable reel • An open in the wire

• Blown bulb • Blown No.9 (7.5A) fuse in the driver's under-dash fuse/relay box • Faulty dimming circuit in the gauge assembly • An open in the wire • Faulty vehicle speed sensor (VSS) (MIT) • An open in the wire • Short to ground

• Blown No.6 (15A) fuse in the under-dash driver's fuse/relay box • Faulty main switch • An open in the wire • Faulty transmission range switch • Faulty or misadjusted clutch pedal position switch • Poor ground (G401) • An open in the wire • Loose connection • Faulty cruise control unit. • Short to ground • Faulty PCM

5. If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, the control unit may be faulty; replace it. Substitute a known-good control unit and retest. If the system works properly, replace the control unit.

BACK

4-47

Cruise Control Main Switch Test/Replacement

Set/Resume/Cancel Switch Test/ Replacement

1. Carefully pry the switch (A) out ofthe instrument panel. 1. Remove the two screws (A), then remove the switch (B).

Terminal side of male terminals

Terminal side of male terminals B

2. Disconnect the 5P connector (B) from the switch.

2. Check for continuity between the terminals in switch position according to the table.

3. Check for continuity between the terminals in each switch position according to the table. Terminal

1

2

3

4

Position

5

OFF

ON

• If there is continuity and it matches the table, but switch failure is occurred on the cruise control unit input test, check and repair the wire harness on the switch circuit. • Ifthere is no continuity in one or both positions, replace the switch.

r\

Terminal Position

4. Ifthe continuity is not as specified, replace the switch.

SET ION, RESUME ION' CANCEL ION'

4-48

BACK

\

2

1

.()

Q -0

()

0

3

I

0 -0

r--:'I I.!!!.I Brake Pedal Position Switch Test

Clutch Pedal Position Switch Test 1. Disconnect the 3P connector from the clutch pedal position switch.

1. Disconnect the 4P connector from the switch (A).

CLUTCH PEDAL POSITION SWITCH 3P CONNECTOR


2. Remove the brake pedal position switch. 2. Remove the clutch pedal position switch. 3. Check for continuity between the terminals according to the table.

3. Check for continuity between the terminals according to the table.

1\

\ Terminal Clutch Switch PRESSED

\

2

3

0

r.

Terminal Brake Switch PRESSED RELEASED

\

1

2

3

,....

4 r.

r0~

D

RELEASED

4. If necessary, replace the switch or adjust the pedal height (see page 12-4).

4. If necessary, replace the switch or adjust the pedal height (see page 19-5).

BACK

4-49

Cruise Control Actuator Solenoid Test 1. Disconnect the 4P connector (A) from the actuator.

2. Check for resistance between the terminals according to the table. NOTE: Resistance will vary slightly with temperature; specified resistance is at 70°F (20°C). Terminal

\

Resistance I Q I

\

2

1

VENT SOLENOID 40-60 Q

3

4

,..

~

-

-

VACUUM SOLENOID

30-50 Q SAFETY SOLENOID 40-60 Q

4 1

3 2

3. If the resistance is not as specified, replace the actuator.

4-50

BACK

r--:'I I.!!:!..I Actuator Test 5. With voltage and vacuum still applied, try to pull the actuator rod out by hand. You should not be able to pull it out. If you can, it is defective.

Special Tools Required Vacuum Pump/Gauge, 0-30 in.Hg A973X-041-XXXXX

1. Disconnect the actuator cable from the actuator rod and disconnect the 4P connector (A).

6. Disconnect ground from the No.3 terminal. The actuator rod should return. If it does not return, but the vent hose and filter are not plugged, the solenoid valve assembly is defective. Terminal side of male terminals

2. Connect battery power to the No.4 terminal and ground the No.1, No.2 and No.3 terminals.

7. Repeat steps 2 through 5, and disconnect ground from the No.1 terminal. The actuator rod should return. If it does not return, but the vent hose and filter are not plugged, the solenoid valve assembly is defective.

3. Connect a vacuum pump to the vacuum hose. Then apply vacuum to the actuator.

8. If you replace the solenoid valve assembly, be sure to use new O-rings on each solenoid.

4. The actuator rod (A) should pull in completely. If the rod pulls in only part-way or not at all, check for a leaking vacuum line or defective solenoid.

9. Disconnect power and ground from the 4P connector. Disconnect the vent hose from the actuator. Connect a vacuum pump to the actuator vent hose port, and apply vacuum. The actuator rod should pull in completely. If not, the vacuum valve is stuck open. Replace the actuator.

-~r

/...

BACK

4-51

Cruise Control Actuator/Solenoid/Cable Replacement Removal/Installation

6. Loosen the locknut (A), then disconnect the actuator cable (8) from the throttle linkage (C).

1. Disconnect the 4P connector (A) from the actuator.

A

c

\

» B

2. Loosen the two mounting bolts (8), and remove the actuator with the bracket.

7. Install in the reverse order of removal, and adjust the free play at the throttle linkage after connecting the actuator cable.

3. Disconnect the vacuum hose (C). 4. Remove the three nuts (A). D

5. Disconnect the actuator cable (8) from the actuator rod (C) by releasing the clip (D) from the rod with a screwdriver.

4-52

BACK

~

I.:!!..I DisassemblyIReassembly

ACTUATOR BRACKET

~ I

VACUUM HOSE

~~~~~

ACTUATOR

BACK

FILTERS

4-53

Cruise Control Actuator Cable Adjustment 1. Check that the actuator cable (A) moves smoothly with no binding or sticking.

4. Turn the adjusting nut (8) until it is 3.75±O.5 mm (O.15±O.02 in.) away from the bracket (C). 3.7S±O.S mm (O.1S±O.02 in.1

D

-------n---

~ ! B

c

~ A

2. Measure the amount of movement of the output linkage (8) until the engine speed starts to increase. At first, the output linkage should be located at the fully closed position (C). The free play (D) should be 3.75±O.5 mm (O.15±O.02 in.). 3. If the free play is not within specs, move the cable to the point where the engine speed starts to increase, and tighten the locknut (A) and adjusting nut (8). B

/

4-54

BACK

B 5. Pull the cable so that the adjusting nut (8) touches

the bracket, and tighten the locknut (A).

~ ~

Engine Mount Control System Component Location Index

--~-----------------==---------

-

REAR MOUNT

-

-~-----

POWERTRAIN CONTROL MODULE (PCM) Troubleshooting, page 4-57

BACK

4-55

Engine Mount Control System Circuit Diagram UNDER-HOOD FUSE/RELAY BOX BATTERY NO.41 (lOOA)

NO.42 (SOA)

+~--+-~D---~~~--~

WHT

IGNITION SWITCH IGI HOT in ON (II) and START (III) BlKlYEl

No.6 (1 SA)

DRIVER'S UNDER-DASH FUSElRElAY BOX

BlKlYEl

2 ENGINE MOUNT CONTROL SOLENOID VALVE

GRNIWHT

A2 PCM

BlK

1 Gl01

4-56

BACK

r--:'I

~

Troubleshooting 6. Measure voltage between the No.2 terminal and body ground.

Special Tools Required Vacuum Pump/Gauge, 0 - 30 in.Hg A973X-041-XXXXX

ENGINE MOUNT CONTROL SOLENOID VALVE CONNECTOR

NOTE: Check the vacuum hoses and lines for damage and proper connections before troubleshooting. Follow this procedure if the engine vibrates excessively when idling.


1. Warm up the engine to normal operating temperature (the cooling fan comes on twice).

Is the idle speed less than 800 rpm?

BlK/VEL

YES - Go to step 2. NO-Adjustthe idle speed (see page 11-110).•

Is there battery voltage? 2. Fully depress the brake pedal. YES-Go to step 7. 3. With the transmission in gear, have an assistant disconnect and reconnect the 2P connector from the engine mount control solenoid valve.

NO- Repair open in BLK/YEL wire between the 2P connector and No.6 (15 A) fuse in the driver's under-dash fuse/relay box .•

Is there a noticeable change in idle smoothness when the 2P connector is disconnected?

7. Measure voltage between the No.1 and No.2 terminals.

YES - Reconnect the 2P connector to the solenoid valve. The engine mount control system is OK.• NO-Goto step 4.

ENGINE MOUNT CONTROL SOLENOID VALVE CONNECTOR GRN/WHT

4. Shift to [N] or ~ position. 4-----, Wire side of t-----I female terminals

5. Disconnect the 2P connector from the engine mount control solenoid valve.

BlK/VEl Is there battery voltage? YES-Go to step 8. NO- Repair open in GRN/WHT wire between Powertrain Control Module (PCM) (A2) and the 2P connector. If the wire is OK, substitute a knowngood Powertrain Control Module (PCM) and recheck (see page 11-3) .•

(cont'd)

BACK

4-57

Engine Mount Control System Troubleshooting (cont'd) 11. Release the vacuum, then apply vacuum again.

8. Raise the engine speed above 1,000 rpm.

Is there a noticeable change in idle smoothness with and without vacuum applied?

9. Measure voltage between the No.1 and No.2 terminals.

VES-Gotostep 12.

ENGINE MOUNT CONTROL SOLENOID VALVE CONNECTOR

NO- Replace the engine mount.•


12. Disconnect the lower vacuum hose (A) from the engine mount control solenoid valve (8) and connect a vacuum pump/gauge to the hose.

A973X-041XXXXX

BLK/VEL

Is there battery voltage? VES- Repair short to body ground in GRN/WHT wi re between PCM (A2) and the 2P connector. If the wire is OK, substitute a known-good PCM and recheck (see page 11-3) .•

Is there manifold vacuum?

NO-Go to step 10. 10. Disconnect the upper vacuum hose (A) from the engine mount control solenoid valve (8), and connect a vacuum pump/gauge to the hose. Apply vacuum for 20 seconds.

B

Does the engine mount hold vacuum? VES-Gotostep 11. NO- Either the vacuum hose or the engine mount has a vacuum leak. Repair as needed .•

4-58

BACK

VES- Replace the engine mount control solenoid valve .• NO- A hose is restricted or pinched or the intake manifold port is plugged. Repair as needed .•

Engine Mechanical Engine Assembly Engine Removal .................................................... 5-2 Engine Installation ................................................ 5-10

Cylinder Head .. ....... .... ....... ............. ......... ... 6-1

Engine Block ... ...... .......... ..... ...... ... ....... ... .... 7-1 Engine Lubrication .......... .............. ............. 8-1 Intake Manifold/Exhaust System ............. 9-1 Engine Cooling ....... ............ ... .... ..... ............ 10-1

Engine Assembly Engine Removal NOTE: • Use fender covers to avoid damaging painted surfaces. • To avoid damage, unplug the wiring connectors carefully while holding the connector portion. • Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.

6.

1. Secure the hood in the open position. 2. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 3. Disconnect the battery negative terminal first, then the positive terminal. 4. Remove the intake air duct (A). 7. Disconnect the connector (C) from the under-hood fuse/relay box (8), and remove the bolt (D). 8. Remove the throttle cable (A) and cruise control cable (8) by loosening the locknuts (C) then slipping the cable ends out of the accelerator linkage. Take care not to bend the cable when removing them. Always replace any kinked cables with a new one.

5. Fix the hood in the vertical position by using a support rod (P/N 74145-S84-AOO) as shown below.

5-2

BACK

9. Relieve fuel pressure (see page 11-115). 10. Remove the fuel feed hose (A) and fuel return hose

12. Remove the mounting bolts (A), then remove the Power Steering (PIS) pump belt (8) and pump without disconnecting the PIS hoses.

(8).

/'

A

B

B

11. Remove the brake booster vacuum hose (A), Evaporative Emission (EVAP) canister hose (8), vacuum hose (e) and PIS hose clamp (0).

A

A

(cont'd)

BACK

5-3

Engine Assembly Engine Removal (cont'd) 14. Disconnect the Engine Control Module (ECM)/ Powertrain Control Module (PCM) connectors from the ECM/PCM.

16. Disconnect the engine wire harness connectors on the right side of the engine compartment.

-~ "

15. Remove the grommet (A), then pull out the ECM/ PCM connectors.

17. Remove the starter cable (A), wire harness clamp (8), ground cable (C) and back-up light switch connectors (D).

A

B

5-4

BACK

18. Remove the shift cable (A) and select cable (B). Take care not to bend the cable when removing it. Always replace any kinked cable with a new one (Mm.

20. Remove the rear engine mount bracket mounting bolt/nut (A).

M/T:

B

AfT:

~

19. Remove the clutch slave cylinder and line/hose assembly (Mm.

A

NOTE: • Do not disconnectthe line/hose assembly. • Do not operate the clutch pedal once the slave cylinder has been removed. • Take care not to bend the line.

21. Remove the rear stiffener (B) (except '01 model

A/T). 22. Remove the front engine mount bracket mounting bolts (A), and loosen the mount bolt (B).

B

(cont'd)

BACK

5-5

Engine Assembly Engine Removal (cont'd) 30. Lower the hoist, then remove the upper radiator hose (A), lower radiator hose (B) and the heater hoses (e).

23. Remove the radiator cap. 24. Raise the hoist to full height. 25. Remove the front tires/wheels. 26. Remove the splash shield.

A

~ B

31. Remove the ATF cooler hoses, then plug the ATF cooler hoses and lines.

--~ 27. Loosen the drain plug in the radiator to drain the engine coolant (see page 10-10). 28. Drain the Manual Transmission Fluid (MTF) (see page 13-3) or Automatic Transmission Fluid (ATF) (see page 14-113). Reinstall the drain plug using a new washer. 29. Drain the engine oil. Reinstall the drain bolt using a new washer (see page 8-5).

5-6

BACK

/

32. Remove the AlC compressor without disconnecting the AlC hoses.

33. Make sure the hoist supports are positioned correctly on the vehicle. Raise the hoist to full height.

35. Remove the bolts (A) securing the shift cable holder (8), then remove the shift cable cover (C). To prevent damage to the control lever joint, be sure to remove the bolts securing the shift cable holder before removing the bolts securing the shift cable cover (AfT).

36. Remove the lock bolt (D) securing the control lever (E), then remove the shift cable (F) with the control lever. Take care not to bend the shift cable while removing it (AfT). 37. Remove the damper fork (see page 18-17). 38. Disconnect the suspension lower arm ball joints (see page 18-17). 39. Remove the driveshafts (see page 16-3). Coat all precision finished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends.

(cont'd)

BACK

5-7

Engine Assembly Engine Removal (cont'd) 40. Remove the rear engine mount bracket.

41. Remove the flange bolts securing the radius rods.

o

MIT:

'98-00 models A/T:

42. Mark the front beam (A) and rear beam (B), then remove the front beam.

'01-02 models A/T:

5-8

BACK

43. Lower the hoist.

45. Remove the ground cable (A) and the stop (B), then remove the upper bracket (C).

44. Attach the chain hoist to the engine as shown.

A~

I'

46. Remove the transmission mount bracket.

47. Check that the engine/transmission is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring. 48. Slowly lower the engine about 150 mm (6 in.). Check once again that all hoses and wires are disconnected from the engine/transmission. 49. Lower the engine all the way. Remove the chain hoist from the engine. 50. Remove the engine from under the vehicle.

BACK

5-9

Engine Assembly Engine Installation 1. Install the accessory brackets and tighten their bolts and nuts to the specified torques. 6x1.0mm 12 N·m (1.2 kgf·m, 8.7Ibf·ft)

10x 1.25 mm 49 N·m (5.0 kgf·m, 36 Ibf·ft)

8x 1.25mm 22 N·m (2.2 kgf·m, 16Ibf·ft)

10x 1.25mm 49 N·m (5.0 kgf.m, 36 Ibf·ft)

5-10

8x 1.25mm 22 N·m (2.2 kgf·m,16Ibf·ft)

BACK

2. Push the engine under the vehicle. Attach the chain hoist to the engine, then lift the engine into position in the vehicle.

5. Install the transmission mount bracket. Tighten the bolt and nuts in the numbered sequence shown.

MIT:

INOTICE I

(V10x1.25mm 38 N·m 13.9 kgf·m, 28Ibf·ft)

Reinstall the mounting bolts/nuts in the sequence given. Failure to follow this sequence may cause excessive noise and vibration, and reduce bushing life. 3. Install the upper bracket (A), then tighten the bolt and nuts in the numbered sequence shown. 6x1.0mm

CD

12, 1.25 mm 12 N·m 1\'.2 ':; :~;~.m. 54 N.m 15.5 kgf.m, 40lbf·ftl

40 Ibf.ft) /

CD 12 x 1.25 mm

54 N·m 15.5 kgf·m, 40Ibf·ft)

A

---....-~\

AIT:

CD 12 x 1.25 mm

54 N·m 15.5 kgf·m, 40 Ibf.ftl ® 10x 1.25 mm 38 N·m 13.9 kgf·m, 28Ibf·ft)

®12x 1.25 mm 54 N·m 15.5 kgf·m, 40 Ibf·ftl

\

4. Install the stop (B).

®10x1.25mm 38 N·m 13.9 kgf·m, 28 Ibf·ft)

6. Remove the chain hoist from the engine. 7. Raise the hoist to full height.

(cont'd)

BACK

5-11

Engine Assembly Engine Installation (cont'd) 8. Install the front beam. Align the marks on the rear beam (B) and front beam (e) then tighten the bolts.

10. Install the rear mount bracket, then tighten the bolts.

B

MIT:

12x1.25mm 54 N·m 15.5 kgf.m, 40 Ibf·ft, Replace.

'98-00 models AIT:

14x 1.5 mm 103 N·m (10.5 kgf.m, 76lbf·ft, Replace.

12x 1.25mm 64 N·m 16.5 kgf.m, 47lbf·ft,

9. Tighten the flange bolts on the radius rods. 14x1.5mm 162 N·m (16.5 kgf·m,119Ibf.ft,

'01-02 models A/T:

12x1.25mm 54N·m 15.5 kgf·m, 40 Ibf·ft, Replace.

11. Lower the hoist.

5-12

BACK

14. Tighten the front mount bracket mounting bolts in the numbered sequence shown.

12. Tighten the rear mount mounting bolt/nut (A).

MIT:

CD 10 x 1.25 mm

38 N·m 13.9 kgf·m, 28 Ibf·tt)

A

12x1.25mm 64 N·m (6.5 kgf·m, 47Ibf·tt)

®10x1.25mm 64 N·m 16.5 kgf.m, 47 Ibf·tt)

Replace.

Replace.

10x1.25mm 38 N·m (3.9 kgf·m, 28 Ibf·tt)

A/T: A 12x 1.25mm 54 N·m 15.5 kgf·m, 40 Ibf·tt)

10x 1.25mm 38 N·m 13.9 kgf·m, 28 Ibf·tt)

~~6

~

"-

/ 13. Install the rear stiffener (B) (except '01-02 models

AfT).

(cont'd)

BACK

5-13

Engine Assembly Engine Installation (cont'd) 15. Raise the hoist to full height. 16. Install a new spring clip on the end of each driveshaft, then install the driveshafts. Make sure each clip "clicks" into place in the differential and intermediate shaft.

21. Install the control lever (A), with the shift cable (B), on the control shaft. Do not bend the shift cable any more than is necessary to install the control lever (AfT).

F

17. Connect the suspension lower arm ball joints. Use new cotter pins (see page 18-17).

6x 1.0 mm 9.8 N·m 11.0 kgf·m, 7.2Ibf·ft)

B

18. Install the damper fork (see page 18-17). 19. Install the AlC compressor.

A

1 ...

\

ax 1.25 mm 26 N·m 12.7 kgf·m, 20Ibf·ft)

~

22. Install the lock bolt (C) with a new lock washer (D), then bend the lock tab of the lock washer (AfT). 23. Install the shift cable cover (E), then install the shift cable holder (F) on the shift cable cover (AfT).

ax 1.25mm 22 N·m (2.2 kgf·m, 16Ibf·tt)

20. Install the exhaust pipe A (A); use new gaskets (B) and new self-locking nuts (C).

24. Connect the upper radiator hose (A), lower radiator hose (B) and heater hoses (C). C

~-I---C

10 x 1.25 mm 54N·m (5.5 kgf·m, 40Ibf·tt)

----C 10 x 1.25 mm 33N·m (3.4 kgf·m, 25 Ibf.tt)

5-14

BACK

25. Connect the Automatic Transmission Fluid (ATF) cooler hoses (AfT).

27. Install the front tires/wheels. 28. Lower the hoist. 29. Install the clutch slave cylinder and line/hose assembly. Take care not to bend the line (MIT). 6x1.0mm 9.8 N·m (1.0 kgf·m, 8.7Ibf·ft)

~

8x 1.25 mm 23 N·m (2.3 kgf·m, 17lbf·ft)

~

26. Install the splash shield.

30. Install the shift cable (A) and select cable (8); use new cotter pins (C). 8x1.25mm 22 N·m (2.2 kgf·m, 16Ibf·ft)

B A

... ~

(PIN 08798-9002)

(cont'd)

BACK

5-15

Engine Assembly Engine Installation (cont'd) 31. Loosely install the alternator belt.

36. Push the ECM/PCM connectors through the bulkhead, then install the grommet (A).

32. Loosely install the PIS pump belt and pump.

A

33. Adjust the alternator belt (see page 4-39) and the

Power Steering (PIS) pump belt (see page 17-12). 34. Install the starter cable (A), wire harness clamp (B),

ground cable (C) and back-up light switch connectors (D).

6x1.0mm 12 N·m 11.2 kgf.m, 8.7Ibf·ftl

A

_----c

37. Connect the ECM/PCM connectors.

35. Connect the engine wire harness connectors on the right side of the engine compartment.

--~

----

5-16

BACK

38. Install the brake booster vacuum hose (A), Evaporative Emission (EVAP) canister hose (B) and vacuum hoses (C). A

\

B

40. Install the cruise control cable, then adjust the cable (see page 4-54). 41. Install the throttle cable, then adjust the cable (see page 11-134).

6x 1.0mm 12 N·m (1.2 kg'.m,

8.7Ib'·tt)

42.

B

A

39. Install the fuel feed hose (A) and fuel return hose (B), using new washers (C).

~

6x1.0mm

12 N·m (1.2 kg'·m, 8.7Ibf·ft)

43. Install the intake air duct.

(cont'd)

BACK

5-17

Engine Assembly Engine Installation (cont'd) 44. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion. 45. Refill the engine with engine oil (see page 8-5). 46. Refill the transmission with MTF (see page 13-3) or ATF (see page 14-113). 47. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open (see page 10-10). 48. Move the shift lever to each gear, and verify that the AfT gear position indicator follows the transmission range switch (AfT). 49. Check that the transmission shifts into gear smoothly (Mrr). 50. Inspect for fuel leaks. Turn ON (II) the ignition switch (do not operate the starter) so that the fuel pump runs for approximately 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line. 51. Enter the anti-theft code for the radio, then enter the customer's radio station presets.

5-18

BACK

Engine Mechanical Cylinder Head Special Tools ................................................................. Component Location Index ........................................ DTC Troubleshooting ................................................... VTEC Solenoid Valve Test ........................................... VTEC Rocker Arms Test ............................................... Valve Clearance Adjustment ....................................... Valve Seal Replacement with Cylinder Head Installed ............................................ Crankshaft Pulley Removal and Installation .............. Timing Belt Inspection ................................................. Balancer Belt Inspection .............................................. Timing Belt and Balancer Belt Adjustment ................ Timing Belt and Balancer Belt Removal ..................... Timing Belt and Balancer Belt Installation ................. Cylinder Head Removal ............................................... Cylinder Head Inspection for Warpage ...................... Rocker Arm Assembly Removal ................................. Rocker Arms shafts Disassembly/Reassembly -F23A 1, F23A4 Engines ............................................. Rocker Arms shafts Disassembly/Reassembly -F23A5 Engines ......................................................... Rocker Arms and shafts Inspection ............................ Camshaft Inspection .................................................... Valves, Springs, and Valve Seals Removal ................ Valve Inspection ........................................................... Valve Stem-to-Guide Clearance Inspection ............... Valve Guide Replacement ........................................... Valve Seat Reconditioning .......................................... Valves, Springs, and Valve Seals Installation ............ Camshaft/Rocker Arms, Camshaft Seal, and Pulley Installation ................... Cylinder Head Installation ........................................... Cylinder Head Cover Installation ................................ CKP/TDC Sensors Replacement ..................................

BACK

6-2 6-3 6-7 6-10 6-11 6-14 6-16 6-18 6-19 6-20 6-22 6-23 6-26 6-30 6-35 6-35 6-36 6-37 6-38 6-40 6-43 6-43 6-43 6-44 6-46 6-48 6-49 6-51 6-54 6-55

Cylinder Head Special Tools Ref.No.

CD ® ® CD ® ® (J)

® ® @-1 @-2 @-3 @-4

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Tool Number 07HAH-PJ7010B 07 JAA-001 020A 07 JAB-001 020A 07LAJ-PR3020B 07MAB-PY3010A 07 NAF-PT001 OA 07NAF-PT0020A 07NAG-PT0010A 07NAJ-P07010A 07406-0020201 07406-0070300 07MAJ-PY4011A 07MAJ-PY40120 07742-0010100

I-

CD

-I

®

"'"

6-2

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Description Valve Guide Reamer, 5.5 mm Socket, 19 mm Holder Handle Air Stopper Holder Attachment, 50 mm, Offset Installer Cup Installer Shaft Seal Guide Pressure Gauge Adaptor A/T Pressure Hose A/T Low Pressure Gauge W/Panel A/T Pressure Hose, 2,210 mm A/T Pressure Hose Adaptor Valve Guide Driver, 5.5 mm

u

0 _.-

®

®

(J)

®

@-1,@-2,@-3,@-4

@

BACK

®

Component Location Index

TIMING BELT UPPER COVER

l_RUBBER SEALS

/

I

~TIMING BELT ~ LOWER COVER

/RUBBER SEAL

@

/

.-/ CRANKSHAFT

PULLEY BOLT Replacement, page 6-18

CRANKSHAFT PULLEY Replacement, page 6-18

~

~

TIMING BELT ADJUSTING BOLT

/ADJUSllNG NUT

(Q)

TIMING BELT

BALANCER BELT Inspection, page 6-20 Removal, page 6-23 Installation, page 6-26

Inspection, page 6-19 Adjustment, page 6-22 Removal, page 6-23 Installation, page 6-26 CKP/TDC SENSORS Replacement, page 6-55

(cont'd)

BACK

6-3

Cylinder Head Component Location Index (cont'd)

1._V

RUBBER SEAL

HEAD COVER GASKET

/

CYLINDER HEAD BOLT /

CYLINDER HEAD COVER

Installation. page 6-54

1

O-RING

/

CYLINDER HEAD GASKET

DOWEL PIN

6-4

/WASHER

BACK

Tightening. page 6-51

F23A 1/F23A4 engines ROCKER ARM ASSEMBLY

Overhaul, page 6-36 Inspection, page 6-38

OIL CONTROL ORIFICE

LOCKNUT

Adjustment, page 6-14

VALVE KEEPERS SPRING RETAINER

1J

DOWEL PIN

~(j

INTAKE VALVE SPRING

INTAKE VALVE SEAL

:

Replacement, page 6-42 VALVE SPRING SEAT INTAKE VALVE GUIDE

'

~

~

SEAL

~ Installation, page 6-49

,)(1 ,~ !

~~.~~~~~~~

CAMSHAFT PULLEY

Removal, page 6-30 Installation, page 6-49

CJQ~ /

Q

I

CYLINDER

~

EXHAUST VALVE GUIDE Replacement, page 6-44

j \

~ro~.

\ EXHAUST VALVE INTAKE VALVE

Removal. page 6-42 Installation, page 6-48

(cont'd)

BACK

6-5

Cylinder Head Component Location Index (cont'd) F23A5 engine ROCKER ARM ASSEMBLY Overhaul, page 6-37 Inspection, page 6-38

OIL CONTROL ORIFICE

LOCKNUT Adjustment, page 6-14

VALVE KEEPERS

~ V ~SPRINGRETAINER DOWEL PIN

~Oo

~J

~=-----.J

oU/

i/

INTAKE VALVE SPRING Replacement, page 6-42

/'NrAJ
CAMSH~ f>?l,?7/l>-: ?>:LJ~

~VALVESPRINGSEAT

' /

INTAKE VALVE GUIDE Replacement, page 6-44

VALVE KEEPERS

CAMSHAFT PULLEY Removal, page 6-30 Installation, page 6-49 SEAL Installation, page 6-49

BACK COVER VALVE SPRING SEAT EXHAUST VALVE SEAL Replacement, page 6-42 EXHAUST VALVE GUIDE Replacement, page 6-44 INTAKE VALVE Removal, page 6-42 Installation, page 6-48

6-6

BACK

DTC Troubleshooting DTC P1259: A problem in the VTEC Oil Pressure Switch circuit or VTEC Solenoid Valve circuit.

6. Disconnect the VTEC oil pressure switch 2P connector. 7. Check for continuity on the VTEC oil pressure switch between the pressure switch 2P connector terminals No.1 and No.2.

Special Tools Required • Pressure Gauge Adaptor 07NAJ-P07010A • AfT Low Pressure Gauge W/Panel 07406-0070300 • AfT Pressure Hose 07406-0020201 • AfT Pressure Hose, 2,210 mm 07MAJ-PY4011A • AfT Pressure Adaptor 07MAJ-PY40120

VTEC OIL PRESSURE SWITCH 2P CONNECTOR

1. Do the Engine Control Module (ECM)/Powertrain Control Module (PCM) reset procedure (see page 11-3). 2. Start the engine. 3. Warm up the engine to normal operating temperature (cooling fan comes on).


4. Road test the vehicle: Accelerate in 1st gear to an engine speed over 4,000 rpm. Hold that engine speed for at least 2 seconds. If DTC P1259 is not repeated during the first road test, repeat this test two more times.

Is there continuity? YES·- Go to step 8. NO -- Replace the VTEC oil pressure switch .•

Is DTC P1259 indicated?


YES - Go to step 5.

9. Measure the voltage between the VTEC oil pressure switch harness 2P connector terminal No.2 and body ground.

NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at VTEC solenoid valve and ECM/PCM .•

VTM


IBLU/BLKI

Wi re side of female terminals

Is there battery voltage? YES-Go to step 10. NO-Inspect for an open or short to ground in the wire between the VTEC oil pressure switch and the ECM/PCM (C10). If the wire is OK, substitute a known-good ECM/PCM and recheck .• (cont'd)

BACK

6-7

Cylinder Head DTC Troubleshooting (cont'd) 14. Remove the VTEC oil pressure switch (A) and install the special tools as shown, then reinstall the VTEC oil pressure switch.

10. Measure voltage across the VTEC oil pressure switch harness 2P connector. VTEC OIL PRESSURE SWITCH HARNESS 2P CONNECTOR

'----~

';;1..1-----'


07406-0020201 or 07MAJ·PV4011A and 07MAJ·PV40120

Is there battery voltage?

15. Reconnect the VTEC solenoid valve 1P connector and VTEC oil pressure switch 2P connector.

YES-Goto step 11. NO-Repair open in the wire between the VTEC oil pressure switch and G101. Ifthe wire is OK, substitute a known-good ECM/PCM and recheck .•

16. Connect a tachometer. 17. Warm up the engine to normal operating temperature (cooling fan comes on).

11. Turn the ignition switch OFF. 12. Disconnect the VTEC solenoid valve 1P connector. 13. Check for continuity on the VTEC solenoid valve between the solenoid valve 1P connector terminal and body ground.

18. Check oil pressure at engine speeds of 1,000, 2,000 and 4,000 rpm. Keep measuring time as short as possible because the engine is running with no load (less than one minute). Is pressure below 49 kPa (0.5 kgflcrrf , 7 psi)?

VTEC SOLENOID VALVE 1P CONNECTOR

YES-Go to step 19. NO -Inspect the VTEC solenoid valve (see page 610) .•

Q

19. Turn the ignition switch OFF. 20. Disconnect the VTEC solenoid valve 1P connector.

= Terminal side of male terminal

Is there 14- 30 Q ?

21. Attach the battery positive terminal to the VTEC solenoid valve terminal. 22. Start the engine and check oil pressure at an engine speed of 3,000 rpm.

YES - Go to step 14.

Is pressure above 390 kPa (4.0 kgflcrrf ,57 psi)?

NO- Replace the VTEC solenoid valve .•

YES- Go to step 23. NO-Inspect the VTEC solenoid valve (see page 6· 10).•

6-8

BACK

23. With the battery positive terminal still connected to the VTEC solenoid valve, measure voltage between C10 and body ground.

27. Check for continuity between the VTEC solenoid valve 1P connector terminal and body ground. VTEC SOLENOID VALVE HARNESS 1P CONNECTOR


=

= Wire side of female terminal


Is there continuity? Is there battery voltage above 4,000 rpm? YES- Repair short in the wire between the ECM/ PCM (812) and VTEC solenoid valve connector.•

YES - Go to step 24. NO- Replace the VTEC oil pressure switch .•

NO - Substitute a known-good ECM/PCM and recheck. If symptom/indication goes away, replace the original ECM/PCM .•

24. Turn the ignition switch OFF. 25. Disconnect the battery positive terminal from the VTEC solenoid valve terminal. 26. Check for continuity between the VTEC solenoid valve harness 1P connector terminal and the ECM/ PCM connector terminal 812. VTEC SOLENOID VALVE HARNESS 1P CONNECTOR

VTS (GRN/YELI

ECM/PCM CONNECTOR B (25 PI


Is there continuity? YES - Go to step 27. NO- Repair open in the wire between the ECM/ PCM (812) and VTEC solenoid valve connector..

BACK

6-9

Cylinder Head VTEC Solenoid Valve Test 1. Disconnect the 1P connector from the VTEC solenoid valve. 2. Measure resistance between the terminal and body ground.

4. If the filter is not clogged, push the VTEC solenoid valve with your finger and check its movement. If the VTEC solenoid valve is normal, check the engine oil pressure. 6x1.0mm

12 ~gf.m. 8.7 Ibf.kl

Resistance: 14 - 30 Q

t

~)fJ !!1 (./. ....... ,~/

= 3. If the resistance is within specifications, remove the VTEC solenoid valve assembly (A) from the cylinder head, and check the VTEC solenoid valve filter/O-ring (8) for clogging. If there is clogging, replace the engine oil filter and the engine oil.

6 x 1.0 mm

12 N·m (1.2 kgf·m, 8.7 Ibf·ft)

6-10

BACK

VTEC Rocker Arm Test 5. Check that the air pressure on the shop air compressor gauge indicates over 400 kPa (4 kgf/cm2, 57 psi).

Special Tools Required Air Stopper 07LAJ-PR3020B 1. Set the No.1 piston at TDC (see page 6-26).

6. Inspect the valve clearance (see page 6-14). 2. Remove the cylinder head cover. 3. Push on the intake mid rocker arm (A) for the No.1 cylinder. The mid rocker arm should move independently of the intake primary rocker arm (B) and intake secondary rocker arm (C) .

7. Cover the timing belt with a shop towel to protect the belt. 8. Plug the relief hole with the air stopper (A).

• If the intake mid rocker arm does not move, remove the mid, primary, and secondary rocker arms as an assembly, and check that the pistons in the mid and primary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary, mid, and secondary rocker arms as an assembly, and test . • If the intake mid rocker arm moves freely, go to step 4. A 07LAJ-PR3020B

4. Repeat step 3 on the remaining intake mid rocker arms with each piston at TDC. When all the mid rocker arms pass the test, go to step 5.

(cont'd)

BACK

6-11

Cylinder Head VTEC Rocker Arm Test (cont'd) 9. Remove the sealing bolt (A) from the inspection hole (8). and connect an air pressure regulator with a 0-100psi gauge (C). NOTE: Remove any oil from the bolt threads and camshaft holder threads before retightening the sealing bolt.

11. With the specified air pressure applied and the piston at TOC, push up the timing plate (A) 2 - 3 mm (0.08 -·0.12 in.) at the plate end then release it. The synchronizing piston will pop out and engage the intake mid, primary (8) and secondary (C) rocker arms. Visually check the engagement of the synchronizing pistons A (0)/8 (E). The synchronizing pistons can be seen in the gap between the mid (F), secondary (C) and primary (8) rocker arms. NOTE: • With the timing plate (A) engaged in the groove on the timing piston (G), the piston is locked in the pushed out position . • Do not apply too much force when pushing up the timing plate.

07LAJ-PR3020B

A

/ B 10. Loosen the valve on the regulator, and apply the specified air pressure.

c

Specified Air Pressure: 400 kPa (4 kgf/cm 2 , 57 psi)

G

D

6-12

BACK

E

12. Make sure that the intake primary (A) and secondary (B) rocker arms are mechanically connected by the pistons, and that the mid rocker arm (C) does not move when pushed manually. If any intake mid rocker arm moves independently of the intake primary and secondary rocker arms, replace the rocker arms as a set.

13. Stop applying air pressure. Push up the timing plate (A); the synchronizing pistons (B) will snap back to their original positions. Visually check the disengagement of the synchronizing pistons AlB. Replace the intake rocker arms as an assembly if either piston does not work correctly. NOTE: When the timing plate is pushed up, it releases the timing piston (C), letting the return spring move the synchronizing pistons to their original positions.

- -------------

c B

A

/

B

14. Remove the special tools. 15. Check for smooth operation of each lost motion assembly by pushing down on each mid rocker arm. Replace any lost motion assembly that does not move smoothly.

BACK

6-13

Cylinder Head Valve Clearance Adjustment NOTE: Adjust the valves only when the cylinder head temperature is less than 100°F (38°C). 1. Remove the cylinder head cover.

4. Insert the feeler gauge (A) between the adjusting screw (8) and the end of the valve stem and slide it back and forth; you should feel a slight amount of drag.

2. Set the No.1 piston at TDC. The "UP" mark (A) on the camshaft pulley should be at the top, and the TDC grooves (8) on the pulley should line up with the top edge of the head.

B

3. Select the correct thickness feeler gauge for the valves you're going to check.

5. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (8) until the drag on the feeler gauge is correct.

Intake: 0.26 mm (0.010 in.)±0.02 mm (0.0008 in.) Exhaust: 0.30 mm (0.012 in.)±0.02 mm (0.0008 in.)

A 7 xO.75mm 20 N·m (2.0 kgf.m, 14lbf·ftJ

Valve Adjusting Screw Locations INTAKE No.4

No.3

No.2

No.1

B

No.4

6-14

No.3 No.2 EXHAUST

6. Tighten the locknut and recheck the clearance. Repeat the adjustment if necessary. '

No.1

BACK

7. Rotate the crankshaft 180° counterclockwise (the camshaft pulley turns only 90°). The "UP" mark (A) on the camshaft pulley should be toward the exhaust side of the head.

11. Rotate the crankshaft 180° counterclockwise to bring No.2 piston to TDC. The "UP" mark (A) should be on the intake side of the head. Number 2 Piston at TDC

Number 3 Piston at TDC

A

A

8. Check and. if necessary. adjust the valve clearance on No.3 cylinder.

12. Check and. if necessary. adjust the valve clearance on No.2 cylinder. 13. Install the cylinder head cover (see page 6-54).

9. Rotate the crankshaft pulley 180° counterclockwise to bring No.4 piston to TDC. Grooves (A) are visible again. Number 4 Piston at TOC

A

10. Check and. if necessary. adjust the valve clearance on No.4 cylinder.

BACK

6-15

Cylinder Head Valve Seal Replacement with Cylinder Head Installed The procedure shown below applies when using the incar valve spring compressor (Snap-on YA8845 with YA8845-2 A 7/8" attachment).

Intake Valve Seals

7. Select the 7/8 in. diameter long compressor attachment, and fasten the attachment to the No.5 hole of the lever arm with the speed pin supplied.

1. Turn the crankshaft so that the No.1 and No.4 pistons are at top dead center (TOC).

8. Insert an air adaptor into the spark plug hole. Pump air into the cylinder to keep the valve closed while compressing the springs and removing the valve keepers.

2. Remove the cylinder head cover. 3. Remove the rocker arm assembly (see page 6-35).

9. Put shop towels over the oil passages (A) to prevent the valve keepers from falling into the cylinder head.

4. Remove the injectors and the wire harness. 5. Using the 8 mm bolts (A) supplied with the tool, mount the two uprights (B) to the cylinder head at the end camshaft holders. The uprights fit over the camshaft as shown.

A

6. Insert the cross shaft (C) through the top hole of the two uprights.

6-16

A

10. Position the lever arm under the cross shaft so the lever is perpendicular to the shaft and the compressor attachment rests on top of the retainer for the spring being compressed. Use the front position slot on the lever as shown.

BACK

11. Using a downward motion on the lever arm, compress the valve spring and remove the keepers from the valve stem. Slowly release pressure on the spring.

18. Using a downward motion on the lever arm, compress the valve spring and remove the keepers from the valve stem. Slowly release pressure on the spring.

12. Remove the valve seals (see page 6-42).

19. Remove the valve seals (see page 6-42).

13. Install the valve seals (see page 6-48).

20. Install the valve seals (see page 6-48).

14. Install the springs, the retainers and the keepers in reverse order of removal.

21. Install the springs, the retainers and the keepers in reverse order of removal.

Exhaust Valve Seals

22. Repeat steps 7 to 21 on the other cylinders.

15. Select the 7/8 in. diameter short compressor attachment, and fasten the attachment to the No.4 hole of the lever arm with the speed pin supplied. 16. Put shop towels over the oil passages to prevent the valve keepers from falling into the cylinder head. 17. Position the lever arm under the cross shaft so the lever is perpendicular to the shaft and the compressor attachment rests on top of the retainer for the spring being compressed. Use the front position slot on the lever as shown.

BACK

6-17

Cylinder Head Crankshaft Pulley Removal and Installation Special Tools Required • Holder Handle 07JA8-001020A • Holder Attachment, 50 mm, Offset 07MA8-PY3010A • Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket

2. Install the crankshaft pulley, and hold with holder handle (A) and holder attachment (8).

Removal 1. Hold the pulley with holder handle (A) and holder attachment (8). A

B 07MAB-PY3010A

07JAB.OJ 020>

'C

07 JAA-001 020A (or Commercially available)

3. Tighten the bolt to 245 N·m (25.0 kgf·m, 181 Ib·ft) with a torque wrench and 19 mm socket (C). Do not use an impact wrench.

\

C 07JAA-001020A (or Commercially available)

2. Remove the bolt with a heavy duty 19 mm socket (C) and breaker bar.

Installation 1. Clean the pulleys (A), crankshaft (8), bolt (C), and washer (D). Lubricate as shown below.

0: Clean . : Lubricate

A

6-18

BACK

Timing Belt Inspection 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset button.

5. Remove the upper cover.

2. Disconnect the battery negative terminal first, then the positive terminal. 3. Disconnect the alternator wire harness. -1 Pull up the lock (A), then release the wire harness tie (8). -2 Pull back the boot and remove the 6 mm nut (e).

-3 Disconnect the connector (D) from the alternator.

A

6. Inspect the timing belt for cracks and oil or coolant soaking. Replace the belt if it is oil or coolant soaked. Remove any oil or solvent that gets on the belt.

4. Remove the cylinder head cover.

7. After inspecting, retorque the crankshaft pulley bolt to 245 N·m (25.0 kgf·m, 181 Ibf·ft). 8. Reinstall all removed parts. 9. Enter the anti-theft code for the radio, then enter the customer's radio station presets.

BACK

6-19

Cylinder Head Balancer Belt Inspection Special Tools Required • Holder Handle 07JAB-001020A • Holder Attachment, 50 mm, Offset 07MAB-PY3010A • Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket

6. Remove the upper cover.

1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative terminal first, then the positive terminal. 3. Remove the alternator (see page 4-32). ..~

4. Remove the alternator bracket (see page 5-10). 5. Remove the cylinder head cover.

6-20

7. Remove the dipstick and tube (A). Discard the O-ring (B).

BACK

8. Hold the pulley with holder handle (A) and holder attachment (8).

11. Install the crankshaft pulley. 12. Inspect the balancer belt for cracks and oil or coolant soaking. Replace the belt if it is oil or coolant soaked. Remove any oil or solvent that gets on the belt.

"-C

07JAA-001020A

lor Commercially available)

9. Remove the bolt with a heavy duty 19 mm socket (e) and breaker bar. 10. Remove the rubber seal (A) from the adjusting nut, then remove the lower cover.

13. Reinstall all removed parts. 14. After inspecting, retorque the crankshaft pulley bolt to 245 N·m (25.0 kgf·m, 181Ibf·ft). 15. Enter the anti-theft code for the radio, then enter the customer's radio station presets.

BACK

6-21

Cylinder Head Timing Belt and Balancer Belt Adjustment NOTE: • Always adjust timing belt tension when the engine is cold . • Always rotate the crankshaft counterclockwise when viewed from the pulley side. Rotating it clockwise may result in improper adjustment of the belt tension.

4. Remove the cylinder head cover .

1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative terminal first, then the positive terminal. 3. Disconnect the alternator wire harness. -1 Pull up the lock (A), then release the wire harness tie (8). -2 Pull back the boot and remove the 6 mm nut (C).


5. Rotate the crankshaft five or six revolutions to set the belt. 6. Set the No.1 piston at TDC. 7. Loosen the adjusting nut (A) 2/3-1 turn. A 44 N·m (4.5 kgf·m, 33 Ibf·ft)

D

8. Rotate the crankshaft counterclockwise three teeth on the camshaft pulley. 9. Tighten the adjusting nut (A). 10. After adjusting, retorque the crankshaft pulley bolt to 245 N·m (25.0 kgf.m, 181 Ibf·ft). 11. Enter the anti-theft code for the radio, then enter the customer's radio station presets.

6-22

BACK

Timing Belt and Balancer Belt Removal 6. Loosen the mounting bolts (A), then remove the PIS belt (B).

Special Tools Required

• Holder Handle 07JAB-001020A • Holder Attachment, 50 mm, Offset 07MAB-PY3010A • Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket

A

1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative terminal first, then the positive terminal. 3. Turn the crankshaft pulley so its TDC mark (A) lines up with the pointer (B). B

A

7. Disconnect the alternator wire harness. -1 Pull up the lock (A), then release the wire harness tie (B). -2 Pull back the boot and remove the 6 mm nut (C).


4. Remove the front tires/wheels. 5. Remove the splash shield.

8. Remove the alternator (see page 4-32). 9. Remove the alternator bracket (see page 5-10).

(cont'd)

BACK

6-23

Cylinder Head Timing Belt and Balancer Belt Removal (cont'd) 10. Support the engine with a jack and wood block under the oil pan.

12. Remove the cylinder head cover. 13. Remove the upper cover.

11. Remove the stopper (A) and ground cable (8), then remove the upper bracket (e).

B~

11·

z

c

14. Remove the dipstick and tube (A). Discard the O-ring (8).

o

6-24

BACK

.________B

15. Hold the pulley with holder handle (A) and holder attachment (8). A 07 JAB-001 020A

/

19. Release tension from the balancer belt: -1 Install a 6 mm bolt (A)(from the timing cover) through the hole in the end of the timing belt adjuster arm to temporarily lock the arm in place. -2 Loosen the adjusting nut (8) 2/3-1 turn. -3 Push the tensioner (e) up to take tension off the balancer belt. -4 Retighten the adjusting nut (8).

A

C

'C

07JAA-001020A (or Commercially available)

16. Remove the bolt with a heavy duty 19 mm socket (e) and breaker bar. 17. Remove the rubber seal from the adjusting nut, then remove the lower cover.

__ o,)L --~ r;~ f@JlJ

\~~A"K ~, "-

20. Release tension from the balancer belt and the timing belt: -1 Loosen the adjusting nut (A) 2/3-1 turn. -2 Push the balancer belt tensioner (8) up to take tension off the balancer belt. -3 Push the timing belt tensioner (e) down to take tension off the timing belt. -4 Retighten the adjusting nut (A).

',--

18. If you are removing only the balancer belt, go to step 19. If you are removing both the balancer belt and the timing belt, go to step 20.

A

21. Remove the balancer belt. 22. Remove the timing belt.

BACK

6-25

Cylinder Head Timing Belt and Balancer Belt Installation Special Tools Required o Holder Handle 07JAB-001020A o Holder Attachment, 50 mm, Offset 07MAB-PY3010A o Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket

5. Install the timing belt in a counterclockwise sequence, starting with the drive pulley. -1 Drive pulley (A). -2 Tensioner pulley (B). -3 Water pump pulley (C). -4 Camshaft pulley (D).

NOTE: o If you are installing the timing belt and the balancer belt, go to step 1. o If you are installing only the balancer belt, go to step

c

7. 1. Remove and clean the balancer belt drive pulley. 2. Clean the timing belt pulleys, and the upper and lower timing cover. 3. Set the crankshaft to TDC. Align the dimple (A) on the tooth of the timing belt drive pulley with the pointer (B) on the oil pump. A

6. Loosen and retighten the adjusting nut to tension the timing belt. 7. Clean any oil off both faces ofthe balancer belt drive pulley. 8. Check the lower cover rubber seal for cracks and other damage.

4. Clean the camshaft pulley and set it to TDC. -1 The "UP" mark (A) on the camshaft pulley should be at the top. -2 Align the TDC grooves (B) on the pulley with the top edge of the head. A

NOTE: o If the rubber seal is coming off, apply liquid gasket to the lower cover and reinstall the rubber seal. Wipe off any liquid gasket that is pressed out. o When replacing the rubber seal, clean the lower cover groove, cut the repair rubber seal to length, and put the rubber seal into the groove evenly. 9. Install the balancer belt drive pulley and the lower cover.

B

6-26

BACK

14. Check the camshaft pulley marks . • If the camshaft pulley marks are also at TOC, go to step 15. • If the camshaft pulley marks are not at TOC, remove the timing belt and repeat steps 3, 4 and

10. Temporarly install the crankshaft pulley and bolt. 11. Rotate the crankshaft pulley five or six turns counterclockwise to seat the timing belt on the pulleys.

5. 12. Adjustthe belttension. -1 Loosen the adjusting nut (A) 2/3-1 turn. -2 Rotate the crankshaft counterclockwise three teeth on the camshaft pulley (B). -3 Tighten the adjusting nut to 44 N·m (4.5 kgf.m, 33Ibf·ft).

A

15. Remove the crankshaft pulley and the lower cover. 16. Turn the crankshaft to TOC again. 17. Lock the timing belt adjuster arm in place with one of the 6 mm timing cover bolts. 18. Loosen the adjusting nut 2/3-1 turn, and make sure the balancer belt tensioner moves freely. Then push the tensioner up and retighten the adjusting nut. 13. Turn the crankshaft pulley so its TOC mark (A) lines up with the pointer (B).

A

(cant'd)

BACK

6-27

Cylinder Head Timing Belt and Balancer Belt Installation (cont'd) 19. Align the rear balancer shaft pulley with a 6 x 100 mm bolt (or equivalent). -1 Remove the bolt (A) and washer (B) from the maintenance hole (C). -2 Scribe a line on a 6 x 100 mm bolt, 74 mm (2.9 in) from the end. -3 Insert the bolt in the maintenance hole and into the hole in the balancer shaft (D) up to the line you scribed.

21. Install the balancer belt. Loosen the adjusting nut 2/3-1 turn to tension the balancer belt. Retighten the bolt. 22. Remove the 6 x 100 mm bolt from the maintenance hole and reinstall the sealing bolt. Tighten the bolt to 29 N·m (3.0 kgf·m, 22 Ib·ft). 23. Adjust the balancer belt. -1 Temporarily reinstall the crankshaft pulley. -2 Loosen the adjusting nut 2/3-1 turn. -3 Turn the crankshaft pulley 1 turn counterclockwise, then tighten the adjusting nut.

24. Remove the 6 mm bolt from the timing bolt adjuster arm.

25. Check the lower cover rubber seal for cracks and other damage. NOTE: • If the seal is coming off, reattach it with liquid gasket. Wipe off any excess liquid gasket. • When replacing the seal, clean out the groove in the cover, cut the repair strip to length, and press the new piece into the groove. 26. Remove the crankshaft pulley and reinstall the lower cover. 27. Install the rubber seal around the adjusting nut. 20. Align the groove (A) on the front balancer shaft with the pointer (B) on the oil pump housing as shown. B

28. Clean the crankshaft pulley bolt and washer. 29. Clean all oil off the inside face (A) of the crankshaft pulley, and apply lubricant to the pulley bolt (B) and washer (C).

/A

B

ml::[ o \

/

A

0

0 0 0 000 0 000 0 0 0 0

C

0: Clean

e: Lubricate

6-28

BACK

30. Install the crankshaft pulley, and hold with holder handle (A) and holder attachment (8).

35. Install the alternator bracket (see page 5-10).

A 07JAB-001020A

I

34. Install the cylinder head cover (see page 6-54).

36. Install the alternator (see page 4-32).

:7MAB-PV30'OA

37. Connect the alternator harness.

-~

38. Install and adjust the power steering pump belt (see page 17-12). 39. Install and adjust the alternator belt (see page 4-40).

'C

07 JAA-001 020A lor Commercially availablel

31. Tighten the bolt to 245 N·m (250 kgf·m, 181 Ibf·ft) with a torque wrench and 19 mm socket (C). Do not use an impact wrench.

40. Install the upper bracket (A), then tighten the bolt and nuts in the numbered sequence shown. 6x 1.0mm 12 N·m 11.2 kgf·m, 8.7Ibf·tt)

\

CD12 x 1.25 mm 54 N·m 15.5 kgf·m, 40Ibf·tt)

/

CD12 x 1.25 mm 54 N·m 15.5 kgf·m, 40Ibf·ft)

32. Install the dipstick and tube (A) with a new O-ring 8x 1.25 mm 22 N·m 12.2 kgf·m, 16Ibf·ft)

(8).

Y:x'oomm

~----

<.j

12 N·m 11.2 kgf·m,

,-I-a.

) 7 l b f ftl o

'.C'

_

"®12x1.25mm ~ 22 N·m (2.2 kgf·m, _. . 16Ibf·ft) ~

A

~-.-~

• ~--

~~~.

B

'-""

41. Install the stop (8). 33. Install the upper cover.

42. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion. 43. Enter the anti-theft code for the radio, then enter the customer's radio station presets.

6x 1.0mm 12 N·m (1.2 kgf.m, 8.7Ibf·ttl

BACK

6-29

Cylinder Head Cylinder Head Removal Engine removal is not required for this procedure. NOTE: • Use fender covers to avoid damaging painted surfaces. • To avoid damage, unplug the wiring connectors carefully while holding the connector portion. • To avoid damaging the cylinder head, wait until the engine coolant temperature drops below 100°F (38°C) before loosening the retaining bolts. • Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.

5. Remove the throttle cable (A) and cruise control cable (8) by loosening the locknuts (C), then slipping the cable ends out of the accelerator linkage. Take care not to bend the cable when removing it. Always replace any kinked cable with a new one.

1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative terminal. 3. Drain the engine coolant (see page 10-10). 6. Remove the breather hose (A) and Positive Crankcase Ventilation (PCV) hose (8).

4. Remove the intake air duct.

A

6-30

BACK

7. Relieve fuel pressure (see page 11-115).

10. Remove the Evaporative Emission (EVAP) canister hose (A), vacuum hose (B) and PIS hose clamp (C).

8. Remove the fuel feed hose (A) and fuel return hose

A

(B).

B

9. Remove the brake booster vacuum hose (A) and vacuum hoses (B).

C

11. Remove the three water bypass hoses (A).

B A

A

(cont'd)

BACK

6-31

Cylinder Head Cylinder Head Removal (cont'd) 14. Disconnect the alternator wire harness. -1 Pull up the lock (A), then release the wire harness tie (8). -2 Pull back the boot and remove the 6 mm nut (C).

-3 Disconnect the connector (D) from the alternator. A

D

13. Remove the alternator belt. -1 Loosen the alternator mounting bolt (A). -2 Loosen the alternator locknut (8). -3 Loosen the adjusting bolt (C). -4 Remove the alternator belt (D). A

c

6-32

B

D

BACK

15. Remove the upper radiator hose (A), lower radiator hose (8) and heater hose (C). A

18. Support the engine with a jack and wood block under the oil pan. 19. Remove the stop (A) and ground cable (8), then remove the upper bracket (C). S

~,

.. ','

I

"-,

-------.... 16. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold. • • • • • • • • • • • • • •

Four injector connectors Intake Air Temperature (lAT) sensor connector Idle Air Control (lAC) valve connector Throttle Position (TP) sensor connector Manifold Absolute Pressure (MAP) sensor connector Primary Heated Oxygen Sensor (primary H02S) connector (F23A 1, F23A5 engine) Air Fuel Ratio (A/F) sensor connector (F23A4 engine) Engine Coolant Temperature (ECT) sensor connector Radiator fan switch connector Coolant temperature gauge sending unit connector ('98-00 models) Exhaust Gas Recirculation (EGR) valve connector CKP/TDC sensor connector VTEC solenoid valve connector (F23A 1/F23A4 engines) VTEC oil pressure switch connector (F23A 1/ F23A4 engines)

20. Remove the cylinder head cover.

17. Remove the spark plug caps and distributor from the cylinder head.

(cont'd)

BACK

6-33

Cylinder Head Cylinder Head Removal (cont'd) 21. Remove the balancer belt and timing belt (see page 6-23).

24. Remove the intake manifold.

22. Remove the camshaft pulley (A) and back cover (B).

A

23. Remove the exhaust manifold cover (A), then remove the exhaust manifold (B). A

25. Remove the cylinder head bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.

\...~(!J

CYLINDER HEAD BOLT LOOSENING SEQUENCE:

®

®

®

CD

®

®

B

® 26. Remove the cylinder head.

6-34

BACK

Rocker Arm Assembly Removal

Cylinder Head Inspection for Warpage

1. Loosen the adjusting screws (A).

A NOTE: If camshaft-to-holder oil clearances (see page 640) are not within specifications, the cylinder head cannot be resurfaced. If camshaft-to-holder oil clearances are within specifications, check the cylinder head for warpage. Measure along the edges, and three ways across the center. o If warpage is less than 0.05 mm (0.002 in.) cylinder head resurfacing is not required. o If warpage is between 0.05 mm (0.002 in.) and 0.2 mm (0.008 in.), resurface cylinder head. o Maximum resurface limit is 0.2 mm (0.008 in.) based on a height of 100 mm (3.94 in.). A

Cylinder Head Height: Standard (New): 99.95-100.05 mm (3.935-3.939 in.)

2. Remove the bolts and the rocker arm assembly. -1 Unscrew the camshaft holder bolts 2 turns at a time, in a crisscross pattern, to prevent damaging the valves or rocker arm assembly. -2 When removing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the camshaft holders, the springs and the rocker arms on the shafts. CAMSHAFT HOLDER BOLT LOOSENING SEQUENCE:

o

C>

®

BACK

®

@

@®

6-35

Cylinder Head Rocker Arms and Shafts DisassemblyIReassembly - F23A 1, F23A4 Engines NOTE: o Identify parts as they are removed to ensure reinstallation in original locations. o Inspect the rocker shafts and rocker arms (see page 6-38). o The rocker arms must be installed in the same positions if reused. o When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders, springs and rocker arms on the shaft. o Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact points. o Bundle the rocker arms with rubber bands to keep them together as a set.

Letter 'A' is stamped on rocker arm.

EXHAUST ROCKER SHAFT EXHAUST ROCKER

~

aUG

E'

I

EXHAUST ROCKER ARMB

dUD

dO ..

• '1

ST

G /

QYY'{)

No.1 CAMSHAFT HOLDER

Q

/9 SP~~ /

p

TIMING PLATE INTAKE ROCKER ARM ASSEMBLY

6-36

"-

4

000

V Q

°0

Q

\

INTAKE ROCKER SHAFT

BACK

9

No.5 CAMSHAFT HOLDER

Rocker Arms and Shafts DisassemblyIReassembly - F23A5 Engine NOTE: o Identify parts as they are removed to ensure reinstallation in their original locations. o Inspect rocker shafts and rocker arms (see page 6-381. o The rocker arms must be installed in the same positions if reused. o When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders, springs and rocker arms on the shaft. o Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact points. EXHAUST ROCKER ARM A Letter 'A' stamped on rocker arm.

EXHAUST ROCKER ARM B Letter '8' stamped on rocker arm.

EXHAUST ROCKER SHAFT

10

\

000

0

000

000

o

01

o o

SPRING

10 INTAKE ROCKER ARM A Letter' A' stamped on rocker arm.

COLLAR

0

0

0

0

0

0

0

/

0

0

INTAKE ROCKER SHAFT

BACK

0

0

01 INTAKE ROCKER ARM B Letter '8' stamped on rocker arm.

6-37

Cylinder Head Rocker Arms and Shafts Inspection 1. Measure the diameter of the shaft at the first rocker location.

3. Measure the inside diameter of the rocker arm, and check it for an out-of-round condition. Rocker Arm-to-Shaft Clearance: Standard (New): 0.026 - 0.067 mm Intake: (0.0010-0.0026 in.) 0.018-0.054 mm Exhaust: (0.0007 - 0.0021 in.) 0.08 mm (0.003 in.) Service Limit:

2. Zero the gauge (A) to the shaft diameter.

Inspect rocker arm face for wear.

4. Repeat for all rockers and both shafts. If the clearance is over the limit, replace the rocker shaft and all overtolerance rocker arms. If any VTEC intake rocker arm needs replacement, replace all three rocker arms in that set (primary, mid, and secondary).

6-38

BACK

5. Inspect the rocker arm piston (A). Push it manually. If it does not move smoothly, replace the rocker arm set. NOTE: • When reassembling the primary rocker arm (B), carefully apply air pressure to its oil passage . • Apply oil to the pistons when reassembling.

B

6. Assemble each timing plate (A) and return spring (B) on its camshaft holder as shown.

B

/A

BACK

6-39

Cylinder Head Camshaft Inspection 4. Unscrew the camshaft holder bolts two turns at a time, in a crisscross pattern. Then remove the camshaft holders from the cylinder head.

NOTE: • Do not rotate the camshaft during inspection. • Remove the rocker arms and rocker shafts.

1. Put the camshaft and the camshaft holders on the cylinder head, then tighten the bolts to the specified torque. Specified torque: 8 mm bolts: 22 N·m (2.2 kgf·m, 16Ibf·ft) 6 mm bolts: 12 N·m (1.2 kgf·m, 8.7Ibf·ft) 6 mm bolts: @, @, @, @

5. Lift the camshaft out of the cylinder head, wipe them clean, then inspect the lift ramps. Replace the camshaft if any lobes are pitted, scored, or excessively worn. 6. Clean the camshaft journal surfaces in the cylinder head, then set the camshaft back in place. Place a plastigage strip across each journal. 7. Install the camshaft holders, then tighten the bolts to the specified torque as shown in step 1.

®

(j)

®

CD

8. Remove the camshaft holders. Measure the widest portion of plastigage on each journal. • If the camshaft-to-holder clearance is within limits, go to step 10. • If the camshaft-to-holder clearance is beyond the service limit and the camshaft has been replaced, replace the cylinder head. • If the camshaft-to-holder clearance is beyond the service limit and the camshaft has not been replaced, go to step 9.

®@

2. Seat the camshaft by pushing it toward the distributor end of the cylinder head. 3. Zero the dial indicator against the end of the distributor drive, then push the camshaft back and forth and read the end play. Camshaft End Play: Standard (New): 0.05-0.15 mm (0.002-0.006 in.) Service Limit: 0.5 mm (0.02 in.)

6-40

BACK

Camshaft-to-Holder Oil Clearance: Standard (New): 0.050-0.089 mm (0.0020 - 0.0035 in.) Service Limit: 0.15 mm (0.006 in.)

9. Check the total runout with the camshaft supported on V-blocks. • If the total runout of the camshaft is within the service limit, replace the cylinder head. • If the total runout is beyond the service limit, replace the camshaft and recheck the camshaftto-holder oil clearance. Ifthe oil clearance is still out of tolerance, replace the cylinder head.

10. Measure cam lobe height.

Camshaft Total Runout: Standard (New): 0.03 mm (0.001 in.) max. Service Limit: 0.04 mm (0.002 in.)

Cam lobe Height Standard (New): INTAKE EXHAUST 37.775 mm 38.366 mm (1.4872 in.) (1.5105 in.) MID 39.725 mm (1.5640 in.) SEC 34.481 mm (1.3575 in.) F23A5 engine 38.339 mm 37.716 mm (1.5094 in.) (1.4849 in.) PRI: Primary MID: Mid SEC: Secondary IN: Intake EX: Exhaust T/B: Timing Belt F23A11 F23A4 engines

PRI

PRI

MID

SEC

EX

IN

EX

Rotate camshaft while measuring.

~T/B

F23A1/F23A4 engines:

Inspect this area for wear.

BACK

6-41

Cylinder Head Valves, Springs and Valve Seals Removal 3. Install the valve guide seal remover.

Identify the valves and valve springs as they are removed so that each item can be reinstalled in its original position. 1. Using an appropriate-sized socket (A) and plastic mallet (B), lightly tap the valve retainer to loosen the valve keepers.

4. Remove the valve seal.

2. Install the spring compressor. Compress the spring and remove the valve keepers.

6-42

BACK

Valve Inspection

Valve Stem-to-Guide Clearance Inspection

Measure the valve in these areas. Intake Valve Dimensions A Standard (New,: B Standard (New,: C Standard (New,: C Service Limit: D Standard (New,: D Service Limit:

33.85-34.15 mm (1.333-1.344 in.' 114.85-115.15 mm (4.522 - 4.533 in.' 5.485 -5.495 mm (0.2159-0.2163 in.) 5.455 mm (0.2148 in.' 0.85-1.15 mm (0.033-0.045 in.' 0.65 mm (0.026 in.'

1. Slide the valve out of its guide about 10mm, then measure the guide-to-stem clearance with a dial indicator while rocking the stem in the direction of normal thrust (wobble method'. • If the measurement exceeds the service limit, recheck it using a new valve. • If the measurement is now within the service limit, reassemble using a new valve. • If the measurement with a new valve still exceeds the service limit, go to step 2. Intake Valve Stem-to-Guide Clearance: Standard (New': 0.04-0.09 mm (0.002 - 0.004 in.' Service Limit: 0.16 mm (0.006 in.)

Exhaust Valve Dimensions A Standard (New,: 28.85 - 29.15 mm 11.136-1.148 in.' B Standard (New,: 112.85-113.15 mm (4.443 - 4.455 in.) C Standard (New): 5.450-5.460 mm (0.2146-0.2150 in.' C Service Limit: 5.420 mm (0.2134 in.' D Standard (New,: 1.05-1.35 mm (0.041-0.053 in.' D Service Limit: 0.95 mm (0.037 in.'

Exhaust Valve Stem-to-Guide Clearance: Standard (New): 0.11- 0.16 mm (0.004 - 0.006 in.' Service Limit: 0.24 mm (0.009 in.'

-II~"-D---- B - - - - - c

f ~I-I----'-:

__

-1-LJIOJ 2. Subtract the 0.0. of the valve stem, measured with a micrometer, from the 1.0. of the valve guide, measured with an inside micrometer or ball gauge. Take the measurements in three places along the valve stem and three places inside the valve guide. The difference between the largest guide measurement and the smallest stem measurement should not exceed the service limit. Intake Valve Stem-to-Guide Clearance: Standard (New,: 0.020-0.045 mm (0.0008-0.0018 in.' Service Limit: 0.08 mm (0.003 in.' Exhaust Valve Stem-to-Guide Clearance: Standard (New': 0.055-0.080 mm (0.0022-0.0031 in.' Service Limit: 0.12 mm (0.005 in.'

BACK

6-43

Cylinder Head Valve Guide Replacement Special Tools Required • Valve Guide Driver, 5.5 mm 07742-0010100 • Valve Guide Reamer, 5.5 mm 07HAH-PJ7010B 1. Modify a commercially available air-impact valve guide driver (A) to the dimensions shown. In most cases, the same procedure can be done using the special tool and a conventional hammer.

I

A

4. Working from the camshaft side, use the driver and an air hammer to drive the guide about 2 mm (0.1 in.) towards the combustion chamber. This will knock off some of the carbon and make removal easier. Hold the air hammer directly in line with the valve guide to prevent damaging the driver. 5. Turn the head over and drive the guide out toward the camshaft side of the head.

S.3mm 10.21 in.)

-0 0

1++

(,,----I

I-- 87 mm - - l - 57 mm ---l Tt \

13.43 in.) .

I.

12.24 in.)

.

I

10.8mm (0.42 in.)

2. Select the proper replacement guides, and chill them in the freezer section of a refrigerator for about an hour. 3. Use a hot plate or oven to evenly heat the cylinder head to 300°F (150°C). Monitor the temperature with a cooking thermometer. Do not get the head hotter than 300°F (150°C); excessive heat may loosen the valve seats.

6. If a valve guide won't move, drill it out with a 8 mm (5/16 inch) bit, then try again. Drill guides only in extreme cases; you could damage the cylinder head if the guide breaks. 7. Remove the new guide(s) from the freezer, one at a time, as you need them.

6-44

BACK

8. Apply a thin coat of clean engine oil to the outside of the new valve guide. Install the guide from the camshaft side of the head; use the special tool to drive the guide in to the specified installed height (A) of the guide (8). If you have all 16 guides to do, you may have to reheat the head.

9. Coat both reamer and valve guide with cutting oil. 10. Rotate the reamer clockwise the full length ofthe valve guide bore. 07HAH-PJ70108

Valve Guide Installed Height: 21.20-22.20 mm (0.835-0.874 in.) Intake: Exhaust: 20.63-21.63 mm (0.812 -0.852 in.)

11. Continue to rotate the reamer clockwise while removing it from the bore. 12. Thoroughly wash the guide in detergent and water to remove any cutting residue.

13. Check the clearance with a valve (see page 6-43). Verify that the valve slides in the intake and exhaust valve guides without exerting pressure.

BACK

6-45

Cylinder Head Valve Seat Reconditioning If the valve guides are worn (see page 6-43), replace them (see page 6-44) before cutting the valve seats. 1. Renew the valve seats in the cylinder head using a valve seat cutter.

2. Carefully cut a 45° seat, removing only enough material to ensure a smooth and concentric seat. 3. Bevel the upper edge of the seat with a 30° cutter and the lower edge of the seat with a 60° cutter. Check the width of the seat and adjust accordingly. 4. Make one more very light pass with the 45° cutter to remove any possible burrs caused by the other cutters. Valve Seat Width: Standard (New): 1.25 -1.55 mm (0.049-0.061 in.) 2.00 mm (0.079 in.) Service Limit:

6-46

BACK

5. After resurfacing the seat, inspect for even valve seating: Apply Prussian Blue compound (A) to the valve face. Insert the valve in its original location in the head, then lift it and snap it closed against the seat several times.

6. The actual valve seating surface (B), as shown by the blue compound, should be centered on the seat. o If it is too high (closer to 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. o If 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 restore seat width. NOTE: The final cut should always be made with the 45° cutter.

7. Insert the intake and exhaust valves in the head and measure valve stem installed height (A). Intake Valve Stem Installed Height: Standard (New): 46.75-47.55 mm (1.841-1.872 in.) 47.80 mm (1.882 in.) Service limit: Exhaust Valve Stem Installed Height: Standard (New): 46.68-47.48 mm (1.838-1.869 in.) 47.73 mm (1.879 in.) Service limit:

8. If valve stem installed height is over the service limit, replace the valve and recheck. If it is still over the service limit, replace the cylinder head; the valve seat in the head is too deep.

BACK

6-47

Cylinder Head Valves, Springs and Valve Seals Installation 1. Coatthe valve stems with engine oil. Install the valves in the valve guides.

5. Install the valve spring and valve retainer. Place the end of the valve spring with closely wound coils toward the cylinder head.

2. Check that the valves move up and down smoothly. 6. Install the valve spring compressor. Compress the spring and install the valve keepers.

3. Install the spring seats on the cylinder head. 4. Install the new valve seals (A) using the valve guide seal installer (8). NOTE: Exhaust valve seal (C) has a black spring (D), and intake valve seal (E) has a white spring (Fl. They are not interchangeable.

E

c B

7. Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper seating of the valve and valve keepers. Tap the valve stem only along its axis so you do not bend the stem. A

\

6-48

BACK

Camshaft/Rocker Arms, Camshaft Seal, and Pulley Installation 5. Apply liquid gasket to the head mating surfaces (the shaded areas) of the No.1 and No.5 camshaft holders.


- Seal Guide 07 NAG-PT001OA - Installer Cup 07NAF-PT0010A -Installer Shaft 07NAF-PT0020A

No.5

NOTE: - To prevent the rocker arm assembly from coming apart, leave the camshaft holder bolts in the holes.

No.1

1. After wiping down the camshaft and the journals in the cylinder head, lubricate both surfaces and install the camshaft. 2. Clean and install the oil control orifice (A) with a new O-ring (B).

6. Set the rocker arm assembly in place and loosely install the bolts. Make sure that the rocker arms are properly positioned on the valve stems.

c

7. Install the camshaft oil seal (A) using the special tools as shown. 07NAG·PT0010A Apply oil.

3. Turn the camshaft until its keyway (C) is facing up. (No.1 piston TDC).

II~(~~ 7F~1M Ie) A

4. Loosen all the valve adjusting screws.

07NAF-PT0020A

07NAF-PT0020A

OA

(cont'd)

BACK

6-49

Cylinder Head Camshaft/Rocker Arms, Camshaft Seal, and Pulley Installation (cont'd) 8. Make sure all the rocker arms are aligned with the valves.

10. Check the back cover rubber seal for cranks and other damage.

9. Tighten each bolt two turns at a time, in the sequence shown below, to ensure that the rockers do not bind on the valves. Specified torque: 8 mm bolts: 22 N·m (2.2 kgf·m, 16Ibf·t) 6 mm bolts: 12 N·m (1.2 kgf·m, 8.7Ibf·t) 6 mm bolts: @, @, @, @

NOTE:

• If the rubber seal is coming off, reattach it with liquid gasket. Wipe off any excess liquid gasket. • When replacing the seal, clean the lower cover groove, cut the repair strip to length, and press the new piece into the groove evenly. • After installing the rubber seal, check the joints. Apply liquid gasket if there is any gap or opening. 11. Install the back cover (A).

®

(J)

®

CD

10x 1.25mm 59 N·m (6.0 kgf·m,

®@

43lbf·ftl 6x 1.0 mm 12 N·m (1.2 kgf·m,

8.7Ibf·ftl

12. Install the camshaft pulley (8) onto the camshaft, then tighten the retaining bolt to the torque shown.

6-50

BACK

Cylinder Head Installation 1. Clean the cylinder head and block surfaces. 2. Install the cylinder head gasket (A) and dowel pins (8) on the cylinder block. Always use a new cylinder head gasket.

4. Clean the camshaft pulley and set it to TOC. -1 The "UP" mark (A) on the camshaft pulley should be at the top. -2 Align the TOC grooves (8) on the pulley with the top edge of the head. A

B 5. Install the cylinder head on the block. 6. Measure the diameter of each cylinder head bolt at point A and point 8. 3. Set the timing belt drive pulley to TOC. Align the dimple (A) on the tooth of the timing belt drive pulley with the pointer (8) on the oil pump.

B 70 mm 12.8 in.) A 45 mm 11.8 in.)

7. If either diameter is less than 11.3 mm (0.44 in.), replace the cylinder head bolt. 8. Apply clean engine oil to the bolt threads and under the bolt heads of all the cylinder head bolts.

(cont'd)

BACK

6-51

Cylinder Head Cylinder Head Installation (cont'd) 9. Tighten the cylinder head bolts. Tighten the cylinder head bolts is sequence to 29 N·m (3.0 kgf·m, 22 Ibf·ft). Use a beam-type torque wrench. When using a preset type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it. CYLINDER HEAD BOLTS TORQUE SEQUENCE:

10. Mark the bolt head (A) and the cylinder head (B) as shown.

11. Tighten the cylinder head bolts until the mark on the bolt head aligns with the second mark on the cylinder head (turn the bolt 180°). If you are using a new cylinder head bolt, tighten the bolt to the the third mark (270°).

8x 1.25 mm -'---...A.I',~

22 N·m (2.2 kgf·m, 23 Ibf·ft)

8X1/~ \z~c

22 N.m (2.2 kgf.m, 23 Ibf.ft)

6-52

BACK

22 N·m (2.2 kgf·m, 23 Ibf·ft)

13. Install the exhaust manifold (A) and tighten the new self-locking nuts (8) in a crisscross pattern in two or three steps, beginning with the inner nuts. Always use a new exhaust manifold gasket (e).

22 N.\m. 1....·ftl

8x 1.25 mm

A

B 8x1.25mm 31 N·m (3.2 kgf·m, 23lbf·ftl

14. Install the exhaust pipe A with a new gasket (D) and new self-locking nuts (E). 15. Install the exhaust manifold bracket (F) and cover (G).

16. Install the timing belt (see page 6-26). 17. Adjustthe valve clearance (see page 6-14).

BACK

6-53

Cylinder Head Cylinder Head Cover Installation 1. Thoroughly clean the head cover gasket and the groove. 2. Install the head cover gasket (A) in the groove of the cylinder head cover (B). Seat the head cover gasket in the recesses for the camshaft first, then work it into the groove around the outside edges. Make sure the head cover gasket is seated securely in the corners of the recesses (C) with no gap.

e

B

..-----e

6x 1.0mm 9.8 N·m (1.0 kgf.m, 7.2Ibf·ft)

I

/\

e

5. Hold the head cover gasket in the groove by placing your fingers on the camshaft holder contacting surfaces (top of the semicircles). Set the spark plug seal (A) on the spark plug tube. Once the cylinder head cover (B) is on the cylinder head, slide the cover slightly back and forth to seat the head cover gasket.

B

3. Check that the mating surfaces are clean and dry. 4. Apply liquid gasket, part No. 08718-0001 or 087180003, to the head cover gasket at the four corners of the recesses (A). NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue.

A

6-54

BACK

6. Inspect the cover washers (C). Replace any washer that is damaged or deteriorated.

CKPITOC Sensors Replacement 7. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence, to 9.8 N·m (1.0 kgf·m, 7.2 Ibf·ft).

CD

®

1. Remove the balancer belt (see page 6-23). 2. Remove the balancer belt drive pulley. 3. Disconnect the CKP(TDC sensors connector (A), then remove the CKP(TDC sensors (8). A

@

/

.------....,

® 8. Check that all tubes, hoses and connectors are installed correctly. 9. After assembly, wait at least 30 minutes before filling the engine with oil. 10. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 4. Install the CKP(TDC sensors in reverse order of removal. 5. Install the balancer belt (see page 6-26).

BACK

6-55

BACK

Engine Mechanical Engine Block Special Tools ................................................................. Component Location Index ......................................... Flywheel Removal and Installation ............................. Drive Plate Removal and Installation .......................... Connecting Rod and Crankshaft End Play Inspection .................................................................. Crankshaft Main Bearing Replacement ...................... Connecting Rod Bearing Replacement ...................... Balancer Shafts Inspection .......................................... Crankshaft, Piston and Balancer Shaft Removal ..................................................................... Crankshaft Inspection .................................................. Block and Piston Inspection ........................................ Cylinder Honing ............................................................ Piston, Pin and Connecting Rod Replacement .......... Piston Ring Replacement ............................................. Piston Installation ......................................................... Connecting Rod Bolt Inspection .................................. Crankshaft and Balancer Shafts Installation .............. Pulley End Crankshaft Seallnstallation-In-car ........... Balancer Shaft Seals Installation-in-car .............•....... Transmission End Crankshaft Seal Installation-In-car ......................................................

BACK

7-2 7-3 7-7 7-7 7-8 7-9 7-13 7-15 7-18 7-21 7-22 7-24 7-25 7-28 7-30 7-31 7-32 7-37 7-37 7-38

Engine Block Special Tools Ref.No.

CD ® ® CD ® ®

Tool Number 07GAF-SE00200 07 LAB-PVOO 100 07 LAD-PT30 1OA 077 46-0030300 077 49-0010000 07948-5B00101 or 07VAD-P8A010A

Description Hub Assembly Guide Attachment Ring Gear Holder Seal Driver Attachment, 30 mm 1.0. Driver Driver Attachment

CD

~ ~ ~ ...

®

7-2

.......

J

®

BACK

Qty 1 1 1 1 1 1

Compo nent Location Index

OIL PAN

Installati~ n, page 7-18 page 7-32

Removal

OIL SCREEN

AfT DRIVE PLATE /

/~~rlqVE PLATE BOLT

~/ ~@U

uesequ page 7-7 ence,

~ ~~NBEARING

WASHER

DOWEL PIN

(cont'd)

BACK

7-3

Engine Block Component Location Index (cont'd)

CRANKSHAFT End play, page 7-8 Runout, Taper and Out-of-Round, page 7-21 Installation, page 7-32

MAIN BEARINGS Oil clearance, page 7-9 Selection, page 7-9

THRUST WASHERS ENGINE BLOCK END COVER

I

BALANCER GEAR CASE

~

o

~

CRANKSHAFT OIL SEAL TRANSMISSION END Installation, page 7-32 and page 7-38

BALANCER DRIVEN GEAR

CRANKSHAFT OIL SEAL, PULLEY END Installation, page 7-37 and page 8-7

7-4

BACK

BALANCER SHAFT BEARINGS Inspection, page 7-15

FRONT BALANCER SHAFT

REAR BALANCER SHAFT End play, page 7-15 Runout, Taper and Out-of-Round, page 7-15 Installation, page 7-32

(cont'd)

BACK

7-5


~SNAPRING

~

---J.Q~

~-/:.

O-~ PISTON RINGS Replacement, page 7-28 Measurement, page 7-28 Alignment, page 7-28

~

Q

PISTON Removal, page 7-18 Measurement, page 7-22

CONNECTING ROD End play, page 7-8 Small end measurement, page 7-25

PISTON PIN Removal, page 7-25 Installation, page 7-25 Inspection, page 7-25

ENGINE BLOCK Cylinder bore inspection, page 7-22 Warpage inspection, page 7-22 Cylinder bore honing, page 7-24 Ridge removal, page 7-18

~~DOWEL~N f\

______ CONNECTING ROD BEARING CAP

~.

~______

CONNECTING ROD BEARINGS

Clearance, page 7-13 Selection, page 7-13

7-6

I ~

~

____ CONNECTING ROD BOLT Inspection, page 7-31

______

BACK

Tightening, page 7-32

Flywheel Removal and Installation

Drive Plate Removal and Installation

Special Tools Required Ring Gear Holder 07LAB-PV00100 1. Remove the transmission (see page 14-114). 1. Remove the transmission (see page 13-4). 2. Remove the pressure plate and clutch disk. 3. Remove the 8 flywheel bolts, then separate the flywheel from the crankshaft flange. After installation, tighten the bolts in the sequence shown.

2. Remove the 8 drive plate bolts, then separate the drive plate from the crankshaft flange. After installation, tighten the bolts in the sequence shown.

07LAB-PV00100

07LAB-PV00100

~ 3. Install the transmission (see page 14-119).

/

Inspect ring gear teeth for wear or damage.

12x 1.0mm 103 N·m (10.5 kgf.m,

76Ibf·ft) 4. Install the transmission (see page 13-10).

BACK

7-7

Engine Block Connecting Rod and Crankshaft End Play Inspection 1. Remove the oil pump (see page 8-8). 2. Remove the baffle plate (see step 13 on page 7-19). 3. Measure the connecting rod end play with a feeler gauge between the connecting rod and crankshaft.

5. Push the crankshaft firmly away from the dial indicator, and zero the dial against the end of the crankshaft. Then pull the crankshaft firmly back toward the indicator; the dial reading should not exceed the service limit. Crankshaft End Play: Standard (New): 0.10-0.35 mm (0.004-0.014 in.' Service Limit: 0.45 mm (0.018 in.)

Connecting Rod End Play: Standard (New): 0.15-0.30 mm (0.006-0.012 in.' Service Limit: 0.40 mm (0.016 in.)

4. If the connecting rod end play is out-of-tolerance, install a new connecting rod, and recheck. If it is still out-of-tolerance; replace the crankshaft (see page 7-18).

7-8

6. If the end play is excessive, replace the thrust washers and recheck. If it is still out-of-tolorance, replace the crankshaft.

BACK

Crankshaft Main Bearing Replacement Main Bearing Clearance Inspection

JAPAN - Produced: F23A1-2500001F23A4-2500001 Standard (New): No. 1,4: 0.013-0.037 mm (0.0005-0.0015 in.) No.2: 0.021-0.045 mm (0.0008-0.0018 in.) No.3: 0.025-0.049 mm (0.0010-0.0019 in.) No.5: 0.009-0.033 mm (0.0004-0.0013 in.) Service Limit: No. 1,4: 0.045 mm (0.0018 in.) No.2: 0.050 mm (0.0020 in.) No.3: 0.055 mm (0.0022 in.) No.5: 0.040 mm (0.0016 in.)

1. To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.

2. Clean each main journal and bearing half with a clean shop towel.

3. Place one strip of plastigage across each main journal. NOTE: If the engine is still in the car when you bolt the main cap down to check clearance, the weight of the crankshaft and flywheel will flatten the plastigage further than just the torque on the cap bolt and give you an incorrect reading. For an accurate reading, support the crank with a jack under the counterweights, and check only one bearing at a time.

4. Reinstall the bearings and caps, then torque the bolts to 69 N·m (7.0 kgf·m, 51 Ibf·ft). NOTE: Do not rotate the crankshaft during inspection.

5. Remove the caps and bearings again, and measure the widest part of the plastigage.

Main 8earing-to-Journal Oil Clearance: USA - Produced: F23A1-1000001-,2000001-, 3000001-, 4000001F23A4 -1000001-,2000001-,3000001-, 4000001F23A5 -1000001-,2000001- ,3000001-, 4000001MEXICO- Produced: F23A1-3400001-, 4400001F23A4-3400001-, 4400001Standard (New): No.1, 2,4:0.021-0.045 mm (0.0008-0.0018 in.) No.3: 0.025-0.049 mm (0.0010-0.0019 in.) No.5: 0.009-0.033 mm (0.0004-0.0013 in.) Service Limit: No.1, 2, 4:0.050 mm (0.0020 in.) No.3: 0.055 mm (0.0022 in.) No.5: 0.040 mm (0.0016 in.)

JAPAN - Produced: F23A 1-3500001-, 4500001 F23A4-3500001- , 4500001F23A5-3500001-, 4500001 Standard (New): No. 1,2: 0.025-0.049 mm (0.0010-0.0019 in.) No.3: 0.021-0.045 mm (0.0008-0.0018 in.) No.4: 0.013-0.037 mm (0.0005-0.0015 in.) No.5: 0.009-0.033 mm (0.0004-0.0013 in.) Service Limit: No. 1,2: 0.055 mm (0.0022 in.) No.3: 0.050 mm (0.0020 in.) No.4: 0.045 mm (0.0018 in.) No.5: 0.040 mm (0.0016 in.)

6. If the plastigage measures too wide or too narrow, (remove the engine if it's still in the car), remove the crankshaft, and remove the upper half of the bearing. Install a new, complete bearing with the same color code(s), and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance. 7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. (cont'd)

BACK

7-9

Engine Block Crankshaft Main Bearing Replacement (cont'd) Main Bearing Selection

Main Journal Code Locations

Crankshaft Bore Code Location 1. Numbers or Letters or Bars have been stamped on the end of the block as a code for the size of each of the 5 main journal bores. Write down the crank bore codes. If you can't read the codes because of accumulated dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

2. The Main Journal Codes are stamped in 1 of 2 locations: either on the side of the crankshaft next to the main journals, or on the No.1 web. Main Journal Code Locations (Numbers or Bars)

Main Journal Code Locations (Numbers or Bars)

No. S BORE (DRIVE PLATE END)

No.1 JOURNAL (PULLEY END)

7-10

BACK

No. S·JOURNAL (DRIVE PLATE END)

3. Use the crank bore codes and crank journal codes to select the appropriate replacement bearings from the following table. NOTE: • Color code is on the edge of the bearing . • When using bearing halves of different colors, it does not matter which color is used in the top or bottom.

JAPAN-Produced: F23A 1-2500001F23A4-2500001No.1,4Journals: Bearing Identification Color code is on the edge of the bearing. - - - -... Smaller bearing (Thicker)

USA-Produced: F23A1-1000001-, 2000001-, 3000001-,4000001F23A4-1 000001-, 2000001-, 3000001-,4000001F23A5-1 000001-, 2000001-, 3000001-,4000001MEXICO-Produced: F23A 1-3400001-,4400001F23A4-3400001-,4400001-

Rod Journal code

Crank bore code

1 or I

Red

2 or II

Red! Pink

3 or III

Pink

Yellow

Pink

Yellow

Yellow! Green

Pink

Yellow

Yellow! Green

Green

4 or 1111

Yellow

Yellow! Green

5 or 11111

Yellow! Green

6 or 111111

Green

Smaller main journal

Yellow

20rll

Yellow! Green Green

3 or III

Green

4 or 1111

Green

Brown

Green

Brown

Brown! Black

Brown

Brown! Black

Black

Green! Brown

Green! Brown

Brown

Green! Brown

Brown

Brown! Black

Green! Brown

Brown

Brown! Black Black

5 or 11111

Brown

Brown! Black Black

6 or 111111

Brown! Black Black

- - - - I... Smaller bearing (Thicker)

Red! Pink

Yellow! Green Green

1 or I


Black! Blue

Black! Blue Blue

Smaller bearing (Thicker)

No.2, 3, 5 Journals: Bearing Identification Color code is on the edge of the bearing. - - -.....~Smaller bearing (Thicker)


1 or I

Pink

Pink! Yellow

Yellow

20rll

Pink! Yellow

Yellow

Yellowl Green Green

3 or III

Yellow

Yellow! Green Green

4 or 1111

Yellow! Green Green

5 or 11111

Green

6 or 111111

Green! Brown


Yellow! Green

Green! Brown

Green! Brown

Brown

Green! Brown

Brown

Brown! Black

Brown

Brownl Black Black


(cont'd)

BACK

7-11

Engine Block Crankshaft Main Bearing Replacement (cont'd) No.4 Journal: Bearing Identification

JAPAN-Produced: F23A 1-3500001-,4500001F23A4-3500001-,4500001F23A5-3500001-,4500001-

Color code is on the edge of the bearing.

No.1, 2 Journals: Bearing Identification Color code is on the edge of the bearing.

10rl

Yellow

Yellow! Green Green

20rll Yellow Yellow! Green

Pink

Pink

2 or II

Pink

Pink! Yellow

Yellow

3 or '"

Pink! Yellow

Yellow

Yellow! Green Green

4 or 1111

Yellow

Yellow! Green Green

5 or "'"

Yellow! Green Green

1 or I

"

Pink! Yellow

Green

6 or """


Green! Brown

Green! Brown Brown

- --- ... __.. _-

._----

Green! Brown

--.--_.- .. _.-

-

--

Green! Brown

---

Brown

--- --

.

Green! Brown

Brown

Brown! Black Black

3 or '"

Green

4 or I'"

Green! Brown

Brown

Brown

Brown! Black Black

__ ..

Brown! Black --

5 or "'"

Green! Brown

Black! Blue 1---

,r Brown

Brown! Black Black

6 or 1111"


Brown! Black


Yellow! Green Green

---

-----

Black! Blue

Blue

Yellow

Yellow! Green


No.5 Journal: Bearing Identification Color code is on the edge of the bearing.

No.3 Journal: Bearing Identification Color code is on the edge of the bearing.

10rl 20rll 30r"l

r

Yellow

Yellow

Yellow! Green Green

Yellow! Green Green

Yellow! Green Green Green! Brown

Green! Brown

Brown

Green! Brown

Brown

Brown! Black

Brown! Black Black

40r""

Green

50r""1

Green! Brown

Brown

6 or 111111

Brown

Brown! Black Black


7-12

Pink! Yellow

Black! Blue


BACK

Pink! Yellow

1 or I

Pink

20rll

Pink! Yellow

3 or '"

Yellow

40r""

Yellow! Green Green

5 or "'''

Green

60rl""

Green! Brown



Yellow! Green Green -Yellow! Green! Green Green Brown Yellow

Green! Brown

Brown

Green! Brown

Brown

Brown! Black

Brown

Brown! Black Black

Connecting Rod Bearing Replacement Rod Bearing Clearance Inspection

Rod Bearing Selection

1. Remove the connecting rod cap and bearing half.

1. Inspect each connecting rod for cracks and heat damage.

2. Clean the crankshaft rod journal and bearing half with a clean shop towel.

Connecting Rod Big End Bore Code locations

3. Place plastigage across the rod journal.

2. Each rod has a tolerance range from 0 to 0.024 mm (0.0009 in), in 0.0006 mm (0.0002 in) increments, depending on the size of its big end bore. It's then stamped with a number or bar (1, 2, 3 or 4/1, II, III, or 1111) indicating the range. You may find any combination of numbers and bars in any engine, (Half the number or bar is stamped on the bearing cap,the other half on the rod.).

4. Reinstall the bearing half and cap, and torque the bolt (see page 7-32). NOTE: Do not rotate the crankshaft during inspection. 5. Remove the rod cap and bearing half and measure the widest part of the plastigage. Connecting Rod Bearing-to-Journal Oil Clearance: Standard (New): 0.021-0.049 mm (0.0008-0.0019 in.) Service Limit: 0.060 mm (0.0024 in.)

If you can't read the code because of an accumulation of oil and varnish, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

6. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color code(s), and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance. 7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearing, replace the crankshaft and start over.

(cont'd)

BACK

7-13

Engine Block Connecting Rod Bearing Replacement (cont'd) 4. Use the big end bore codes and rod journal codes to select appropriate replacement bearings from the following table.

Connecting Rod Journal Code Locations

3. The Connecting Rod Journal Codes are stamped in 2 locations: either on the side of the crankshaft next to the rod journals, or on the No.1 web.

NOTE: Color code is on the edge of the bearing. - - - - - - - - i... Larger big end bore

Connecting Rod Journal Code Locations (Letters or Bars) Rod Journal code

Connecting Rod Journal Code Locations (Letters or Bars)


7-14

Aorl

Red

Pink

Yellow

Green

B or II

Pink

Yellow

Green

Brown

C or III

Yellow

Green

Brown

Black

o or 1111

Green

Brown

Black

Blue

Smaller rod journal

No.4 JOURNAL (DRIVE PLATE ENOl

BACK

12 or II 1 3 or III 14 or 1111 1 or I Big end bore - - -....~ Smaller bearing (Thicker) code


Balancer Shafts Inspection NOTE: Inspect the balancer shaft end play before removing the right side cover and the balancer gear case (see page 7-18).

4. Remove the balancer shafts (see page 7-18). 5. Clean the balancer shafts, and Inspect the surface of each balancer shaft journal and bearing.

1. Remove the oil pan and the right side cover (see page 7-18). 2. Push the front balancer shaft firmly away from the dial indicator. Zero the dial against the end of the balancer shaft, then pull the shaft firmly back toward the indicator. If end play is excessive, inspect the retainer and thrust surfaces on the shaft.

6. Replace the bearing or balancer shaft if there is wear, damage or discoloration on the surface of the bearing or the balancer shaft journal. A mirror-like surface is normal. When replacing the rear No.1 bearing, be sure to replace the oil pump housing with a new one. 7. Measure taper at the edges of each journal. The difference between measurements on each journal must not exceed the standard.

NOTE: The thickness of the retainer must not be changed either by grinding or shimming. Front Balancer Shaft End Play Standard (New): 0.10-0.40 mm (0.004-0.016 in.)

Journal Taper Standard (New): 0.005 mm (0.0002 in.)

3. Push the rear balancer shaft firmly away from the dial indicator. Zero the dial against the end of the balancer shaft, then pull the shaft firmly back toward the indicator. If end play is excessive, inspect the thrust washer and the thrust surfaces on the driven gear and the oil pump body. NOTE: The thickness of the thrust washer must not be changed either by grinding or shimming.

A

A1

B1 ~

)

(cont'd)

BACK

7-15

Engine Block Balancer Shafts Inspection (cont'd) 8. Measure runout on the No.2 journal (A) of each balancer shaft to make sure the balancer shafts are not bent. Balancer Shaft Total Indicated Runout Standard (New): 0.02 mm (0.001 in.) 0.03 mm (0.001 in.) Service Limit:

\

A

~~ B

\ D

9. Measure the diameters of the journals on the front balancer shaft (A) and the rear balancer shaft (B). Journal Diameter Standard (New): No.1 journal: Front (C): 42.722-42.734 mm (1.6820 -1.6824 in.) Rear (D): 20.938 - 20.950 mm (0.8243-0.8248 in.) No.2 journals front (E) and rear (F): 38.712-38.724 mm (1.5241 -1.5246 in.) No.3 journals front (G) and rear (H): 34.722-34.734 mm (1.3670-1.3675 in.)

10. Remove the crankshaft, the pistons and the other parts from the block, then clean the balancer shaft journal bearings in the block and the oil pump housing with a clean shop towel. 11. Check the surface of the bearings; if there is wear, damage or dicoloration, replace the bearings or the oil pump housing.

Service Limit: No.1 journal: 42.71 mm (1.681 in.) Front (C): Rear (D): 20.92 mm (0.824 in.) No.2 journals front (E) and rear (F): 38.70 mm (1.524 in.) No.3 journals front (G) and rear (H): 34.71 mm (1.367 in.)

7-16

BACK

12. Measure the inner diameters of the bearings for the front balancer shaft (A) and the rear balancer shaft (B).

Bearing Inner Diameter Standard (New): No.1 journal: 42.800-42.820 mm Front (C): (1.6850-1.6858 in.) Rear (D): 21.000-21.013 mm (0.8268-0.8273 in.) No.2 journals front (E) and rear (F): 38.800 - 38.820 mm (1.5276-1.5283 in.' No.3 journals front (G) and rear (H): 34.800 - 34.820 mm (1.3701 -1.3709 in.) Service Limit: No.1 journal: Front (C): 42.83 mm 11.686 in.) 21.02 mm (0.828 in.) Rear (D): No.2 journals front (E) and rear (F): 38.83 mm (1.529 in.) No.3 journals front (G) and rear (H): 34.83 mm (1.371 in.) C

E

G

13. Calculate the shaft-to-bearings oil clearances. A

BEARING I.D. -JOURNAL O.D.= OIL CLEARANCE Shaft-to-Bearings Oil Clearances Standard (New): No. 1 front journal, No.3 front and rear journals: 0.066-0.098 mm (0.0026-0.0039 in.) No.2 front and rear journals: 0.076-0.108 mm (0.0030-0.0043 in.) No.1 rear journal: 0.050-0.075 mm (0.0020-0.0030 in.'

B

F

H

Service Limit: No.1 front journal, No.3 front and rear journals: 0.12 mm (0.005 in.' No.2 front and rear journals: 0.13 mm (0.005 in.' No.1 rear journal: 0.09 mm (0.004 in.)

BACK

7-17

Engine Block Crankshaft, Piston and Balancer Shaft Removal 1. Remove the engine assembly (see page 5-2).

6. Remove the right side cover.

2. Remove the transmission: • Manual transmission (see page 13-4). • Automatic transmission (see page 14-114). 3. Remove the bolts securing the oil pan. 4. Drive an oil pan seal cutter between the oil pan and cylinder block.

7. Remove the CKPfTDC sensors. 8. Remove the timing belt drive pulley. 9. Remove the balancer gear case.

5. Cut the oil pan seal by striking the side of the cutter to slide the cutter along the oil pan. Remove the oil pan.

10. Insert a screwdriver (A) in the front balancer shaft maintenance hole (B), and remove the front balancer driven pulley (C).

7-18

BACK

11. Remove the balancer driven gear. -1 Remove the bolt (A) and washer (8) from the maintenance hole (C). -2 Scribe a line on a 6 X 100 mm bolt, 74 mm (2.9 in.) from the end. -3 Insert the bolt in the maintenance hole and into the hole in the rear balancer shaft (D) up to the line you scribed. -4 Remove the bolt and balancer driven gear (E).

14. Remove the 6 mm bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.

15. Remove the 11 mm bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened. E

12. Remove the oil screen (A) and the oil pump (8). A

t

It "

C

16. Remove the bearing cap bridge. 17. Turn the crankshaft so No.2 and 3 crankpins are at the top. 18. Remove the rod caps/bearings and main caps/ bearings. Keep all caps/bearings in order.

B

13. Remove the baffle plate (C). (cont'd)

BACK

7-19

Engine Block Crankshaft, Piston and Balancer Shaft Removal (cont'd) 19. Lift the crankshaft (A) out of the engine, being careful not to damage the journals.

23. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are pushed out.

A

20. Remove the front balancer shaft and the rear balancer shaft. -1 Remove the bolt and the retainer (A). -2 Pull out the front balancer shaft (B). -3 Pull out the rear balancer shaft (e).

24. Use the wooden handle of a hammer (A) to drive out the pistons (B).

B

21. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps.

25. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.

22. Reinstall the main caps and bearings on the engine in the proper order.

26. To avoid mixup on reassembly, mark each piston/ connecting rod assembly with its cylinder number. NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.

7-20

BACK

Crankshaft Inspection Straightness

Out-of-Round and Taper

NOTE: • Clean the crankshaft oil passages with pipe cleaners or a suitable brush. • Check the keyway and threads.

1. Measure out-of-round at the middle of each rod and main journal in two places. The difference between measurements on each journal must not be more than the service limit.

1. Remove the crankshaft from the engine block (see page 7-18).

Journal Out-of-Round: Standard (New): 0.005 mm (0.0002 in.) max. 0.006 mm (0.0002 in.) Service Limit:

2. Clean the crankshaft oil passages with pipe cleaners or a suitable brush. 3. Clean the keyway and thread; repair or replace it if necessary. 4. Support the crankshaft with a V-blocks. 5. Measure runout on all main journals to make sure the crank is not bent. Rotate the crankshaft two complete revolutions. The difference between measurements on each journal must not be more than the service limit. Crankshaft Total Indicator Runout: Standard (New): 0.03 mm (0.001 in.) max. 0.04 mm (0.002 in.) Service Limit:

J t

'f

r

2. Measure taper at the edge of each rod and main journal. The difference between measurements on each journal must not be more than the service limit. Journal Taper: Standard (New): 0.005 mm (0.0002 in.) max. Service Limit: 0.006 mm (0.0002 in.)

BACK

7-21

Engine Block Block and Piston Inspection 1. Remove the piston from the engine block (see page 7-18).

4. Measure wear and taper in direction X and Y at 3

2. Check the piston for distortion or cracks.

levels in each cylinder as shown. If measurements in any cylinder are beyond the Oversize Bore Service Limit, replace the block. If the block is to be rebored, refer to step 6 after reboring.

3. Measure the piston diameter at a point 16 mm (0.6 in) from the bottom of the skirt. There are two standard-size pistons (No Letter or A, and B). The letter is stamped on the top ofthe piston. Letters are also stamped on the block as cylinder bore sizes. Piston Diameter: Standard (New): No Letter (or A): 85.980-85.990 mm (3.3850 - 3.3854 in.) B: 85.970 - 85.980 mm (3.3846-3.3850 in.)

Cylinder Bore Size: Standard (New): Aorl: 86.010-86.020 mm (3.3862-3.3866 in.) B or II: 86.000-86.010 mm (3.3858-3.3862 in.) 86.070 mm (3.3886 in.) Service Limit: Oversize: 0.25: 86.250-86.260 mm (3.3957-3.3960 in.) Reboring limit:

Service Limit: No Letter (or A): 85.970 mm (3.3846 in.) B: 85.960 mm (3.3842 in.)

0.25 mm (0.01 in.) max.

Bore Taper: Limit: (Difference between 1st and 3rd measurement) 0.05 mm (0.002 in.)

· iE

6 mm (0.2 in.)

-'T " .' •

,

'

,1st ~ Measurement " 2nd : Measurement ',,,,,, 3rd <~'.' Measurement

6 mm (0.2 in.) No.1

7-22

BACK

No.4

5. Scored or scratched cylinder bores must be honed. 6. Check the top of the block for warpage. Measure along the edges and across the center as shown.

7. Calculate the difference between the cylinder bore diameter and the piston diameter. If the clearance is near or exceeds the service limit, inspect the piston and cylinder block for excessive wear.

Engine Block Warpage: Standard (New': 0.07 mm (0.003 in.' max. 0.10 mm (0.004 in.) Service Limit:

Piston-to-Cylinder Clearance: Standard (New,: 0.020 - 0.040 mm (0.0008-0.0016 in.' Service Limit: 0.05 mm (0.002 in.' Oversize Piston Diameter: 0.25: 86.230-86.240 mm (3.3949-3.3953 in.'

PRECISION STRAIGHT EDGE

BACK

7-23

Engine Block Cylinder Honing Only a scored or scratched cylinder bore must be honed. 1. Measure the cylinder bores (see page 7-22). If the block is to be reused, hone the cylinders and remeasure the bores. 2. Hone the cylinder bores with honing oil and a fine (400 grit) stone in a 60 degree cross-hatch pattern (A). Use only a rigid hone with 400 grit or finer stone such as Sunnen, Ammco, or equivalent. Do not use stones that are worn or broken.

x.

. .x. x. .x..

3. When honing is complete, thoroughly clean the engine block of all metal particles. Wash the cylinder bores with hot soapy water, then dry and oil them immediately to prevent rusting. Never use solvent, it will only redistribute the grit on the cylinder walls. 4. If scoring or scratches are still present in the cylinder bores after honing to the service limit, rebore the cylinder block. Some light vertical scoring and scratching is acceptable if it is not deep enough to catch your fingernail and does not run the full length ofthe bore.

7-24

BACK

Piston, Pin and Connecting Rod Replacement Disassembly

3. Heat the piston and connecting rod assembly to about 158°F (700e), then remove the piston pin.

1. Apply engine oil to the piston pin snap rings (A) and turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (8). NOTE: Take care not to damage the ring grooves.

[J@El ~/ ~ A

B

2. Remove both snap rings (A). Start at the cutout in the piston pin bore. Remove the snap rings carefully so they do not go flying or get lost. Wear eye protection. A

(cont'd)

BACK

7-25

Engine Block Piston, Pin and Connecting Rod Replacement (cont'd) Inspection

3. Check the difference between the piston pin diameter and piston pin hole diameter in the piston.

NOTE: Inspect the piston, piston pin and connecting rod when they are at room temperature.

Piston Pin-to-Piston Clearance: Standard (New): -0.0050 to +0.0010 mm ( - 0.00020 to + 0.00004 in.) 0.004 mm (0.0002 in.) Service Limit:

1. Measure the diameter of the piston pin. Piston Pin Diameter: Standard (New): 21.962-21.965 mm (0.8646-0.8648 in.) Service Limit: 21.954 mm (0.8643 in.)

4. Measure the piston pin-to-connecting rod clearance.

2. Zero the dial indicator to the piston pin diameter.

7-26

BACK

Piston Pin-to-Connecting Rod Clearance: Standard (New): 0.005-0.014 mm (0.0002 - 0.0006 in.) 0.019 mm (0.0007 in.) Service Limit:

Reassembly

4. Install the piston pin (A). Assemble the piston (8) and connecting rod (C) with the embossed marks (D) on the same side.

1. Install a piston pin snap ring (A). A

o

/ZA

2. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with engine oil. 3. Heat the piston to about 158°F (70°C).

/

~

/. '-~.;.~I

~;J

.V .

5. Install the remaining snap ring.

,4·/

.~-

'="'"

BACK

7-27

Engine Block Piston Ring Replacement 4. Using a ring expander (A), remove the old piston rings (B). B

1. Remove the piston from the cylinder block (see page 7-18).

\~

2. Using a piston, push a new ring (A) into the cylinder bore 15-20 mm (0.6-0.8 in.) from the bottom.

~'/"// ,/

~~ ~~ . A

&

,'

;,;

(".:t~~5S::~f ~

<..................... t

15-20 mm (0.6-0.8 in.)

/~

3. Measure the piston ring end-gap (B) with a feeler gauge: • If the gap is too small, check to see if you have the proper rings for your engine. • If the gap is too large, recheck the cylinder bore diameter against the wear limits (see page 7-22). Ifthe bore is over the service limit, the cylinder block must be rebored.

5. Clean all ring grooves thoroughly with a squaredoff broken ring or ring groove cleaner with a blade to fit the piston grooves. The top and second ring grooves are 1.2 mm (0.05 in.) wide. The oil ring groove is 2.8 mm (0.11 in.) wide. File down a blade if necessary . Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with cleaning tools .

Piston Ring End-Gap: Top Ring Standard (New): 0.20 - 0.35 mm (0.008-0.014 in.) Service limit: 0.60 mm (0.024 in.) Second Ring Standard (New): 0.40-0.55 mm (0.016-0.022 in.) 0.70 mm (0.028 in.1 Service limit: Oil Ring Standard (New): 0.20-0.70 mm (0.008-0.028 in.) Service limit: 0.80 mm (0.031 in.)

7-28

BACK

NOTE: If the piston is to be separated from the connecting rod, do not install new rings yet.

6. Install the rings as shown. The top ring (A) has a 18 mark and the second ring (8) has a 28 mark. The manufacturing marks (C) must be facing upward.

7. Rotate the rings in their grooves to make sure they do not bind. 8. Position the ring end gaps as shown: DO NOT position any ring gap at piston thrust surfaces.

DO NOT position any ring gap in line with the piston pin hole.

OIL RING GAP

9. After installing a new set of rings, measure the ring-to-groove clearances: Top Ring Clearance Standard (New): 0.035-0.060 mm (0.0014-0.0024 in.) 0.13 mm (0.005 in.) Service Limit: Second Ring Clearance Standard (New): 0.030-0.055 mm (0.0012-0.0022 in.) Service Limit: 0.13 mm (0.005 in.) Piston Ring Dimensions: Top Ring (Standard): A: 3.1 mm (0.12 in.) B: 1.2 mm (0.05 in.)

A

Second Ring (Standard): A: 3.4 mm (0.13 in.) B: 1.2 mm (0.05 in.)

BACK

7-29

Engine Block Piston Installation If the crankshaft is already installed

6. Check the connecting rod bearing clearance with plastigage (see page 7-13).

1. Set the crankshaft to BOC for each cylinder. 2. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place. 3. Position the arrow (A) and the mark (B) facing the timing belt side of the engine.

7. Apply engine oil to the bolt threads, then install the rod caps with bearings. Torque the bolts to 20 N·m (2.0 kgf·m, 14Ibf·ft). 8. Mark the connecting rod (A) and bolt head (B) as shown. B

A

Hll._---B A

4. Position the piston in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore.

5. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.

7-30

BACK

9. Tighten the bolt until the mark on the bolt head lines up with the mark on the connecting rod (turn the bolt 90°).

Connecting Rod Bolt Inspection If the crankshaft is not installed

1. Measure the diameter of each connecting rod bolt at point A and point B.

1. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place.

35mm (1.3Bin.)

A

2. Position the arrow (A) and the mark (B) facing the timing belt side ofthe engine. A

20mm (0.79 in.)

B

3. Position the piston in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore.

2. Calculate the difference in diameter between point A and point B. Point A - Point B = Difference in Diameter Difference in Diameter: Specification: 0-0.1 mm (0-0.004 in.) 3. If the difference in diameter is out oftolerance, replace the connecting rod bolt.

4. Position all pistons at top dead center.

BACK

7-31

Engine Block Crankshaft and Balancer Shafts Installation Special Tools Required . Driver 07749-0010000 . Driver Attachment 07948-S800101

10. Apply engine oil to the bolt threads, then install the rod caps with bearings, and torque the bolts to 20 N·m (2.0 kgf·m, 14 Ibf·ft).

1. Check the connecting rod bearing clearance with plastigage (see page 7-9).

11. Mark the connecting rod (A) and bolt head (8) as shown.

2. Check the main bearing clearance with plastigage (see page 7-7).

..

3. Inspect the connecting rod bolts (see page • • -• ).

4. Apply a coat of engine oil to the main bearings and rod bearings. 5. Install the bearing halves in the cylinder block and connecting rods.

A

6. Hold the crankshaft so rod journal No.2 and rod journal No.3 are straight up. 7. Install the thrust washers (A) in the No.4 journal of the cylinder block.

B


E 13. Check main bearing clearance with plastigage (see page 7-9). 14. Install the main bearing caps and bearing cap bridge. Coat the bolt threads with engine oil. 15. Tighten the 11 mm bolts in two steps. In the first step, tighten all bolts in sequence to about 29 N·m (3.0 kgf·m, 22 Ibf·ft): in the final step, tighten in the same sequence to 78 N·m (8.0 kgf.m, 58 Ibf·ft).

®l D

@

®

@

®

CD

®

®

c

8. Lower the crankshaft into the block, seating the rod journals into connecting rod No.1 (8) and connecting rod No.4 (C). Install the connecting rod caps and bolts finger tight. 9. Rotate the crankshaft clockwise, seat the journals into connecting rod No.2 (D) and connecting rod No.3 (E). Install the connecting rod caps and bolts finger tight. Install caps so the bearing recess is on the same side as the recess in the rod.

7-32

BACK

16. Tighten the 6 mm bolts in sequence to 12 N·m (1.2 kgf·m, 8.7 Ibf·ft).

18. Confirm thatthe clearance is equal all the way around with a feeler gauge.

NOTE: Whenever any crankshaft or connecting rod bearing is replaced, it is necessary after reassembly to run the engine at idling speed until it reaches normal operating temperature, then continue to run it for approximately 15 minutes.

@

®

®

Clearance:

®

0.S-0.8mm (0.02-0.03 in.)

19. Clean and dry the right side cover mating surfaces. Apply a light coat of oil to the crankshaft and to the lip ofthe seal.

®

17. Drive the crankshaft oil seal squarely into the right side cover. 077 49-0010000

0.5-0.8 mm (0.02-0.03 in.)

20. Apply liquid gasket, part No. 08718-0001 or 08718-0003, evenly to the block mating surface of the right side cover and to the inner threads of the bolt holes. Install the dowel pins (A) and the right side cover (B) on the cylinder block. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the old residue. B

07948-S800101

,/ ____ 6 x 1.0 mm d'~ 12 N·m (1.2 kgf.m. 8.7Ibf·ft)

21. After assembly, wait at least 30 minutes before filling the engine with oil.

(cont'd)

BACK

7-33

Engine Block Crankshaft and Balancer Shafts Installation (co nt'd) 22. Install the rear balancer shaft (A) and the front balancer shaft (B) into the block, then install the retainer (C).

23. Clean and dry the oil pump mating surfaces. 24. Install the oil pump (A). -1 Install a new crankshaft oil seal in the oil pump (see step 17 on page 8-9). -2 Apply liquid gasket part, No. 08718-0001 or 08718-0003, evenly to the block mating surface of the oil pump and to the inner threads of the bolt holes. -3 Grease the lips ofthe oil seals and apply oil to the new O-ring (B). -4 Install the dowel pins (C), then align the inner rotor with the crankshuft and install the oil pump. -5 Clean the excess grease off the crankshaft and balancer shaft and check the seals for distortion.

6x1.0mm 12 N·m (1.2 kgf·m, 8.7Ibf·ft)

~::-----

6x 1.0mm 20 N·m (2.0 kgf·m, 14lbf·ftl

D

A

6x1.0mm 12 N·m (1.2 kgf·m, 8.7Ibf·ft)

25. Install the baffle plate (0), then install the oil screen (E).

7-34

BACK

26. Hold the front balancer shaft with a screwdriver (A), then install the timing balancer belt driven pulley (8).

28. Install the balancer driven gear. -1 Remove the bolt (A) and washer (B) from the maintenance hole (C). -2 Scribe a line on a 6 x 100 mm bolt, 74 mm from the end. -3 Insert the bolt in the maintenance hole and into the hole in the rear balancer shaft (0) up to the line you scribed. -4 Install the balancer driven gear (E).

8x 1.25 mm 29 N·m (3.0 kgf·m, 22 Ibf·ftl

27. Before installing the balancer driven gear (A) and the balancer gear case (B) apply molybdenum disulfide (C) to the thrust surfaces of the balancer gears as shown. A

o~ ~~B

C/ A

12x 1.5 mrn 29 N·m (3.0 kgf·m, 22 Ibf.ftl

(cont'd)

BACK

7-35

Engine Block Crankshaft and Balancer Shafts Installation (cont'd) 29. Install the balancer gear case (A). -1 Apply clean engine oil to the new a-ring (B). -2 Hold the rear balancer shaft with the 6 x 100 mm bolt. -3 Align the notch (C) on the pulley edge with the pointer (D) on the gear case. -4 Install the gear case (A).

31. Clean and dry the cylinder block mating surfaces. 32. Apply liquid gasket part No. 08718-0009 evenly to the cylinder block mating surface of the oil pan and to the inner threads of the bolt holes, then install the oil pan. NOTE: • Apply liquid gasket in a 4 mm wide bead. • Apply a second bead where the two ends of the first bead meet. • Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue.

8x 1.25mm 25 N·m (2.5 kgf·m, 18Ibf·ft)

Apply liquid gasket along the broken line.

c 30. After installation, make sure the pulley pointer (A) aligns with the oil pump pointer (B). A

33. Tighten the bolts/nuts in two or three steps. In the final step, tighten all bolts/nuts, in sequence, to 12 N·m (1.2 kgf·m, 8.7Ibf·ft). @

CD

®

®

! !! !

-0

{

@@

.'

@ @

7-36

BACK

@

@@

Pulley End Crankshaft Seal Installation - In-car

Balancer Shaft Seals Installation In-car



Seal Driver 07LAD-PT3010A

. Hub Assembly Guide Attachment 07GAF-SE00200 . Attachment, 30 mm 1.0. 077 46-0030300

1. Dry the crankshaft oil seal housing. 1. Dry the crankshaft oil seal housing. 2. Apply a light coat of grease to the crankshaft and to the lip of the seal. 3. Using the seal driver, drive in the crankshaft oil seal until the driver bottoms against the oil pump. When the seal is in place, clean any excess grease off the crankshaft and check that the oil seal lip is not distorted.

2. Apply a light coat of grease to the balancer shaft and to the lip of the seal. 3. Using the special tools, drive in the front balancer shaft oil seal until the driver bottoms against the oil pump. When the seal is in place, clean any excess grease off the balancer shaft, and check that the oil seal lip is not distorted.

07LAD-PT3010A Install seal with the part number side facing out.

07GAF-SE00200

07746-0030300

)\

BACK

7-37

Engine Block Transmission End Crankshaft Seal Installation - In-car Special Tools Required

. Driver 07749-0010000 . Driver Attachment 07948-5800101 or 07VAD-P8A010A 1. Dry the crankshaft oil seal housing. 2. Apply a light coat of grease to the crankshaft and to the lip of the seal. 3. Using the special tools, drive the crankshaft oil seal into the right side cover to the point where the clearance between the bottom of the crankshaft oil seal and right side cover is 0.5 - 0.8 mm (0.02 - 0.03 in.) (see page 7-32). Align the hole in the driver attachment with the pin on the crankshaft. 07749·0010000

07948·5800101 Install seal with the part number side facing out.

4. Clean any excess grease off the crankshaft, and check that the oil seal lip is not distorted.

7-38

BACK

Engine Mechanical Engine Lubrication Special Tools ................................................................. Component Location Index ......................................... Oil Pressure Switch Test .............................................. Oil Pressure Test ........................................................... Engine Oil Replacement .............................................. Engine Oil Filter Replacement ..................................... Oil Pump Overhaul .......................................................

BACK

8-2 8-3 8-4 8-4 8-5 8-6 8-7

Engine Lubrication Special Tools Tool Number 07LAD-PT3010A 077 46-0010300 07749-0010000 07912-6110001

Number

CD ® ® CD

Description Seal Driver Attachment, 42 X 47 mm Driver Oil Filter Wrench

, 0 .

.,

.:~.

~~

-.-

CD

8-2

.

®

®

BACK

Qty 1 1 1 1

Component Location Index BALANCER DRIVEN GEAR THRUST WASHER

FRONT BALANCER BELT DRIVEN PULLEY

DDWEL~~/' ~60

0___________

D.RING

OIL PUMP Overhaul, page 8-7

O-RING

~

Qg~ OIL PRESSURE SWITCH

Cir~uit Diagram, page 22-79

\

SWitch test, page 8-4 Oil pressure test, page 8-4

OIL FILTER Replacement, page 8-6

OIL SCREEN

OIL PAN Removal, page 7-18 Installation, page 8-7

~~---

WASHER

DRAIN BOLT

BACK

8-3

Engine Lubrication Oil Pressure Test

Oil Pressure Switch Test 1. Remove the VEL/RED wire (A) from the engine oil pressure switch (B).

B

c

A

Ifthe oil pressure warning light stays on with the engine running, check the engine oil level. If the oil level is correct:

1. Connect a tachometer or a Honda PGM Tester. 2. Remove the engine oil pressure switch, and install an oil pressure gauge (A).

2. Check for continuity between the positive terminal (C) and the engine (ground). There should be continuity with the engine stopped. There should be no continuity with the engine running.

3. If the switch fails to operate, check the engine oil level. If the engine oil level is OK, check the engine oil pressure.

3. Start the engine. Shut it off immediately if the gauge registers no oil pressure. Repair the problem before continuing. 4. Allow the engine to reach operating temperature (fan comes on at least twice). The pressure should be: Engine Oil Temperature: 176°F (SO°C) Engine Oil Pressure: At Idle: 70 kPa (0.7 kgf/cm2, 10 psi) minimum At 3,000 rpm: 340 kPa (3.5 kgf/cm2, 50 psi) minimum 5. If oil pressure is NOT within specifications, inspect these items: • Check the oil filter for clogging . • Check the oil pump (see step 11 on page 8-8).

8-4

BACK

Engine Oil Replacement NOTE: Under normal conditions, the oil filter should be replaced at every other oil change. Under severe conditions, the oil filter should be replaced at each oil change. Change interval Every 7,500 miles (12,000 km) or 12 months (Normal conditions) Every 3,750 miles (6,000 km) or 6 months (Severe conditions). 1. Warm up the engine.

A 44 N·m 14.5 kgf.m, 33 Ibf·ft) Do not overtighten.

3. Reinstall the drain bolt with a new washer (B). 4. Refill with the recommended oil (see page 3-2). Capacity 4.0 A (4.2 US qt, 3.5 Imp qt) at oil change. 4.3 A (4.5 US qt, 3.8 Imp qtl at oil change including filter. 5.6 A (5.9 US qt, 4.9 Imp qtl after engine overhaul. 5. Run the engine for more than three minutes, then check for oil leakage.

BACK

8-5

Engine Lubrication Engine Oil Filter Replacement Special Tools Required Oil Filter Wrench 07912-6110001

1. Remove the oil filter with the special oil filter wrench. 2. Inspect the threads (A) and rubber seal (B) on the

new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. Use only filters with a built-in bypass system.

5. If eight numbers (1 to 8) are printed around the outside of the filter, use the following procedure to tighten the filter. • Spin the filter on until its seal lightly seats against the block, and note which number is at the bottom . • Tighten the filter by turing it clockwise 7 numbers from the one you noted. For example, if number 2 is at the bottom when the seal is seated, tighten the filter until the number 1 comes around the bottom.

Number after tightening.

Number when rubber seal is seated.

A

3. Install the oil filter by hand. 4. After the rubber seal seats, tighten the oil filter clockwise with the special tool. Tighten: Tightening torque:

7/8 turn clockwise. 22 N·m (2.2 kgf.m, 16Ibf·ft)

Number when rubber seal is seated

1

2

3

4

5

6

7

8

Number after tightening

8

1

2

3

4

5

6

7

07912-6110001

\

8-6

6. After installation, fill the engine with oil up to the specified level, run the engine for more than 3 minutes, then check for oil leakage.

BACK

Oil Pu mp Overhaul Exploded y.lew

6x 1.0 mm . gf·m, 8.7 Ibf·ft) 12N·m (12k

PUMP COVER

b OIL SEALS Replace.

PUMP/

Apply Ii O~SING to mati~Uld gasket the cYlin~ surface of when inst:fli~g~k

OUTER ROTOR

Ej~

I -----

INNER ROTOR

RELIEF VALVE V .Inalve mu " freely houSingst~hde

Replace "f ore. ~ I scored.

~

SPIUNG

:~L1NGBOLT

·m (4.0 kgf·m, 29 Ib'·ft)

(cont'd)

BACK

8-7

Engine Lubrication Oil Pump Overhaul (cont'd) Inspection

Special Tools Required • Seal Driver 07LAD-PT3010A • Driver 07749-0010000 • Attachment, 42 x 47 mm 07746-0010300 NOTE: Refer to the Exploded View as needed during this procedure.

11. Check the inner-to-outer rotor radial clearance between the inner rotor (A) and outer rotor (8). If the inner-to-outer rotor clearance exceeds the service limit, replace the inner and outer rotors. Inner Rotor-to-Outer Rotor Radial Clearance Standard (New): 0.02-0.16 mm (0.001-0.006 in.) Service Limit: 0.20 mm (0.008 in.)

Removal 1. Drain the engine oil. 2. Remove the timing belt and the balancer belt (see page 6-23). 3. Remove the timing belt tensioner and the balancer belt tensioner.

4. Remove the CKP/TDC sensors, then remove the timing belt drive pulley (see page 6-55). 5. Remove the balancer belt driven pulley (see page 7-18). 6. Remove the balancer gear case and the balancer driven gear (see page 7-18).

7. Separate the oil pan from the cylinder block with an oil pan seal cutter (see page 7-18).

12. Check the housing-to-rotor axial clearance between the rotor (A) and pump housing (8). If the housingto-rotor axial clearance exceeds the service limit, replace the set of inner and outer rotors and/or the pump housing.

8. Remove the oil pan and the oil screen (A).

Housing-to-Rotor Axial Clearance Standard (New): 0.02-0.07 mm (0.001-0.003 in.) Service Limit: 0.12 mm (0.005 in.)

B

,~...\\"'' '~/

B

9. Remove the mounting bolts and the oil pump assembly (8). 10. Remove the screws from the pump housing, then separate the housing and cover.

8-8

BACK

A

13. Check the housing-to-outer rotor radial clearance between the outer rotor (A) and pump housing (B). If the housing-to-outer rotor radial clearance exceeds the service limit, replace the set of inner and outer rotors and/or the pump housing.

16. Gently tap in the new oil seals until the special tool bottoms on the pump.

Housing-to-Outer Rotor Radial Clearance Standard (New): 0.10-0.19 mm (0.004-0.007 in.) Service Limit: 0.21 mm (0.008 in.) o

07LAD-PT3010A

14. Inspect both rotors and the pump housing for scoring or other damage. Replace parts if necessary. 07746-0010300

15. Remove the old oil seals from the oil pump. Installation

17. Reassemble the oil pump, applying liquid thread lock to the pump housing screws. 18. Check that the oil pump turns freely. 19. Clean and dry the oil pump mating surface.

(cont'd)

BACK

8-9

Engine Lubrication Oil Pump Overhaul (cont'd) 23. Hold the front balancer shaft with a screwdriver (A), then install the timing balancer belt driven pulley

20. Install the oil pump (A).

-1 Apply liquid gasket, part No. 08718-0001 or 08718-0003, evenly to the block mating surface of the oil pump and to the inner threads of the bolt holes. -2 Grease the lips ofthe oil seals and apply oil to the new O-ring (B). -3 Install a dowel pins (C), then align the inner rotor with the crankshaft and install the oil pump. -4 Clean the excess grease off the crankshaft and balancer shaft and check the seals for distortion. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue. 6x 1.0 mm 12 N·m (1.2 kgf·m, 8.7 Ibf.ft)

(B). B

8x 1.25 mm 29 N·m 13.0 kgf.m, 22 Ibf·ft)

24. Before installing the balancer driven gear (A) and the balancer gear case (B), apply molybdenum disulfide (C) to the thrust surfaces of the balancer gears as shown.

c

~

C

()~·'A \J

'2f

~

B

6x 1.0mm 12 N·m (1.2 kgf.m, 8.7Ibf·ft)

6x 1.0mm 12 N·m (1.2 kgf·m, 8.7Ibf·ft)

21. After assembly, wait at least 30 minutes before filling the engine with oil. 22. Install the baffle plate (D).

8-10

BACK

A

25. Install the balancer driven gear. -1 Remove the bolt (A) and washer (8) from the maintenance hole (C). -2 Scribe a line on a 6 x 100 mm bolt, 74 mm from the end. -3 Insert the bolt in the maintenance hole and into the hole in the rear balancer shaft (D) up to the line you scribed. -4 Install the balancer driven gear (E).

26. Install the balancer gear case (A). -1 Apply clean engine oil to the new O-ring (8). -2 Hold the rear balancer shaft with the 6 x 100 mmbolt. -3 Align the notch (C) on the pulley edge with the pointer (D) on the gear case. -4 Install the gear case (A).

8x 1.25mm 25 N·m (2.5 kgf·m, 18Ibf·ft)

c

c

27. After installation, make sure the pulley pointer (A) aligns with the oil pump pointer (8). A

(cont'd)

BACK

8-11

Engine Lubrication Oil Pump Overhaul (cont'd) 28. Clean and dry the cylinder block mating surfaces. 29. Apply liquid gasket, part No. 08718-0009, evenly to the cylinder block mating surface of the oil pan and to the inner threads of the bolt holes, then install the oil pan. NOTE: • Apply a 4 mm wide bead of liquid gasket. • Apply a second bead where the two ends of the first bead ends meet. • Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue.

I

I I

~o o

-

,=-0==-

0

-~

Apply liquid gasket along the broken line.

30. Tighten the bolts/nuts in two or three steps. In the final step, tighten all bolts/nuts, in sequence to 12 N·m (1.2 kgf·m, 8.7Ibf·ft).

@@

@@

8-12

(l)

®

1111

@@

@@

BACK

Engine Mechanical Intake Manifold and Exhaust System Intake Manifold Removal and Installation ................. 9-2 Exhaust Manifold Removal and Installation .............. 9-3 Exhaust Pipe and Muffler Replacement ..................... 9-5

BACK

Intake Manifold and Exhaust System Intake Manifold Removal and Installation NOTE: • Use new a-rings and gaskets when reassembling. • Check for folds or scratches on the surface of the gasket. • Replace with a new gasket if damaged. 8x 1.25mm 22 N·m (2.2 kgf·m. 16lbf·ftl

INTAKE MANIFOLD CHAMBER Replace if cracked or if mating surface is damaged.

GASKET Replace.

__________'0 INTAKE AIR TEMPERATURE (lATI SENSOR 18 N·m (1.8 kgf·m. 13lbf·ft

/

'" /8x1.25mm ~, 22 N·m (2.2 kgf·m. ~ 16lbf.ftl O-RING Replace.

~THROTTLEBODV

O

~

6x 1.0mm 12 N·m (1.2 kgf.m. 8.7Ibf.ftl

IDLE AIR CONTROL (lACIVALVE

A:?:8X1.25mm 22 N·m (2.2 kgf·m. 16lbf·ftl

'It{l'II

GASKET Replace.

8 x 1.25 mm 22 N·m (2.2 kgf.m. ~ 16lbf·ftl @

O-RING Replace.

__

\f;II

iiiii1~

GASKET Replace.

EXHAUST GAS RECIRCULATION (EGRIVALVE

\GAmT

INTAKE MANIFOLD Replace if cracked or if mating surface is damaged.

Replace.

O-RING Replace.

8x1.25mm 22 N·m (2.2 kgf·m. 16 Ibf·ftl 8x1.25mm 22 N·m (2.2 kgf.m. 16lbf·ftl

9-2

BACK

INTAKE MANIFOLD BRACKET

Exhaust Manifold Removal and Installation F23A1, F23A5 engines:

NOTE: • Use new gaskets and self-locking nuts when reassembling. • Check for folds or scratches on the surface of the gasket. • Replace with a new gasket if damaged. 8x 1.25 mm 22 N·m 12.2 kgf·m, 16lbf·ftl

EXHAUST MANIFOLD

~GASKET

PRIMARY HEATED OXYGEN SENSOR (H02SI 44 N·m (4.5 kgf·m, 32 Ibf·ftl

Replace.

SELF-LOCKING NUT 8x 1.25 mm 31 N·m (3.2 kgf·m, 23 Ibf.ftl Replace.

SELF-LOCKING NUT 10x1.25mm 54 N·m (5.5 kgf·m, 40 Ibf·ftl Replace. 10 x 1.25 mm 44 N·m (4.5 kgf·m, 33lbf·ft,

BACK

10 x 1.25 mm 44 N·m 14.5 kgf·m, 33lbf·ftl

9-3

Intake Manifold and Exhaust System Exhaust Manifold Removal and Installation (cont'd) F23A4 engine:

NOTE: • Use new gaskets and self-locking nuts when reassembling. • Check for folds or scratches on the surface of the gasket. • Replace with a new gasket if damaged.

i

8 x 1.25 mm N·m 12.2 kgl.m. 16 Ibf·ftl

o

o_:~:;'

COVER 6x 1.0mm 12 N·m 11.2 kgf·m. 8.7Ibf·ftl

~

~®i

AIR FUEL RATIO lA/F) SENSOR

\

l

~

EXHAUST MANIFOLD

'€?v~' ~ .

EXHAUST MANIFOLD BRACKET

10x 1.25 mm 44 N·m 14.5 kgf·m. 33 Ibf·ftl

9-4

BACK

COVER

Exhaust Pipe and Muffler Replacement Except F23A4 engine SULEV model: NOTE: Use new gaskets and self-locking nuts when reassembling. MUFFLER

I.

~p~

SELF-LOCKING NUT

10x 1.25mm 54 N·m (5.5 kgf·m, 40lbf·ftl Replace.

______Eif ____~ GASKET l---Replace. HEATSHILD

HEAT SHIELD

6x1.0mm 12N·m 11.2 kgf·m, 8.7Ibf·ftl

6x1.0mm 12 N·m (1.2 kgf·m, 8.7Ibf.ftl

SELF-LOCKING NUT

10x1.25mm 33 N·m (3.4 kgf·m, 251bf.ftl Replace. 10 x 1.25 mm 38 N·m (3.9 kgf·m, _____ 28lbf·ftl

a

""

_____0

44

N·m (4.5 kgf·m, 33lbf·ftl

GASKET

GASKET

~

Replace.

~@

EX~~UST

~

SECONDARY HEATED OXYGEN SENSOR (H02SI

Replace.

THREE WAY CATALmC CONVERTER (TWCI

~

PIPE/"

SELF-LOCKING NUT

10x1.25mm 54 N·m (5.5 kgf·m, 4Olbf·ftl Replace. 8x1.25mm 22N·m (2.2 kgf·m, 16lbf·ftl

SELF-LOCKING NUT

10x1.25mm

THREE WAY CATALmC CONVERTER (TWCI TIGHTENING SEQUENCE

33 N·m (3.4 kgf·m, 25 Ibf·ftl

Replace.

BACK

9-5

Intake Manifold and Exhaust System Exhaust Pipe and Muffler Replacement (cont'd) F23A4 engine SULEV model: NOTE: Use new gaskets and self-locking nuts when reassembling. /MUFFLER

~ SELF-LOCKING NUT lOx 1.25mm 54 N·m (5.4 kgf·m. 40Ibf·ft) Replace.

SECONDARY HEATED OXYGEN SENSOR (SECONDARY H02S) 44 N·m (4.5 kgf·m. 33Ibf·ft)

"

~>

~GASKET Replace.

~____

-~ 'lY

~ TWC

~~6Xl'0mm

12 N·m (1.2 kgf·m. 8.7Ibf·ft)

GASKET Replace.

TWC TIGHTENING SEQUENCE SELF-LOCKING NUT lOx 1.25 mm 33 N·m (3.4 kgf·m. 25 Ibf·ft) Replace.

9-6

BACK

Engine Cooling Cooling System Component Location Index ......................................... Coolant Temperature Gauge Test ............................... Sending Unit Test ......................................................... Radiator Cap Test ......................................................... RadiatorTest ................................................................. Fan Motor Test .............................................................. ThermostatTest ........................................................... Water Pump Inspection ............................................... Water Pump Replacement ........................................... Coolant Replacement ................................................... Water Outlet Replacement .......................................... Thermostat Replacement ............................................ Radiator and Fan Replacement ...................................

10-2 10-5 10-7 10-7 10-8 10-8 10-9 10-9 10-10 10-10 10-12 10-13 10-14

Fan Controls Component Location Index ......................................... Symptom Troubleshooting Index ............................... Circuit Diagram With AlC ............................................. Circuit Diagram Without AlC ....................................... Radiator Fan Circuit Troubleshooting ........................ Radiator Fan Switch Circuit Troubleshooting (Open) ........................................... Radiator Fan Switch Circuit Troubleshooting (Short) .......................................... Radiator Fan Switch Test .............................................

BACK

10-15 10-16 10-17 10-18 10-19 10-21 10-21 10-22

Cooling System Component Location Index

RADIATOR CAP

~re=======::::n-,

/

RADIATOR Replacement, page 10-14

AIC CONDENSER FAN ASSEMBLY Replacement, page 10-14

ATf COOLER HOSES

~ /

FAN MOTOR Test, page 10-8 Replacement, page 10-14

10-2

RADIATOR FAN SHROUD Replacement, page 10-14

BACK

IDLE AIR CONTROL UAC) VALVE

WATER BYPASS HOSE

O-RING

O-RING

HEATER HOSE

HEATER HOSE

HEATER VALVE

(cant'd)

BACK

10-3

Cooling System Component Location Index (co nt'd)

WATER OUTLET COVER

'98-'99 models: ENGINE COOLANT TEMPERATURE (ECT) SENSOR

COOLANT TEMPERATURE GAUGE SENDING UNIT

Test, page 10-7

O-RINGS

\

CONNECTING PIPE

10-4

BACK

Coolant Temperature Gauge Test '00-02 models:

'98-99 models:

Coolant Temperature Gauge Needle Does Not Move at All

1. Check the No.9 (7.5 A) fuse in the driver's underdash fuse/relay box before testing.

1. Turn the ignition switch OFF, and connect ECM/ PCM connector terminal C24 to body ground with a jumper wire.

2. Make sure the ignition switch is OFF, then disconnect the YEL/GRN wire (A) from the coolant temperature gauge sending unit (B), and ground it with a jumper wire.


S

1

2

/ /

V

3

5

6

7

8

9 10

13 14 15 16 17 18 19 20 21

23 24 25

26 27 28

29 30

/ /

YEL/GRN

-Wire side of female terminals

2. Turn the ignition switch ON (II) . 3. Turn the ignition switch ON (II). Check that the pointer of the coolant temperature gauge starts moving toward the "H" mark. Turn the ignition switch OFF before the pointer reaches "H" on the gauge dial. Failure to do so may damage the gauge . • Ifthe pointer ofthe gauge does not move at all, check for an open in the YEL/GRN wire. If the wires are OK, replace the coolant temperature gauge . • If the coolant temperature gauge works, test the coolant temperature sending unit.

After 30 seconds or more, does the temperature gauge needle move to the Hot side? YES-Substitute a known-good ECM/PCM and recheck (see page 11-5).lfthe symptom/indication goes away, replace the original ECM/PCM. NO-Go to step 3. 3. Turn the ignition switch OFF, and disconnect ECMI PCM connector C (31P).

(cont'd)

BACK

10-5

Cooling System Coolant Temperature Gauge Test (cont'd) 4. Turn the ignition switch ON (II), and measure voltage between ECM/PCM connector terminal C24 and body ground.

Coolant Temperature Gauge Needle Goes Past the Hot Mark 1. Turn the ignition switch OFF, and disconnect ECM/ PCM connector C (31P).


1

2

V

3

VV

5

7

6

2. Turn the ignition switch ON (II) , and watch the coolant temperature gauge.

9 10

8

1/ 30 1/

13 14 15 16 17 18 19 20 21

23 24 25

26 27 28

29

fEUGRN =

Does the temperature gauge needle move at all ? (you may have to watch it for about 30 seconds.) YES-Go to step 3. NO-Substitute a known-good ECM/PCM and recheck (see page 11-5).lfthe symptom/indication goes away, replace the original ECM/PCM.


3. Turn the ignition switch OFF, then turn it ON (II) again, and watch the coolant temperature gauge.

Is there about 5V ? YES - Replace the fuel and temperature gauge assembly.

Does the temperature gauge needle immediately go past the Hot mark?

NO- Go to step 5.

YES- Replace the fuel and temperature gauge assembly. NO- The temperature gauge needle went past the Hot mark after about 30 seconds ormore. Go to step 4.

5. Turn the ignition switch OFF, and check for continuity between ECM/PCM connector terminal C 24 and gauge assembly connector terminal C2. ECM/PCM CONNECTOR C (31P) 11

2

3V

V 1/ 13

5

6

7

8

4. Turn the ignition switch OFF, and disconnect the gauge assembly connector C.

9 10

14 15 16 17 18 19 20 21 1 / 26 27 28 29 30 1/

5. Check for continuity between ECM/PCM connector terminal C24 and gauge assembly connector terminal C2.

23 24 25

vEL/GRN

Q vEL/GRN

GAUGE CONNECTOR C (16P)

><

4

6

5

7

1

2

3

8

9

10 111XI12 1 / 14 15 16

5

ECM/PCM CONNECTOR C (31PI 6

7

8

9 10

13 14 15 16 17 16 19 20 21 26 27 26

29 30


Is there continuity? YES- Replace the fuel and temperature gauge assembly.


NO-Repair open in the wire between ECM/PCM connector terminal C24 and gauge connector terminal C2.

10-6

BACK

Is there continuity? YES-Repair short in the wire between ECM/PCM connector terminal C24 and gauge connector terminal C2. NO - Replace the fuel and temperature gauge assembly.

Sending Unit Test

Radiator Cap Test

'98-99 models:

1. Remove the radiator cap (A), wet its seal with engine coolant, then install it on the pressure tester (B) (commercially available).

B

A 2. Using an ohmmeter, measure the change in resistance between the positive terminal (C) and the engine (ground) with the engine cold and with the engine at operating temperature.

Temperature

Resistance (Q )

2. Apply a pressure of 93 -123 kPa (0.95 -1.25 kgf/cm2, 14-18 psi). 3. Check for a drop in pressure. 4. If the pressure drops, replace the cap.

133°F (56°C)

185°F (85°C)212°F (100°C)

137

46-30

3. If the obtained readings are substantially different from the specifications above, replace the sending unit.

BACK

10-7

Cooling System Fan Motor Test

Radiator Test 1. Wait until the engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant to the top of the filler neck.

1. Disconnect the 2P connectors from the radiator fan motor (A) and condenser fan motor (B). LOCK

2. Attach the pressure tester (A)(commercially available) to the radiator and apply a pressure of 93-123 kPa (0.95-1.25 kgf/cm2, 14-18 psi).

A~

A

3. Inspect for engine coolant leaks and a drop in pressure. 4. Remove the tester and reinstall the radiator cap.

2. Test the motor by connecting battery power to the No.1 terminal, and ground to the No.2 terminal.

5. Check for engine oil in the coolant and/or coolant in the engine oil.

3. If the motor fails to run or does not run smoothly, replace it.

10-8

BACK

Water Pump Inspection

Thermostat Test

1. Remove the timing belt (see page 6-23).

Replace the thermostat if it is open at room temperature.

2. Turn the water pump pulley counterclockwise. Check that it turns freely.

To test a closed thermostat: 1. Suspend the thermostat (A) in a container of water. Do not let the thermometer (B) touch the bottom of the hot container.

I~"-----------

3. Check for signs of seal leakage. A small amount of "weeping" from the bleed hole (A) is normal.

B

Jr'l~'~-::::--?4-+---- A

A

2. Heat the water and check the temperature with the thermometer. Check the temperature at which the thermostat first opens, and at which it is fully open. 3. Measure the lift height of the thermostat when it is fully open. STANDARD THERMOSTAT Lift height: above B.O mm (0.31 in.) Starts opening: 169-176°F (76-BO°C) Fully open: 194°F 190°C)

BACK

10-9

Cooling System Water Pump Replacement

Coolant Replacement

2. Remove the camshaft pulley and the back cover (see step 22 on page 6-34).

1. Start the engine. Set the heater temperature control dial to maximum heat, then turn off the engine. Make sure the engine and radiator are cool to the touch.

3. Remove the water pump (A) by removing five bolts.

2. Remove the radiator cap.

4. Inspect, repair and clean the O-ring groove and the mating surface on the cylinder block.

3. Loosen the drain plug (A), and drain the coolant.

1. Remove the timing belt (see page 6-23).

A

4. Remove the drain bolt (A) from the rear side of the cylinder block. 5. Install the water pump, with a new O-ring (8), in the reverse order of removal. 6. Clean the spilled engine coolant.

A 83 N·m (S.5 kgf·m,

61Ibf·ft)

5. After the coolant has drained, apply liquid gasket to the drain bolt threads, then reinstall the bolt with a new washer and tighten it securely. 6. Tighten the radiator drain plug securely.

10-10

BACK

7. Remove, drain and reinstall the reservoir. Fill the

9. Tighten the bleed bolt as soon as coolant starts to run out in a steady stream.

tank to the MAX mark with Honda All Season Antifreeze/Coolant Type 2. 8. Loosen the air bleed bolt (A) in the thermostat housing, then pour Honda All Season Antifreeze/ Coolant Type 2 into the radiator to the bottom of the filler neck. Do not let coolant spill on any electrical parts or the paint. If the any coolant spills, rinse it off immediately.

10. With the radiator cap off, start the engine and let it run until warmed up (radiator fan comes on at least twice). Then, if necessary, add more Honda All Season Antifreeze/Coolant Type 2 to bring the level back up to the bottom ofthe filler neck. 11. Put the radiator cap on tightly, then run the engine again and check for leaks.

NOTE: • Always use Honda All Season Antifreeze/Coolant Type 2. Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail. • Honda All Season Antifreeze/Coolant Type 2 is a mixture of 50 % antifreeze and 50 % water Premixing is not required. Engine Coolant Refill Capacity [including the reservoir capacity of 0.6 ~ (0.6 US qt, 0.5 Imp qt)] MIT: 5.5 ~ (5.8 US qt, 4.8 Imp qt) A/T: 5.4 ~ (5.7 US qt, 4.8 Imp qt) A 9.8 N·m (1.0 kgf·m. 7.2Ibf·ft)

(

BACK

10-11

Cooling System Water Outlet Replacement Install the water outlet (AI with a new O-ring (BI.

",~

A

/~

Metal-type: Replace the O-ring whenever the outlet is removed. Plastic type: Replace the outlet (with built-in O-ring) whenever it's removed.

10-12

BACK

Thermostat Replacement NOTE: Use new a-rings when reassembling.

PIN THERMOSTAT COVER

THERMOSTAT HOUSING

THERMOSTAT Install with pin up.

6x 1.0mm 12 N·m (1.2 kgf·m, S.7Ibf.ft)

BACK

10-13

Cooling System Radiator and Fans Replacement 1. Drain the engine coolant. 2. Remove the upper and lower radiator hoses, and ATF cooler hoses.

UPPER RADIATOR HOSE

AlC CON, DENSER FAN ASSEMBLY

""~' ""

ATF COOLER HOSE 6x1.0mm 9.8 N·m (1.0 kgf.m, 7.2Ibf·ft)

\

~

N

l

~ RADIATOR CAP

lilt \

/\' .

---:

~~

-::'

--6X1.0mm 9.8 N·m (1.0 kgf.m, 7.2Ibf·ft)

~

.

_ _ _ _ UPPER BRACKET AND CUSHION

'0_ _.. :::::

u

~~~~~~§-----RADIATOR ~~~--------------LOWER

CUSHION 6x 1.0mm

7 N·m IO~' Ibf·ftl O-RING Replace. ».=----LOWER RADIATOR HOSE

FAN MOTOR

~~~~S::~:::::::;::::::''''''' CONNECTORS

RADIATOR FAN SHROUD FAN MOTOR

3. Disconnect the fan motor connectors. 4. Remove the radiator upper brackets, then pull up the radiator. 5. Remove the fan shroud assemblies and other parts from the radiator. 6. Install the radiator in the reverse order of removal. Make sure the upper and lower cushions are set securely. 7. Fill the radiator with engine coolant and bleed the air.

10-14

BACK

Fan Controls Component Location Index

UNDER-HOOD FUSEIRELAY BOX

AIC CONDENSER FAN RELAY

Test. page 22-52

_ _ RADIATOR FAN RELAY

Test. page 22-52

RADIATOR FAN SWITCH

Test. page 10-22

AIC CONDENSER FAN ASSEMBLY

RADIATOR FAN ASSEMBLY

Motor Test. page 10-8

Motor Test. page 10-8

BACK

10-15

Fan Controls Symptom Troubleshooting Index Before performing any troubleshooting procedures check: • Fuses • Grounds • Cleanliness and tightness of all connectors

SYMPTOM

PROCEDURE

Radiator fan does not run at all

Radiator Fan Circuit Troubleshooting (see page 10-19).

Radiator fan does not run for engine cooling, but it runs withA/C on

Radiator Fan Switch Circuit Troubleshooting (Open) (see page 10-21).

Radiator fan runs with ignition switch ON (11), A/C oft, and engine temperature below 199°F (93°C)

Radiator Fan Switch Circuit Troubleshooting (Short) (see page 10-21).

10-16

BACK

Circuit Diagram With AIC

UNDER·HOOD FUSE/RELAY BOX SATTERY

IGNITION SWITCH

No.41 (1OOA)

+

No.42 (50A) WHT

No.~

No.57 (20A)

-<>'""-

I

RADIATOR FAN RELAY


~ YEl-+-a""-'C>-+-.., ~ IG2 HOT ON (II) in

1

~-------~.

I

I

~-------~1 .

CONDENSER FAN RELAY

I

AIR CONDITIONING SYSTEM

I

BlUlBlK

BlUIYEl

ECMlPCM

RADIATOR

RADIATOR FAN SWITCH

M FAN

MOTOR

CONDENSER

M FAN

MOTOR

Above)

( Closed: 199°F (93"C)

BlK

BlK

BlK

G201

G101

G201

BACK

10-17

Fan Controls Circuit Diagram Without AIC

IGNITION SWITCH

UNDER-HOOD FUSEIRELAY BOX BATTERY

+

No.4! (!OOA)

No.42 (SOA) WHT

DRIVER'S UNDER-DASH FUSEIRELAY BOX

-@->Q~ BAT

IG2

IG2 HOT in ON (II) No.57 (20A) ......

,...

RADIATOR FAN RELAY

BlKIYEL - - - - -......

~--------------~

BLU/BLK

GRN

RADIATOR FAN SWITCH

Above)

( Closed: !9S"F (93"C)

10-18

BlK

BlK

G201

GIO!

BACK

Radiator Fan Circuit Troubleshooting 1. Check the No. 57 (20A) fuse in the under-hood fuse/relay box, and the No.4 (7.5A) fuse in the under-dash fuse/relay box.

4. Connect the No.1 and No.2 terminals of the radiator fan relay 4P socket with a jumper wire.

Is the fuse (s) OK?

RADIATOR FAN RELAY 4P SOCKET

YES-Go to step 2.

~

NO - Replace the fuse (s) and recheck.•

2

2. Remove the radiator fan relay from the under-hood fuse/relay box, and test it (see page 22-52).

JUMPER WIRE

4 3

Is the relay OK? YES-Go to step 3.

Terminal side of female terminals

NO - Replace the radiator fan relay.•

Does the radiator fan run? 3. Measure the voltage between the No.1 terminal of the radiator fan relay 4P socket and body ground.

YES-Go to step 5. NO - Go to step 6.


5. Disconnect the jumper, and turn the ignition switch ON (II). Check for voltage between the No.3 terminal of the radiator fan relay 4P socket and body ground.


1

2



=

YES - Go to step 4.


NO-Replace the under-hood fuse/relay box.•

Is there battery voltage? YES-Go to step 9. NO-Check for an open in the wire between the under-hood fuse/relay box and under-dash fuse/ relay box.•

(cont'd)

BACK

10-19

Fan Controls Radiator Fan Circuit Troubleshooting (cont'd) 6. Disconnect the radiator fan motor 2P connector. 7. Check for continuity between the No.2 terminal of the radiator fan relay 4P socket and the No.2 terminal of the radiator fan motor 2P connector.

9. Reinstall the radiator fan relay. 10. Disconnect the radiator fan switch 2P connector. 11. Connect the No.1 and No.2 terminals, of the radiater fan switch 2P connector with a jumper wire. RADIATOR FAN SWITCH 2P CONNECTOR


1 Terminal side of female terminals

2

~JUMPER

4 3

CD---JWIRE Wire side of female terminals RADIATOR FAN MOTOR 2P CONNECTOR


Is there continuity? Does the radiator fan run? YES-Goto step 8. YES- Replace the radiator fan switch .• NO- Repair open in the wire between the underhood fuse/relay box and the radiator fan motor 2P connector terminal No.2 .• 8. Check for continuity between the No.1 terminal of the radiator fan motor 2P connector and body ground.

NO-Gotostep 12. 12. Remove the jumper wire, and measure the voltage between the No.2 terminal of the radiator fan switch connector and body ground. RADIATOR FAN SWITCH 2P CONNECTOR

RADIATOR FAN MOTOR 2P CONNECTOR



Is there battery voltage? Is there continuity? YES - Replace the radiator fan motor.• NO-Check for an open in the wire between radiator fan motor 2P connector terminal No.1 and body ground. If the wire is OK, check for a poor ground at G201 .•

10-20

BACK

YES-Check for an open in the wire between radiator fan switch 2P connector terminal No.1 and body ground. If the wire is OK, check for a poor ground at G302 .• NO- Repair open in the wire between the radiator fan switch terminal No.2 and the under-hood fuse/relay box .•

Radiator Fan Switch Circuit Troubleshooting (Open)

Radiator Fan Switch Circuit Troubleshooting (Short)

1. Disconnect the radiator fan switch 2P connector.

1. Remove the radiator fan relay from the under-hood fuse/relay box, and test it (see page 22-52).

2. Turn the ignition switch ON (II). /s the relay OK?

3. Measure voltage between the No.2 terminal of the radiator fan switch 2P connector and body ground.

YES - Go to step 2. NO- Replace the radiator fan relay .•

RADIATOR FAN SWITCH 2P CONNECTOR

2. Remove the radiator fan switch, and test it (see page 10-22).

Is the radiator fan switch OK? YES - Go to step 3.


NO- Replace the radiator fan switch .•

= 3. Disconnect ECM/PCM connector B (24P) and the under-hood fuse relay box 14P connector. /s there battery voltage?

4. Check for continuity between the No.2 terminal of the radiator fan switch 2P connector and body ground.

YES-Go to step 4. NO- Repair open in the wire between the radiator fan switch 2P connector terminal No.2 and underhood fuse/relay box.•

RADIATOR FAN SWITCH 2P CONNECTOR

4. Turn the ignition switch OFF, and check for continuity between the No.1 terminal of the radiator fan switch 2P connector and body ground. RADIATOR FAN SWITCH 2P CONNECTOR




=

YES-Repair short in the wire between the radiator fan switch 2P connector terminal No.2 and underhood fuse/relay box.•

/s there continuity?

NO - Replace the under-hood fuse/relay box.• YES- Replace the radiator fan switch .• NO-Check for an open in the wire between the radiator fan switch 2P connector terminal No.1 and body ground. If the wire is OK, check for a poor ground at G201 .•

BACK

10-21

Fan Controls Radiator Fan Switch Test NOTE: Bleed air from the cooling system after installing the radiator fan switch (see page 10-10). 1. Remove the radiator fan switch from the thermostat cover (see page 10-2). 2. Suspend the radiator fan switch (A) in a container of water as shown.

C

D

A

3. Heat the water and check the temperature with a thermometer. Do not let the thermometer (B) touch the bottom of hot container. 4. Measure the continuity between the A terminal (e) and B terminal (D) according to the table. 1\ Operation

Terminal A B Temperature 196°-203°F 0ON (91°-95°C) O 0 5 -15°F (3°-S C) lowe OFF than the temperature when it goes on

f-O

SWITCH

10-22

BACK

Fuel and Emissions Fuel and Emissions Systems Special Tools ............................ General Troubleshooting Information ........................... DTC Troubleshooting Index .... Symptom Troubleshooting .... System Descriptions ................ How to Set Readi ness Codes ..

11-2 11-3 11-6 11-9 11-10 11-42

PGM-FI System Component Location Index DTC Troubleshooting .............. MIL Circuit Troubleshooting ... DLC Circuit Troubleshooting .. Injector Replacement ............... H02S and AlF Sensor Replacement .........................

11-45 11-47 11-91 11-95 11-97

11-104 11-106

Catalytic Converter System

11-99

11-100 11-101

11-129 11-130

11-131 11-132 11-132 11-133 11-134 11-135 11-136

DTC Troubleshooting .............. 11-137 11-107

EGRSystem 11-108

DTC Troubleshooting .............. 11-138

PCV System 11-109 11-110

Fuel Supply System Component Location Index PGM-FI Main Relay Circuit Troubleshooting ................... Fuel Pressure Relieving ........... Fuel Pressure Test ................... FuelPumpTest ........................ Fuel Line Inspection ................ Fuel Tube/Quick·Connect Fittings Precautions ........................... Fuel Tube/Quick·Connect Fittings Removal ................................ Fuel Tube/Quick·Connect Fittings Installation ............................

11-123 11-123 11-124 11-125 11-128

Intake Air System Component Location Index Th rottle Body Test ............ ....... Intake Air Bypass Control ValveTest ............................. Air Cleaner Element Replacement ......................... Throttle Cable Adjustment ...... Throttle Body Removal/ Installation ............................ Throttle Body Disassembly/ Reassembly ..........................

Idle Control System Component Location Index DTC Troubleshooting ............. . AlC Signal Circuit Troubleshooting .................. . Alternator FR Signal Circuit Troubleshooting .................. . Starter Switch Signal Circuit Troubleshooting .................. . PSP Switch Signal Circuit Troubleshooting .................. . Brake Pedal Position Switch Signal Circuit Troubleshooting .................. . Idle Speed Adjustment ........... .

Fuel Pressure Regulator Replacement ......................... Fuel Filter Replacement ........... Fuel Pump Replacement ......... Fuel Tank Replacement ........... Fuel Gauge Test ....................... Fuel Gauge Sending Unit Test/Replacement ................ Low Fuel Indicator Light Test ........................................

PCV Valve Inspection and Test ........................................ 11-143

EVAP System 11-111 11-112 11-115 11-115 11-117 11-118 11-120 11-120 11-121

Component Location Index DTC Troubleshooting ............. . EVAP Two Way Valve Test ..... . Fuel Tank Vapor Control Valve Test ....................................... . Fuel Tank Vapor Control Valve Replacement ........................ .

11-144 11-145 11-159 11-160 11-162

r.) , ___

Fuel and Emissions Systems Special Tools Ref. No.

CD ® ® G)

®

Tool Number A973X-041-XXXXX 07JAZ-001000B 07SAZ-001 OOOA 07VAJ-0040100 07406-0040001

Description Vacuum Pump/Gauge, 0-30 in. Hg Vacuum/Pressure Gauge, 0-4 in. Hg Backprobe Set Fuel Pressure Gauge Attachment Fuel Pressure Gauge

®

®

11-2

BACK

Oty 1 1 2 1 1

General Troubleshooting Information Intermittent Failures The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the Malfunction Indicator Lamp (MIL) on the dash does not come on, check for poor connections or loose wires at all connectors related to the circuit that you are troubleshooting.

2. If the MIL stays on, connect the Honda PGM Tester (A) or an OBDII scan tool to the Data Link Connector (DLC) (B) located under the driver's side of the dashboard.

Opens and Shorts "Open" and "Short" are common electrical terms. An open is a break in a wire or at a connection. A short is an accidental connection of a wire to ground or to another wire. In simple electronics, this usually means something won't work at all. With complex electronics such as ECMs/PCMs, this can sometimes mean something works, but not the way it's supposed to.

How to Use the PGM Tester or a Scan Tool 3. Turn the ignition switch ON (II). If the MIL (MaHunction Indicator Lamp) has come on 1. Start the engine and check the MIL.

4. Check the Diagnostic Trouble Code (DTC) and note it. Then also check the freeze data. Refer to the DTC Troubleshooting Index and begin the appropriate troubleshooting procedure. NOTE: • Freeze data indicates the engine conditions when the first malfunction, misfire, or fuel trim malfunction was detected. • The scan tool and the Honda PGM tester can read the DTC, freeze data, current data, and other Engine Control Module (ECM)/Powertrain Control Module (PCM) data. • For specific operations, refer to the user's manual that came with the scan tool or PGM Tester.

If the MIL did not come on If the MIL did not come on but there is a driveablility problem, refer to the Symptom Troubleshooting index in this section. If you can't duplicate the DTC Some of the troubleshooting in this section requires you to reset the ECM/PCM and try to duplicate the DTC. Ifthe problem is intermittent and you can't duplicate the code, do not continue through the procedure. To do so will only result in confusion and, possibly, a needlessly replaced ECM/PCM.

(cont'd)

BACK

11-3

Fuel and Emissions Systems General Troubleshooting Information (cont'd) How to Reset the ECM/PCM

How to Remove the ECM/PCM for Testing

You can reset the ECM/PCM in either of two ways:

If the inspection for a trouble code requires voltage or resistance checks at the ECM/PCM connectors, remove the ECM/PCM and test it:

• Use the OBO II scan tool or Honda PGM Tester to clear the ECM/PCM memory. See the OBO II scan tool or Honda PGM Tester user's manuals for specific instructions. • Turn the ignition switch OFF, and remove the No.13 CLOCK BACKUP fuse (7.5A) (A) from the passenger's under-dash fuse/relay box (B) for 10 seconds.

1. Pull back the carpet from the passenger's and driver's side of the center console to expose the ECM/PCM. 2. Remove the two bolts (4 cylinder model), or three bolts (V6 model) from the ECM/PCM (A).

NOTE: If the No. 13 CLOCK BACK UP (7.5A) fuse is removed and engine is started, the MIL will come on and the PCM will store OTC P0560 (F23A4 engine).

How to End a Troubleshooting Session (required after any troubleshooting) 1. Reset the ECM/PCM as described above. 2. Turn the ignition switch OFF. 3. Disconnect the OBO II scan tool or Honda PGM Tester from the OLC. NOTE: The ECM/PCM is part of the immobilizer system. If you replace the ECM/PCM, it will have a different immobilizer code. In order for the engine to start, you must rewrite the immobilizer code with the Honda PGM Tester.

11-4

BACK

How to Troubleshoot Circuits at the ECM/PCM

How to substitute the ECM/PCM for testing purposes

Special Tools Required • Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter • 8ackprobe Set 07SAZ-001000A (2)

Use this procedure if you need a known-good ECM/ PCM to test a vehicle. It allows you to swap an ECM/ PCM from a "donor" vehicle without having to program it to the test vehicle's ignition key.

1. Connect the backprobe adapters (A) to the stacking patch cords (8), and connect the cords to a multi meter (C).

1. Cut a temporary ignition key for the test vehicle with a non-immobilizer key blank.

A

2. Remove the ECM/PCM from the test vehicle. 3. Write the test vehicle's VIN on the ECM/PCM you just removed to avoid confusing it with the donor vehicle's ECM/PCM. 4. Remove the known-good ECM/PCM from the donor vehicle, and install it in the test vehicle. 5. Tape the donor vehicle's ignition key head-to-head to the test vehicle's temporary key (A). The ECM/ PCM will recognize the code from the donor vehicle's key (8) and allow you to start the engine with the temporary key.

07SAZ-001000A

2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end ofthe wire terminal. 3. If you cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (8) from the terminal side. Do not force the probe into the connector.

INOTICEI Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections.

B

6. After completing your tests, reinstall both ECMs/ PCMs, and destroy the temporary key. A

B

BACK

11-5

Fuel and Emissions Systems OTe Troubleshooting Index DTC (MIL indication *)

Temporary DTC

Detection Item

P0107 (3)

--

P0108 (3)

--

P0112 (10) P0113(10) P0116 (86)

--

Manifold Absolute Pressure (MAP) Circuit Low Voltage Manifold Absolute Pressure (MAP) Circuit High Voltage Intake Air Temperature (lAT) Circuit Low Voltage Intake Air Temperature (lAT) Circuit High Voltage Engine Coolant Temperature (ECT) Sensor Circuit Range/Performance Problem Engine Coolant Temperature (ECT) Sensor Circuit

P0117 (6)

-P0116 --

Note

(see page 11-47) (see page 11-48) (see page 11-50) (see page 11-51) (see page 11-52) (see page 11-52)

LowVolt~ge

P0118 (6)

--

P0122 (7) P0123 (7) P0128*3.*7 (87) P0131*5 (1)

-P0128 P0130

P0132*· (1)

P0130

P0133*· (61)

P0133*·

P0135*· (41)

--

--

Engine Coolant Temperature (ECT) Sensor Circuit High Voltage Throttle Position (TP) Sensor Circuit Low Voltage Throttle Position (TP) Sensor Circuit High Voltage Cooling System Malfunction Primary Heated Oxygen Sensor (Primary H02S) (Sensor 1) Circuit Low Voltage Primary Heated Oxygen Sensor (Primary H02S) (Sensor 1) Circuit High Voltage Primary Heated Oxygen Sensor (Primary H02S) (Sensor 1) Slow Response Primary Heated Oxygen Sensor (Primary H02S) (Sensor 1) Heater Circuit Malfunction Secondary Heated Oxygen Sensor (Secondary H02S) (Sensor 2) Circuit Low Voltage

P0137 (63)

P0136

P0138 (63)

P0136

Secondary Heated Oxygen Sensor (Secondary H02S) (Sensor 2) Circuit High Voltage

P0139 (63)

P0136

Secondary Heated Oxygen Sensor (Secondary H02S) (Sensor 2) Slow Response Secondary Heated Oxygen Sensor (Secondary H02S) (Sensor 2) Heater Circuit Malfunction Fuel System Too Lean Fuel System Too Rich Random Misfire

P0141 (65)

--

(see page 11-53) (see page (see page (see page (see page

11-54) 11-57) 11-58) 11-59)

(see page 11-60) (see page 11-61) (see page 11-67) F23A4 SULEV engine: (see page 11-63), Except F23A4 SULEV engine: (see page 11-62) F23A4 SULEV engine: (see page 11-65), Except F23A4 SULEV engine: (see page 11-64) (see page 11-66) (see page 11-67)

(see~~e 11-69) P0171 (45) P0170 (see page 11-69) P0172 (45) P0170 (see page 11-70) P1399 P0300 and some of P0301 (71) P0302(72) P0303 (73) P0304 (74) (see page 11-71) P0301 (71) P1399 No.1 Cylinder Misfire P0302(72) No.2 Cylinder Misfire No.3 Cylinder Misfire P0303 (73) No.4 Cylinder Misfire P0304 (74) *. These DTCs are indicated by a blinking MalfunctIon IndIcator Lamp (MIL) when the SCS servIce slgnallrne IS jumped with the Honda PGM Tester. **. The D4 indicator light and the MIL may come on simultaneously. *1: MIT *5: F23A1, F23A5 engine *6: '00 model *2: AfT *3: F23A4 engine *7: '01-02 models *4: F23A1 engine

11-6

BACK

DTC (MIL indication *) P0325 (23) P0335 (4) P0336 (4)

Temporary DTC

----

P0401 (80) P0420 (67) P0451*6 (91)

P0401

P0452 (91) P0453 (91) P0500*' (17) P0505 (14) P0560*3 (34) P07XX*2.** (70)

P0450 P0450

P1106 (13)

P1106

--

P0451

--

P0505 --

--

Detection Item Knock Sensor (KS) Circuit Malfunction Crankshaft Position (CKP) Sensor Circuit No signal Crankshaft Position (CKP) Sensor Intermittent Interruption Exhaust Gas Recirculation (EGR) Insufficient Flow Catalyst System Efficiency Below Threshold Fuel Tank Pressure (FTP) Sensor Range/Performance Problem Fuel Tank Pressure (FTP) Sensor Circuit Low Volt~e Fuel Tank Pressure (FTP) Sensor Circuit High Voltage Vehicle Speed Sensor (VSS) Circuit Malfunction Idle Control System Malfunction ECM/PCM Back up Circuit Low Voltage Automatic Transaxle

Note (see page 11-72) (see page 11-73) (see page 11-73) (see~~e 11-138) (see page 11-137) (see page 11-145)

(see~age 11-146) (see page 11-147) (see~~e 11-75) (seepage 11-101) (see~~e 11-76) Refer to the Automatic Transmission DTC Troubleshooting Index (see page 11-77)

Barometric Pressure (BARD) Sensor Range/ Performance Problem -P1107 (13) Barometric Pressure (BARD) Sensor Circuit Low (see page 11-77) Voltage -P1108 (13) (see page 11-77) Barometric Pressure (BARD) Sensor Circuit High Voltage P1121 (7) P1121 Throttle Position (TP) Sensor Lower Than E~ected (see~~e 11-56) P1122 (7) P1122 (see page 11-56) Throttle Position (TP) Sensor Higher Than Expected P1 128 (5) P1128 Manifold Absolute Pressure (MAP) Sensor Lower (see page 11-49) Than Expected P1129 (5) P1129 Manifold Absolute Pressure (MAP) Sensor Higher (see page 11-49) Than Expected P1149*3 P1149*" (61) Air Fuel Ratio (A/F) Sensor (Sensor 1) Range/ (see page 11-78) Performance Problem -P1162*3 (48) Air Fuel Ratio (A/F) Sensor (Sensor 1) Circuit (see page 11-79) Malfunction P1163*3(61) P1163*3 Air Fuel Ratio (A/F) Sensor (Sensor 1) Slow Response (see page 11-61) P1164*3 (61) P1164*3 Air Fuel Ratio (A/F) Sensor (Sensor 1) Range/ (see page 11-80) Performance Problem P1165*3 P1165*"(61) Air Fuel Ratio (A/F) Sensor (Sensor 1) Rangel (see page 11-78) Performance Problem -P1166*3 (41) Air Fuel Ratio (A/F) Sensor (Sensor 1) Heater Circuit (see page 11-81) Malfunction -P1167*3 (41) Air Fuel Ratio (A/F) Sensor (Sensor 1) Heater System (see page 11-83) Malfunction *: These DTCs are mdlcated by a bllnkmg Malfunction Indicator Lamp (MIL) when the SCS service signal line jumped with the Honda PGM Tester. **: The D4 indicator light and the MIL may come on simultaneously. *1: MIT *2:A/T *3: F23A4 engine *4: F23A1 engine *5: F23A1, F23A5 engine *6: '00 model *7: '01-02 models *8: F23A4 ULEV engine

IS

(cont'd)

BACK

11-7

Fuel and Emissions Systems DTC Troubleshooting Index (co nt'd) DTC (MIL indication *) P1259*3,*4 (22) P1297 (20)

Temporary DTC

Detection Item

--

VTEC System Malfunction Electrical Load Detector (ELD) Circuit Low Voltage Electrical Load Detector (ELD) Circuit High VoltaQe Crankshaft Position (CKP)fTop Dead Center (TDC) Sensor Circuit Malfunction Top Dead Center (TDC) Sensor Intermittent Interruption Top Dead Center (TDC) Sensor No Signal Cylinder Position (CYP) Sensor Intermittent Interruption Cylinder Position (CYP) Sensor No Signal Evaporative Emission (EVAP) Control System Leakage (Fuel Tank System) Evaporative Emission (EVAP) Control System Leakage (EVAP Canister System) Cooling System Malfunction Exhaust Gas Recirculation (EGR) Valve Insufficient Lift Exhaust Gas Recirculation (EGR) Valve Position Sensor Circuit High Voltage Idle Air Control (lAC) Valve Circuit Malfunction Engine Control Module (ECM)/Powertrain Control Module (PCM) Internal Circuit Malfunction Automatic Transaxle

--

P1298 (20)

--

P1359 (8)

--

P1361 (8)

--

P1362 (8) P1381 (9)

--

---

P1382 (9) P1456 (90)

P1456

P1457 (90)

P1457

P1486*6 (87) P1491 (12)

P1486 P1491

P1498 (12)

--

P1519 (14) P1607 (-)

---

P17xx*2,** (70)

--

Note

(see page 6-7) (see page 11-84) (see page 11-85) (see page 11-87) (see page 11-73) (see page 11-73) (see page 11-88) (see page 11-88) (see page 11-149) (see page 11-152) (see page 11-58) (see page 11-138) (see page 11-142) (see page 11-102) (see page 11-90)

Refer to the Automatic Transmission DTC Troubleshooting Index *: These DTCs are indicated by a blinking Malfunction Indicator Lamp (MIl) when the SCS service signal line IS jumped with the Honda PGM Tester. **: The D4 indicator light and the MIL may come on simultaneously. *1: MfT *2: AfT *3: F23A4 engine *4: F23A1 engine *5: F23A1, F23A5 engine *6: '00 model *7: '01-02 models

11-8

BACK

Symptom Troubleshooting Index These symptoms DO NOTtrigger Diagnostic Trouble Codes (DTCs) and cause the Malfunction Indica~or Lam~ (MIL) to come on. If the MIL is reported on, check for DTCs. If the vehicle has one of these symptoms, do the diagnostic procedure for it, in the sequence listed, until you find the cause. Diagnostic procedure

Also check for

Testthe battery (see page 22-51) Test the starter (see page 4-5) Testthe fuel pump (see page 11-117) Testthe ignition wires (see page 4-25) Test the ignition coil (see page 4-24) 6. Check the ICM (ignition control module) inputs (see page 4-23) 7. Troubleshoot the PGM-FI main relay circuit (see page 11112)

• Low compression • No ignition spark • Intake air leaks • Locked up engine • Slipped! broken timing belt • Contaminated fuel

Symptom

Engine will not start (MIL works OK, no DTCs set)

1. 2. 3. 4. 5.

Engine will not start (MIL comes on and stays on, or never comes on at all, no DTCsset) Engine will not start (immobilizer indicator light comes on) Hard starting (MIL works OK, no DTCs set)

Troubleshoot the MIL circuit (see page 11-91)

Cold fast idle too low (MIL works OK, no DTCs set) Cold fast idle too high (MIL works OK, no DTCs set)

Check/adjustthe idle speed (see page 11-110)

Idle speed fluctuates (MIL works OK, no DTCs set) Low power (MIL works OK, no DTCs set) Engine stalls (MIL works OK, no DTCs set)

Difficult to refuel (MIL works OK, no DTCs set)

Fuel overflows during refueling (No DTCs set)

Troubleshoot the immobilizer system (see page 22-204)

1. Testthe battery (see page 22-51) 2. Check the fuel pressure (see page 11-115) 3. Testthe ignition wires (see page 4-25) 4. Test the ignition coil (see page 4-24) 5. Check the ICM (ignition control module) inputs (see page 4-24)

1. 2. 3. 1. 2. 3. 1. 2. 3. 1. 2. 3. 4.

Check/adjust the idle speed (see page 11-110) Inspect/adjust the throttle cable (see page 11-134) Inspect and test the throttle body (see page 11-132) Check/adjust the idle speed (see page 11-110) Inspect/adjustthe throttle cable (see page 11-134) Inspect and test the throttle body (see page 11-132) Check the fuel pressure (see page 11-115) Inspect and testthe throttle body (see page 11-132) Inspect/adjustthe throttle cable (see page 11-134) Check the fuel pressure (see page 11-115) Test the ignition wires (see page 4-25) Check!adjustthe idle speed (see page 11-110) Troubleshoot the brake pedal position switch signal circuit (see page 11-109) 1. Test the fuel tank vapor control valve (see page 11-160) 2. Inspect the fuel tank vapor control signal tube between the fuel pipe and the fuel tank vapor control valve 3. Inspect the fuel tank vapor vent tube between the EVAP canister and the fuel tank vapor control valve 4. Check the EVAP canister (see page 11-138) Replace the fuel tank vapor control valve (see page 11-162)

BACK

• Low compression • Intake air leaks • Contaminated fuel • Weak ignition spark

Intake air leaks

Low compression • Intake air leaks • Faulty harness and sensor connections Malfunctioning gas station filling nozzle

Malfunctioning gas station filling nozzle

11-9

Fuel and Emissions Systems System Descriptions Electronic Control System The functions of the fuel and emission control systems are managed by the engine control module (ECM) on vehicles with manual transmissions or the powertrain control module (PCM) on vehicles with automatic transmissions. Fail-safe Function When an abnormality occurs in the signal from a sensor, the ECM/PCM ignores that signal and assumes a preprogrammed value for that sensor that allows the engine to continue to run. Back-up Function When an abnormality occurs in the ECM/PCM, the injectors are controlled by a back-up circuit independent of the system in order to permit minimal driving. Self-diagnosis When an abnormality occurs in the signal from a sensor, the ECM/PCM supplies ground for the Malfunction Indicator Lamp (MIL) and stores the Diagnostic Trouble Code (DTC) in erasable memory. When the ignition is first turned on, the ECM/PCM supplies ground to the MIL for 2 seconds ('98-01 models) or 15 to 20 seconds ('02 models) to check the MIL bulb condition. Two Driving Cycle Detection Method To prevent false indications, the "two driving cycle detection method" is used for some self-diagnostic functions. When an abnormality occurs, the ECM/PCM stores it in its memory. When the same abnormality recurs after the ignition switch is turned OFF and ON (II) again, the ECM/PCM turns on the MIL.

11-10

BACK

ECM/PCM Data You can retrieve data from the ECM/PCM by connecting the OBD II scan tool or the Honda PGM Tester to the data link connector (DLC). The items listed in the table below conform to SAE recommended practice. The Honda PGM Tester also reads data beyond that recommended by SAE to help you find the causes of intermittent problems. NOTE: • The "operating values" listed are approximate and may vary depending on the environment and the individual vehicle . • Unless noted otherwise, "at idle speed" means idling with the engine completely warmed up, AfT in park or neutral, . turne d off . MIT in neutra I position, an d t he A/C an d aII accessories Data

Diagnostic Trouble Code (DTC) Engine Speed

Vehicle Speed

Manifold Absolute Pressure (MAP)

Operating Value

Description

If the ECM/PCM detects a problem, it will store it as a code consisting of one letter and four numbers. Depending on the problem, as SAE-defined code (POxxx) or a Hondadefined code (P1 xxx) will be output to the tester. The ECM/PCM computes engine speed from the signals sent from the Crankshaft Position sensor. This data is used for determining the time and amount of fuel injection. The ECM/PCM converts pulse signals from the Vehicle Speed Sensor (VSS) (MIT) or countershaft speed sensor (AfT) into speed data. The absolute pressure caused in the intake manifold by engine load and speed.

Engine Coolant Temperature (ECT)

The ECT sensor converts coolant temperature into voltage and signals the ECM/PCM. The sensor is a thermistor with internal resistance that changes with coolant temperature. The ECM/PCM uses the voltage signals from the ECT sensor to determine the amount of injected fuel.

Heated Oxygen Sensor (H02S) (Primary, Sensor 1) (Secondary, Sensor 2)

The Heated Oxygen Sensor detects the oxygen content in the exhaust gas and sends voltage signals to the ECM/ PCM. Based on these signals, the ECM/PCM controls the air/fuel ratio. When the oxygen content is high (that is, when the ratio is leaner than the stoichiometric ratio), the voltage signal is lower. When the oxygen content is low (that is, when the ratio is richer than the stoichiometric ratio), the voltage signal is higher. The A/F sensor detects the oxygen content in the exhaust gas and sends voltage signals to the ECM/PCM. Based on these signals, the ECM/PCM controls the air/fuel ratio. When the oxygen content is high (that is, when the ratio is leaner than the stoichiometric ratio), the voltage signal is lower. When the oxygen content is low (that is, when the ratio is richer than the stoichiometric ratio), the voltage signal is higher. The A/F sensor Signals are electrical current that are indicated as voltage on the scan tool.

Air Fuel Ratio (A/F) Sensor, (Sensor 1) (F23A4 engine)

Freeze Data

If no problem is detected, there is no output.

YES

Nearly the same as tachometer indication At idle speed: 700±50 rpm Nearly the same as speedometer indication With engine stopped: Nearly the same as atmospheric pressure. At idle speed: about 21 -41 kPa (160-310 mmHg, 6.3-12.2 inHg), 0.7-1.3V With cold engine: Same as ambient temperature and IAT With engine warmed up: about 158-212°F (70-100°C) 0.5to 0.7 Volts 0.0-1.25V At idle speed: about 0.1-0.9 V

YES

0.0-1.25 V At idle speed: about 0.1 - 0.9 V

YES

YES

YES

YES (Primary, Sensor 1 only)

NO

(cont'd)

BACK

11-11

Fuel and Emissions Systems System Descriptions (cont'd) ECM/PCM Data (cont'd) Data

Fuel System Status

Short Term Fuel Trim

long Term Fuel Trim

Intake Air Temperature (IAT) Throttle Position Ignition Timing

Calculated load Value (ClV)

11-12

Description

loop status is indicated as "open" or "closed". Closed: Based on the H02S and/or A/F Sensor output, the ECM/PCM determines the air/fuel ratio and controls the amount of injected fuel. Open: ignoring H02S or A/F Sensor output, the ECM/PCM refers to signals from the Throttle Position (TP), Manifold Absolute Pressure (MAP), Intake Air Temperature ((AT), Barometric Pressure (BARO), and Engine Coolant Temperature (ECT) sensors to control the amount of injected fuel. The air/fuel ratio correction coefficient for correcting the amount of injected fuel when the Fuel System Status is "closed". When the ratio is leaner than the stoichiometric ratio, the ECM/PCM increases short term fuel trim gradually, and the amount of injected fuel increases. The air/fuel ratio gradually gets richer, causing a lower oxygen content in the exhast gas. Consequently, the short term fuel trim is lowered, and the ECM/PCM reduces the amount of injected fuel. This cycle keeps the air/fuel ratio close to the stoichiometric ratio when in closed loop status. long term fuel trim is computed from short term fuel trim and indicates changes occuring in the fuel supply system over a long period. If long term fuel trim is higher than 1.00, the amount of injected fuel must be increased. If it is lower than 1.00, the amount of injected fuel must be reduced. The IAT sensor converts intake air temperature into voltage and signals the ECM/PCM. When intake air temperature is low, the internal resistance ofthe sensor increases, and the voltage signal is higher. Based on the accelerator pedal position, the opening angle of the throttle valve is indicated. Ignition timing is the ignition advance angle set by the ECM/PCM. The ECM/PCM matches ignition timing to the driving conditions.

ClV is the engine load calculated from the MAP data.

BACK

Operating Value

At idle speed: closed

Freeze Data YES

1.00±0.20

YES

1.00±0.20

YES

With cold engine: Same as ambient temperature and ECT

YES

At idle speed: approx.10% At idle speed: 12°±2° BTDC with the SCS service signal line is jumped with the Honda PGMTester At idle speed: 21-41% At 2,500 rpm with no load: 13-26%

YES NO

YES

ECM/PCM Electrical Connections PGM.fI MAIN RELAY

'--

811GP1

PG182 ~

891GP2

PG2810 ~

A24STS

IMOFLR A1S

>- t--

821 V8U

CYP SENSOR

roc SENSOR CKP SENSOR

-=-

820 LG1

I

822LG2

----- --- ----

-----

Ej I r==i.

._---

b9 ___________

-----

~

INJECTORS No.1 CZ9CVPP

INJ1 811

C30CVPM

1NJ283

C20TDCP

INJ384

CZ1 TDCM

1NJ48S

lAC VALVE

IACV823

>-~~

_--I-I--~A30;ELEL~I_r h ~ 4i _1....:.V~S~S~"~"':~:.~~~'--"-~~~.~.~.~-:..'~'1-~_9V_:_SS_O*_~_*_2 M_I_L_A1_8--1~If<>-------'

To SPEEDOMETER

ToELD

,",

*1

~.~

CSCKPP CSCKPM

~

E

-"1

••

-,-_ _

i. .. ---.::.~.j DATA UNK CONNECTOR loll---~

A21 K-LINE

r-----

ACCA17

ToAIC CLUTCH RELAY

1-----l--F-A-NC-A20---I~ To RADIATOR FAN RELAY. r----

ACS A27

RADIATOR FAN SWITCH

~ To AIC SWITCH

L-----l C

~-----~~A~10~S~C~S_ _~_~A~U~C~C:2~--t11rl ~

L_A~L~TF~C5~[--tiU ~ ALT

FUSES:

(j) BACK UP, ACC (40A)*A

IMOLMPA12

(2) STOP (20A)U @ACGS (15A)*A ®BATTERY (100A) *A <5> IG MAIN (50A)*A @No.1 FUEL PUMP (15A)*B r:t> No.9 BACK UP LIGHT INSTRUMENT UGHT (7.5A)*B @ No.6 ECU (ECMlPCM) CRUISE CONTROL (15A)*B ® No.13 STARTER SIGNAL (7.5A)* B (10 No.13 CLOCK BACKUP (7.5A)*C @POWERSEAT (40A)*A @No.6 LAF HEATER (20A)*C *A : in the under-hood fuse/relay box * B : in the under-dash driver's fuse/relay box *c: In the under-dash passenger's fuse/relay box

r

~If<>-------' IMM081l1ZER INDICATOR UGHT

*1 :M/T

*2:A/T

*3: F23A4 engine *4: F23A1, F23A4 engine *5: F23A1, F23A5 engine *6: '0D--iI2 models

(cont'd)

BACK

11-13

Fuel and Emissions Systems System Descriptions (cont'd) ECM/PCM Electrical Connections (cont'd)

-

_/

C28 VCC2

TP SENSOR

ICMB13

C27TPS

I

C&EGRL

-1 T

~

r

NEPAl. CRSAS

87E-EGR

l!:~

EG R VALVE

1

ICM

C18SG2

.--

EGRVALVE POsmON SENSOR

1

To GAUGE ASSEMBLY TEST TACHOMETER To CRUISE CONTROL UNIT

~

FTP

I

SENSOR

EVAP ~TOR PURGE VALVE

_J

MAP SENSOR

A29PTANK

PCSA8

C19VCC1

MCSA2

C17MAP

.2VBSOLDS

ENGI~AUNT CONTROL SOLENOID VALVE '00

C7SGl

I

To CUMATE CONTROL UNIT

EVAP Bm,.SS SOLENOID VALVE

E~ENSORI

...

2WBSA3 C26 ECT

VSVA4 VTEC .4VTSB12

IA!,SENSOR

.....

C25IAT

A28PSPSW

04 KSC3

[A~

...=-

VTEC~URE

'00

j ---"{[]I

.... m_

1 l

IMOCDA2S

To IMMOBIUZER RECEIVER

A32BKSW

IMOENA13

To IMMOBILIZER RECEIVER

C10VTM 04

02ILUA28

To MULTIPLEX CONTROL UN IT (DRIVER'S)·2

BPPA'CH

B

S~OID VALVE·4

KNOCK SENSOR·4

PSP;;;;'CH

--..:..7

~TER VENT SHUT VALVE

EVA;-

SWlTCH·4

-S '-7

E PRIMARY HO2S (SENSOR 1)·5

1;1

II

I~~

SECONDARY HO2S (SENSOR 2)

II

..

I~~

-_ ... -..

---

C1 P02SHTC·5

------

......... ----

OiiMTRTWC24

C16PH02S .5

~ A8S02SHTC

----._.- ... - __ 00--.. .. ---- ... -

A23SH02S

BARO SENSOR (Buih Into lhe ECMlPCM)

~

11-14

BACK

ToECTGAUGE

-

0

~

0

2NDQ'CH PRESSURE SWITCH '2

'20P2SWB14

1

3RDQ'CH PRESSURE SWITCH' 2 '20P3SWB24

r--

---
!

B16 P02SHTCli1

=

A/F'sENsoR

HEATED CONTROL RELAY'3 C13 P02SHTC-j!

u, 'Ilf'A

B19 P02SHTC 03

jr

C15 PH02S

IF/"

03

C14 PH02S+ 03

AlFSENSOR (SENSOR 1)03

TCC~NOIDVALVE'2

02 LC 01

r

VV

SHI~LENOID VALVE A oZ OZSHAD7

'VV

~~;~BLy02 SHIFT SOLENOID VALVE B' 2

02 SHB D2

'VV

A14D41ND 02

SHIFT SOLENOID VALVE C' 2

*zSHC D3

'uu

~

D13ATPNP02

v: rI

0 lID

01Qil [ill

IQiI

rn

[I] AlTGEAR POSITION SWITCH *2

I

DiATPR 02 D9ATPD4'2

II

02LSA+B17 02 LSA

,........

B8

IF

I

AIT~~UTCH PRESSURE CONTROL

D8ATPD3*2

SOLENOID VALVE A 02

D14ATP2*Z

02 LSB+B25

D15ATPl 02

*2 LSB

I

BIB

AIT ;LUUTCH PRESSURE CONTROL SOLENOID VALVE B *2 C ww e

w _ _ _ _ .. _ _ .. _ _ _ _ _ _

*2NM 011

-----'

'2 NMSG 012 *2 NC OlD

-=

.... -- -_ .. --- .. --

~ ~:~~~H:E~OR*

---- .. ------ 8J COUNTERSHAFT SPEED SENSOR • c

'2NCSG D16

ECMlPCM B (25P)

ECMlPCM A (32P)

ECMlPCM C (31 p)

ECMlPCM D (16P)

TERMINAL LOCATIONS

(cont'd)

BACK

11-15

Fuel and Emissions Systems System Descriptions (cont'd) ECM/PCM Inputs and Outputs at Connector A (32P)

V

2 3 4 MCS 2\NBS vsv 12 13 14 15 IMO lMO IMO 05 LMP EN INO FLR

V

25 26 27 IMO PSPSN I>CS CD

5 CRS

6 PCS

17

18 MIL

I>CC

8 9 S02S VSS HTC OTU

/

19 20 21 NEP FANC K-UNE

28

29

ILU PTANK

30 EL

/

/

10

scs 23

SH02S

/ 24 STS

32 8KSW


NOTE: Standard battery voltage is 12 V. Terminal number 2

Wire color

Terminal name

Description

GRN/WHT

3

BLU

5

LTGRN/ WHT BLU/GRN

Drives engine mount control solenoid valve. Drives EVAP bypass solenoid valve. Drives EVAP canister vent shut valve. Detects cruise control signal.

Atidle:OV Above idle: batterv voltaae With ignition switch ON (II): battery voltage

4

6

RED/YEL

MCS (ENGINE MOUNT CONTROL SOLENOID VALVE) 2WBS (EVAP BYPASS SOLENOID VALVE) VSV (EVAP CANISTER VENT SHUT VALVE) CRS (CRUISE CONTROL SIGNAL) PCS (CANISTER PURGE VALVE)

Drives EVAP canister purge valve.

8

BLK/WHT

Drives secondary heated oxygen sensor heater.

9*'

BLU/WHT

10

BRN

S02SHTC (SECONDARY HEATED OXYGEN SENSOR HEATER CONTROL) VSSOUT (VEHICLE SPEED SENSOR OUTPUT SIGNAL) SCS (SERVICE CHECK SIGNAL)

With engine running, engine coolant, below 167°F (75°C): battery voltage With engine running. engine coolant, above 167°F (75°C): dutv controlled With ignition switch ON (II): battery voltage With fully warmed up engine running: duty controlled Depending on vehicle speed: pulses

12

PNK

IMOLMP (IMMOBILIZER INDICATOR LIGHT)

Drives immobilizer indicator light.

13

BLU

IMOEN (IMMOBILIZER ENABLE SIGNAL) D41ND (D4INDICATOR)

Sends immobilizer enable sianal. Drives D4 indicator light.

IMO FLR (IMMOBILIZER FUEL PUMP RELAY) ACC lAIC CLUTCH RELAY)

Drives fuel pump relay.

14*'

GRN/BLK

15

GRN/YEL

17

RED

18

GRN/ORN

19 20

BLU GRN

MIL (MALFUNCTION INDICATOR LIGHT) NEP (ENGINE SPEED PULSE) FANC (RADIATOR FAN CONTROL)

Sends vehicle speed sensor signal. Detects service check connector signal (the signal causing a DTC indication).

Drives AlC clutch relay. Drives MIL. OutDuts engine ~ed~ulse. Drives radiator fan relay.

*1: MIT *2:A/T *3: F23A4 engine * 4: F23A 1, F23A4 engine

11-16

BACK

Signal

With ignition switch ON (II): battery voltage With ignition switch ON (II): pulses

With the service check signal shorted with the PGM Tester: 0 V With the service check signal opened: about 5 V or batterv voltaae With immobilizer indicator light turned ON: 0 V With immobilizer indicator lightturned OFF: battery voltage

With D4 indicator light turned ON: 0 V With D4 indicator light turned OFF: battery voltaae oV for two seconds after turning ignition switch ON (II) then battery voltage With compressor ON: 0 V With compressor OFF: batterv voltaae With MIL turned ON: 0 V With MIL turned OFF: batterv voltaae With enaine runnina: Dulses With radiator fan running: 0 V With radiator fan stopped: batterv voltaQe

ECM/PCM Inputs and Outputs at Connector A (32P)

/

12 IMO LMP

2 MCS

3 2W8S

13 IMO EN

14 05 INO 25 IMO

4

vsv 15 IMO FLR

/

26

27

CD PSPSW />CS

CRS

5

6 PCS

17 ACC

16 MIL

V

19 NEP

2B 29 ILU PTANK

6 9 S02S vss HTC OTU 20 21 FANC K-UNE 30 EL

V

/

10 SCS

23 SH02S

/ 24 STS

32

BKSW


NOTE: Standard battery voltage is 12 V.

Terminal name

Description

Terminal number 21

Wire color

23

WHT/RED

24

BLU/ORN

25 26

RED GRN

27

BLU/RED

ACS (AlC SWITCH SIGNAL)

Detects AlC switch signal.

28*'

WHT/RED

ILU (INTERLOCK CONTROL UNIT) PTANK (FUEL TANK PRESSURE (HP) SENSOR) EL(ELD)

Drives interlock control unit.

BKSW (BRAKE PEDAL POSITION SWITCH)

Detects brake pedal position switch sional.

GRY

29

LTGRN

30

GRN/RED

32

WHT/BLK

K-LiNE SH02S (SECONDARY HEATED OXYGEN SENSOR, SENSOR 2) STS (STARTER SWITCH SIGNAL) IMOCD (IMMOBILIZER CODE) PSPSW (P/S PRESSURE SWITCH SIGNAL)

Sends and receives scan tool sional. Detects secondary heated oxygen sensor (sensor 2) si~:mal.

Detects starter switch signal. Detects immobilizer signal. Detects PSP switch signal.

Detects FTP sensor signal. Detects ELD signal.

Signal With ignition switch ON (II): battery voltage With throttle fully opened from idle and fully warmed up engine: above 0.6 V With throttle ouickly closed: below 0.4 V With starter switch ON (III): battery voltage With starter switch OFF: 0 V At idle with steering wheel in straight ahead position: 0 V At idle with steering wheel at full lock: battery voltaQe With AlC switch ON: 0 V With AlC switch OFF: about 5 V With ignition switch ON (II) and brake pedal pressed: batteryvolt
*1: MIT *2:A/T *3: F23A4 engine *4: F23A1, F23A4 engine

(cont'd)

BACK

11-17

Fuel and Emissions Systems System Descriptions (cont'd) ECM/PCM Inputs and Outputs at Connector B (25P) 1 IGPI

PGl

9 IGP2

10 PG2

19 PQ2S HTC

20 LGI

2 11 INJI

3 INJ2

4 INJ3

5 INJ4

12 VTS

13 ICM

14 OP 2SW

21

22 LG2

VBU

/

23 IACV

/

16 PQ2S HTCR 24 OP 3SW

7

E·EGR

6 LSA-

17 LSA+

16 LSB-

25 LSB+

Wire side of female terminals NOTE: Standard battery voltage is 12 V. Terminal name

Terminal number 1

Wire color VEL/BlK

IGP1 (POWER SOURCE)

2

BlK

PG1 (POWER GROUND)

3 4 5

7

RED BLU VEL PNK

INJ2(No.2INJECTOR) INJ3 (No.3 INJECTOR) INJ4 (No.4 INJECTOR) E-EGR

8*'

WHT

lSA-(NT CLUTCH PRESSURE CONTROL SOLENOID VALVE A-SIDE) IGP2 (POWER SOURCE)

9

VEL/BlK

10

BlK

PG2 (POWER GROUND)

11

BRN

INJ1 (No.1 INJECTOR)

12*'

GRN/VEl

13

VEL/GRN

14*'

BLU/BlK

16*'

GRN/RED

17*'

RED

18*'

GRN

19*'

BlK/WHT

20

BRN/BlK

VTS (VTEC SOLENOID VALVE) ICM (IGNITION CONTROL MODULE) OP2SW (2ND Oil PRESSURE SWITCH) P02SHTCR (AIR FUEL RATIO SENSOR HEATER CONTROL RELAV) lSA + (NT CLUTCH PRESSURE CONTROL SOLENOID VALVE A + SIDE) lSB - (NT CLUTCH PRESSURE CONTROL SOLENOID VALVE B-SIDE) P02SHTC (AIR FUEL RATIO SENSOR HEATER CONTROL) lG1 (lOGIC GROUND)

21

WHT/VEl

VBU (VOLTAGE BACK UP)

22

BRN/BlK

lG2 (lOGIC GROUND)

23

BlK/BlU

24*'

BLU/WHT

25*'

ORN

IACV (IDLE AIR CONTROL VALVE) OP3SW (3RD Oil PRESSURE SWITCH) lSB + (NT CLUTCH PRESSURE CONTROL SOLENOID VALVE B + SIDE)

Description Power source for the PCM control ci rcu it. Ground for the ECM/PCM control circuit. Drives No.2 iniector. Drives No.3 iniector. Drives No.4 injector. Drives EGR valve. NT clutch pressure control solenoid valve A power suoolv neaative electrode Power source for the PCM control circuit. Ground for the ECM/PCM control circuit. Drives No.1 injector. Drives VTEC solenoid valve. Sends ignition pulse. Detects 2nd oil pressure switch. Drives air fuel ratio sensor heater relay.

With ignition switch ON (II): battery voltage With ignition switch OFF: 0 V less than 1.0 V at all times With ignition switch ON (II): battery voltage With engine running: duty controlled With EGR operation during driving with fully warmed up engine: duty controlled With EGR not ooeratina: 0 V With ignition switch ON (II): duty controlled With ignition switch ON (II): battery voltage With ignition switch OFF: 0 V less than 1.0 V at all times With ignition switch ON (II): battery voltage With enaine run nina: duty controlled With engine at low rpm: 0 V With enaine at hiah rom: battery voltaae With ignition switch ON (II): battery voltage With el1Qjne running:_pulses With ignition switch ON (II): about 5 V With ignition switch ON (II): 0 V

NT clutch pressure control solenoid valve A power supply positive electrode NT clutch pressure control solenoid valve B power suoolv neaative electrode Drives air fuel ratio sensor heater. Ground for the ECM/PCM control circuit. Power source for the ECM/ PCM control circuit. Power source for the DTC memory. Ground for the ECM/PCM control circuit. Drives lAC valve.

With ignition switch ON (II): duty controlled

Detects 3rd oil pressure switch. NT clutch pressure control solenoid valve B power suppl'Lru)sitive electrode

With ignition switch ON (II): about 5 V

*1: MIT *2: NT *3: F23A4 engine *4: F23A1. F23A4 engine

11-18

Signal

BACK

With ignition switch ON (II): duty controlled With ignition switch ON (II): battery voltage With fully warmed uo enaine run nina: 0 V less than 1.0 V at all times Battery voltage at all times

less than 1.0 V at all times With engine running: duty controlled

With ignition switch ON (II): duty controlled

ECM/PCM Inputs and Outputs at connector C (31P) 1 P02S HTC

2 AlTC

1/1/ 23

vss

3 KS

V

14 13 P02S PH02 HTC+ 5+ 24 MTRTW

25 lAT

10 VTM

20 TDCP

21 TDCM

28

29

30

V

veC2

CYPP

CYPM

6 EGAL

7 SGI

16

17

18 SG2

5 15 PH02

9 8 CKPP CKPM

AlTF

5- PH02S MAP 26 ECT

27 TPS

19 veCI

lL:

Wife side of 'emilie tormln.'s

NOTE: Standard battery voltage is 12 V. Terminal number 1*'

Wire color

Terminal name

Description

Signal

BLK/WHT

Drives primary heated oxygen sensor heater.

2

WHT/GRN

P02SHTC (PRIMARY HEATED OXYGEN SENSOR HEATER CONTROL) ALTC (ALTERNATOR CONTROL)

3*' 5

RED/BLU WHT/RED

6

WHT/BLK

With ignition switch ON (II): battery voltage With fully warmed up engine running: duty controlled With fully warmed up engine running: battery voltage Duril'lg driving with small electrical load: 0 V With engine knocking: pulses With fully warmed up engine running: 0 V-battery voltaae (deoending on electrical load) At idle: about 1.2 V

7 8 9 10*'

GRN/WHT BLU WHT BLU/BLK

13*'

WHT

14*'

RED

15*'

BLU

16*'

WHT

17

RED/GRN

18 19

GRN/BLK YEL/RED

20 21 23*'

GRN RED BLU/WHT

24*"

YEL/GRN

25

RED/YEL

26

RED/WHT

27

RED/BLK

28

YEL/BLU

29 30

YEL BLK

KS (KNOCK SENSOR) ALTF (ALTERNATOR FR SIGNAL) EGRL (EXHAUST GAS RECIRCULATION (EGR) VALVE POSITION SENSOR) SG1 (SENSOR GROUND) CKPP (CKP SENSOR P SIDE) CKPM (CKP SENSOR M SIDE) VTM (VTEC PRESSURE SWITCH SIGNAL) P02SHTC+ (AIR FUEL RATIO (A/F) SENSOR HEATER CONTROL + SIDE) PH02S+ (AIR FUEL RATIO (NF) SENSOR. SENSOR 1 + SIDE) PH02S (AIR FUEL RATIO (A/F) SENSOR. SENSOR 1SIDE) PH02S (PRIMARY HEATED OXYGEN SENSOR. SENSOR 1) MAP (MANIFOLD ABSOLUTE PRESSURE SENSOR) SG2 (SENSOR GROUND) VCC1 (SENSOR VOLTAGE) TDCP (TDC SENSOR P SIDE) TDCM (TDC SENSOR M SIDE) VSS (VEHICLE SPEED SENSOR) MTRTW

Sends alternator control signal. Detects KS sianal. Detects alternator FR signal. Detects EGR valve position sensor signal. Ground for MAP sensor. Detects CKP sensor. Ground for CKP sensor. Detects VTEC pressure switch signal. Detects A/F sensor heater voltage.

Less than 1.0 V at all times With engine running: oulses With engine at low engine speed: 0 V With engine at high engine speed (vehicle runnina): battery volt!rn.e With ignition switch ON (II): battery voltage

Detects A/F sensor (sensor 1) signal. Detects A/F sensor (sensor 1) signal. Detects primary heated oxygen sensor (sensor 1) signal. Detects MAP sensor signal. Sensor ground. Power source to MAP sensor. Detects TDC sensor. Ground for TDC sensor. Detects VSS signal. Sends engine coolant temoerature signal. Detects IAT sensor signal.

IAT(lNTAKEAIR TEMPERATURE SENSOR) ECT (ENGINE COOLANT TEMPERATURE SENSOR) TPS (THROTILE POSITION SENSOR) VCC2 (SENSOR VOLTAGE)

Provides sensor voltage.

CYPP (CYP SENSOR P SIDE) CTPM (CYP SENSOR M SIDE)

Detects CYP sensor. Ground for CYP sensor.

Detects ECT sensor signal. Detects TP sensor signal.

With throttle fully opened from idle with fully. warmed up engine: above 0.6 V With throttle Quickly closed: below 0.4 V With ignition switch ON (II): about 3 V At idle: about 1.0 V (dl!l>~ndil'lgon engine soeed) Less than 1.0 V at all times. With ignition switch ON (II): about 5 V With ianition switch OFF: 0 V With engine running: oulses With ignition switch ON (II) and front wheel rotating: cycles 0 V-5 V With ignition switch ON (II): pules With ignition switch ON (II): about 0.1- 4.8 V (d~endi~on intake airtemoerature) With ignition switch ON (II): about 0.1 4.8V (de.Rending on engine coolant temoerature) With throttle fully open: about 4.8 V With throttle fully closed: about 0.5 V With ignition switch ON (II): about 5 V With ignition switch OFF: 0 V With engine runninQ: oulses

*1. MIT *2:A/T *3: F23A4 engine * 4: F23A 1. F23A4 engine *5: F23A 1. F23A5 engine *6: '00-02 models (cont'd)

BACK

11-19

Fuel and Emissions Systems System Descriptions (cont'd) ECM/PCM Inputs and Outputs at Connector D (16P) 1

LC

2 SHB

3 SHC

8

9

6 ATPR

SHA

ATPD3 ATPD4

13 ATPNP

14 ATP2

15 ATP1

7

V 10 NC

5 VBSOL 11 NM

12 NMSG

16 NCSG

Wire side of female terminals NOTE: Standard battery voltage is 12 V. Terminal number 1*'

Wire color

Terminal name

VEL

LC (TORQUE CONVERTER CLUTCH (TCC) PRESSURE CONTROL SOLENOID VALVE) SHB (SHIFT SOLENOID VALVE (3)

2*'

GRN/WHT

3*'

GRN

5*'

BLK/YEL

6*'

WHT

7*'

BLU/YEL

8*'

PNK

9*'

VEL

10*'

BLU

11*'

RED

12*'

WHT

13*'

BLU/WHT

14*'

BLU

15*'

BRN

16*'

GRN

Description Drives TCC pressure control solenoid valve.

With lock-up ON: battery voltage With lock-up OFF: 0 V

Drives shift solenoid valve B.

With engine running in 1st, 2nd gears: battery voltage With engine runnimtin 3rd 4th aears: abaut 0 V With engine running in 1st and 3rd gears: battery voltage With engine running in 2nd and 4th gears: about OV With ignition switch ON (II): battery voltage

SHC (SHIFT SOLENOID VALVE C)

Drives shift solenoid valve C.

VBSOL (BATTERV VOLTAGE FOR SOLENOID VALVE) ATPR (AT GEAR POSITION SWITCH) SHA (SHIFT SOLENOID VALVE A)

Power source of solenoid valve. Detects AfT gear position switch sianal. Drives shift solenoid valve A.

ATPD3 (AT GEAR POSITION SWITCH) ATPD4 (AT GEAR POSITION SWITCH) NC (COUNTERS HAFT SPEED SENSOR) NM (MAINSHAFT SPEED SENSOR) NMSG (MAINSHAFT SPEED SENSOR GROUND) ATPNP (AT GEAR POSITION SWITCH) ATP2 (AT GEAR POSITION SWITCH) ATP1 (AT GEAR POSITION SWITCH) NCSG(COUNTERSHAFT SPEED SENSOR GROUNDI

Detects AfT gear position switch sianal. Detects AfT gear position switch sianal. Detects countershaft speed sensor signals. Detects mainshaft speed sensor signals. Ground for mainshaft speed sensor. Detects AfT gear position switch sianal. Detects AfT gear position switch signal. Detects AfT gear position switch sional. Ground for countershaft soeed sensor.

*1: MIT *2: AfT *3: F23A4 engine *4: F23A1, F23A4 engine

11-20

Signal

BACK

In R position: 0 v In any other position: battery voltaoe With engine running in 2nd, 3rd gears: battery voltage With enaine runnina in 1st 4th Clears: about 0 V In D3 position: 0 V In any other position: battery voltaae In 04 position: 0 V In any_ othel"Qosition: about 5V or battery voltaae With ignition switch ON (II) and front wheels rotatina: oulses With engine running: pulses

In Park or Neutral: 0 V In any other position: batt~voltaae In 2nd position: 0 V In any other oosition: battery voltaae In 1st position: 0 V In any other oosition: battery voltaae

Vacuum Hose Routing: '98-00 models

VACUUM

i

T~,

To CRUISE CONTROL DIAPHRAGM

(with cruise control)

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

To ENGINE MOUNT CONTROL SOLENOID VALVE

IDLE AIR CONTROL (lAC) VALVE

/

EVAPORATIVE EMISSION (EVAPI PURGE CONTROL SOLENOID VALVE

. - . . - - PURGE JOINT

To EVAPORATIVE EMISSION (EVAP) PURGE CONTROL CANISTER

FUEL PRESSURE REGULATOR FRONT OF VEHICLE

(cant'd)

BACK

11-21

Fuel and Emissions Systems System Descriptions (cont'd) Vacuum Hose Routing: '01-02 models AfT

r-------------

:

CHECK VALVE

I

--+:

I: I: VACUUM TANK

-,.,

'--, -,

,

!

-----.t.. i :

L_______ _ To CRUISE CONTROL DIAPHRAGM (with cruise control)

-,

-->--

-_./ /-/_-~

:

I

, -,

./

-_/-

./

--------'-

\. To ENGINE MOUNT \ CONTROL SOLENOID --\ -VALVE


\.

\

IDLE AIR CONTROL (lAC) VALVE ".".0'

/

1-....,.------~ EVAPORATIVE EMISSION (EVAP) PURGE CONTROL SOLENOID VALVE

To EVAPORATIVE EMISSION (EVAP) PURGE CONTROL CANISTER FUEL PRESSURE REGULATOR

FRONT OF VEHICLE

11-22

BACK

Vacuum Distribution

r-··1

(AfT) l.._ .. _ .. _ .. ~

.

I

L,

TOENGINE MOUNT

:

I

.. _ .. _.j

"3

=·_·_··_·1

~~~~Ji~~J;~b1~"===d ---"'b~i=;;=...dL=""=",,,!··

I I

I :

!I

l._ .. _ .. _ .. _ .. _ .. _ .. ...;

*1: *2: *3: *4: (j) AIR FUEL (A/F) SENSOR OR PRIMARY HEATED OXYGEN SENSOR (PRIMARY H02S) (SENSOR 1) ® SECONDARY HEATED OXYGEN SENSOR (SECONDARY H02S) (SENSOR 2) @ MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR ® ENGINE COOLANT TEMPERATURE (ECT) SENSOR @ INTAKE AIR TEMPERATURE UAT) SENSOR @ CRANKSHAFT POSITION (CKP) SENSOR (j) TOP DEAD CENTER (TOC) SENSOR @ KNOCK SENSOR (KS) ® IDLE AIR CONTROL UAC) VALVE @ THROTTLE BODY @INJECTOR @ FUEL PULSATION DAMPER FUEL FILTER I FUEL PRESSURE REGULATOR ~FUELPUMP \!.!V FUEL TANK ® AIR CLEANER @RESONATOR @ EXHAUST GAS RECIRCULATION IEGR) VALVE and POSITION SENSOR

I

'98-99 model of F23A5 engine for 49ST and Canada models F23A4, F23A 1 engine '98-01 models '02 model

®> POSITIVE CRANKCASE VENTILATION IPCV) VALVE ® THREE WAY CATALYTIC CONVERTER @ EVAPORATIVE EMISSION IEVAP) CANISTER @ EVAPORATIVE EMISSION (EVAP) CANISTER FILTER @ EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE

@ EVAPORATIVE EMISSION (EVAP) CANISTER VENT SHUT VALVE

@ EVAPORATIVE EMISSION IEVAP) TWO WAY VALVE

® EVAPORATIVE EMISSION IEVAP) BYPASS SOLENOID VALVE

@ FUEL TANK PRESSURE (FTP) SENSOR @ FUEL TANK VAPOR CONTROL VALVE @ FUEL TANK VAPOR RECIRCULATION VALVE

® ENGINE MOUNT CONTROL SOLENOID VALVE

@ PURGE JOINT

(cant'd)

BACK

11-23

Fuel and Emissions Systems System Descriptions (cont'd) PGM-FI System The Programmed Fuel Injection (PGM-FI) system is a sequential multi port fuel injection system. Air conditioning (A/C) Switch The AlC (air conditioning) switch signals the ECM/PCM whenever there is a demand for cooling.

Crankshaft Position (CKP) and Top Dead Center (TOC) Sensors The CKP sensor determines fuel injection timing and ignition timing for each cylinder, and also detects engine speed. The TDC sensor determines ignition timing at start-up and when crankshaft position signal is abnormal.

~,,~::~

AIC Compressor Clutch Relay When the ECM/PCM receives a demand for cooling from the AlC system, it delays the compressor from being energized, and enriches the mixture to assure smooth transition to the AlC mode.

~'

Air Fuel Ratio (AI F) Sensor (F23A4 engine) The AlF Sensor operates over a wide air/fuel range. The AlF Sensor is installed in the exhaust manifold.

SENSOR TERMINALS

~-

~

TDCSENSOR

Cylinder Position (CYP) Sensor The CYP sensor inside the distributor detects the position ofthe No.1 cylinder as a reference for sequential fuel injection to each cylinder. F23A 1, F23A4 engine: PICKUP ASSEMBLY

HEATER TERMINALS HEATER

Alternator Control The alternator signals the ECM/PCM during charging. The ECM/PCM then controls the voltage generated at the alternator according to the electrical load determined by the ELD (Electrical Load Detector) and driving mode. This reduces engine load to improve fuel economy. F23A5 engine: Barometric Pressure (BARO) Sensor The barometric pressure sensor is inside the ECM/PCM. It converts atmospheric pressure into a voltage signal that modifies the basic duration of the fuel injection discharge.

11-24

BACK

ROTOR

Engine Coolant Temperature (ECT) Sensor The ECT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the Engine Coolant temperature increases.

Knock Sensor (F23A1, F23A4 engine) The knock control system adjusts the ignition timing for the octane rating of the gasoline used. PIEZO CERAMIC DIAPHRAGM

TERMINAL THERMISTOR

Intake Air Temperature (lAT) Sensor The IAT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature increases.

Manifold Absolute Pressure (MAP) Sensor The MAP sensor converts manifold absolute pressure into electrical signals to the ECM/PCM. SENSOR UNIT

THERMISTOR

Ignition Timing Control The ECM/PCM contains the memory for basic ignition timing at various engine speeds and manifold air flow rates. It also adjusts the timing according to engine coolant temperature. The ECM/PCM detects misfiring by using the CKP sensor to monitor fluctuations in crankshaft speed. It will then set DTCs depending on how much misfiring occurs. Injector Timing and Duration The ECM/PCM contains the memory for basic discharge duration at various engine speeds and manifold pressures. The basic discharge duration, after being read out from the memory, is further modified by signals sent from various sensors to obtain the final discharge duration. By monitoring Long Term Fuel Trim, the ECM/PCM detect long term malfunctions in the fuel system and set a Diagnostic Trouble Code (DTC) if the malfunction occurs during two consecutive trips.

Malfunction Indicator Lamp (MIL) Indication (In relation to Readiness Codes)-F23A4 engine The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems. If the vehicle's battery has been disconnected or gone dead, ifthe DTCs have been cleared, or ifthe ECM/PCM has been reset, these codes are reset. In some states, part of the emissions testing is to make sure these codes are set to complete. If all of them are not set to complete, the vehicle may fail the test. To check if the readiness codes are set, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15 - 20 seconds. If it then goes off, the readiness codes are set. If it blinks several times, one or more readiness codes are not set to complete. To set each code, drive the vehicle or run the engine as described in the procedures to set them in this section (see page 11-42). (cont'd)

BACK

11-25

Fuel and Emissions Systems System Descriptions (cont'd) Primary Heated Oxygen sensor (Primary H02S) The primary H02S detects the oxygen content in the exhaust gas and sends signals to the ECM/PCM which varies the duration offuel injection accordingly. To stabilize its output, the sensor has an internal heater. The primary H02S is installed in the exhaust manifold. By controlling the air fuel ratio with primary H02S and secondary H02S, the deterioration of the primary H02S can be evaluated by its feedback period. When the feedback period exceeds a certain value during stable driving conditions, the sensor is considered deteriorated and the ECM/PCM sets a DTC.

Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable apart from the throttle body. BRUSH HOLDER

BRUSH

fi~~~31IIf:L--RESISTOR

SENSOR TERMINALS

TERMINAL INNER BUSHING

HEATER

HEATER TERMINALS

Vehicle Speed Sensor (VSS) (MIT) The speed sensor is driven by the differential. It generates a pulsed signal from an input of 5 volts. The number of pulses per minute increases/decreases with the speed of the vehicle.

Secondary Heated Oxygen sensor (Secondary H02S) The secondary H02S detects the oxygen content in the exhaust gas downstream of the Three Way Catalytic Converter (TWC) and sends signals to the ECM/PCM which varies the duration of fuel injection accordingly. To stabilize its output, the sensor has an internal heater. The secondary H02S is installed in the TWC.

SENSOR TERMINALS

HEATER

11-26

HEATER TERMINALS

BACK

Intake Air System

Idle Control System

Refer to the System Diagram to see the functional layout of the system.

When the engine is cold, the AlC compressor is on, the transmission is in gear, the brake pedal is pressed, the PIS load is high, or the alternator is charging, the ECM/PCM controls current to the lAC valve to maintain the correct idle speed. Refer to the System Diagram to see the functional layout of the system.

Throttle Body The throttle body is a single-barrel side draft type. The lower portion of the throttle valve is heated by engine coolant from the cylinder head. The idle adjusting screw, which increases/decreases bypass air, is located on the top of the throttle body.

IDLE ADJUSTING SCREW

Idle Air Control (lAC) Valve To maintain the proper idle speed, the lAC valve changes the amount of air bypassing the throttle body in response to an electrical signal from the ECM/PCM.

To INTAKE

MANIFOLD

From AIR

CLEANER

Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Starter (Ignition) Switch The starter switch signals the ECM/PCM when the engine is cranking. Brake Pedal Position Switch The brake pedal position switch signals the ECM/PCM when the brake pedal is pressed.

(cont'd)

BACK

11-27

Fuel and Emissions Systems System Descriptions (cont'd) Fuel Supply System

Exhaust Gas Recirculation (EGR) System

Fuel Pump Control When the ignition is turned on, the ECM/PCM grounds the PGM-FI main relay which feeds current to the fuel pump for 2 seconds to pressurize the fuel system. With the engine running, the ECM/PCM grounds the PGM-FI main relay and feeds current to the fuel pump. When the engine is not running and the ignition is on, the ECM/PCM cuts ground to the PGM-FI main relay which cuts current to the fuel pump.

Refer to the System Diagram to see the functional layout of the system. EGRValve The EGR valve is designed to lower peak combustion temperatures and reduce oxides of nitrogen emissions (NOx) by recirculating exhaust gas through the intake manifold and into the combustion chambers.

Positive Crankcase Ventilation (PCV) System Fuel Cut-off Control During deceleration with the throttle valve closed, current to the fuel injectors is cut off to improve fuel economy at speeds over 1,100 rpm. Fuel cut-off action also occurs when engine speed exceeds 6,500 rpm, regardless of the position of the throttle valve, to protect the engine from over-revving. On AfT models, when the vehicle is stopped, the PCM cuts the fuel at engine speeds over 5,000 rpm.

The PCV valve prevents blow-by gasses from escaping into the atmosphere by venting them into the intake manifold.

PGM-FI Main Relay The PGM-FI relay contains two separate relays. One is energized whenever the ignition is on which supplies battery voltage to the ECM/PCM, power to the fuel injectors, and power for the second relay. The second relay is energized to supply power to the fuel pump for two seconds when the ignition is switched ON (II), and when the engine is running. No.2

No.4

11-28

No.5

No.6

No.7

BACK

, rnr~=~~~~~~=w ,,-pcv

I

/BREATHER HOSE

HOSE

. . : BLOW-BY VAPOR ~ : FRESH AIR

Evaporative Emission (EVAP) Control System

Catalytic Converter System

Refer to the System Diagram to see the functional layout of the system. EVAP Canister The EVAP canister temporarily stores fuel vapor from the fuel tank until it can be purged back into the engine and burned.

Three Way Catalytic Converter (TWC) The TWC converts hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) in the exhaust gas to carbon dioxide (C02), dinitrogen (N2), and water vapor. FRONT OF VEHICLE

EVAP Canister Parge Valve When the engine coolant temperature is below 167°F (75°C), the ECM/PCM turns off the EVAP canister purge valve which cuts vacuum to the EVAP canister. Fuel Tank Pressure (FTP) Sensor The FTP sensor converts fuel tank absolute pressure into an electrical input to the ECM/PCM. SENSOR CHIP

THREE WAY CATALYSTS

(cont'd)

BACK

11-29

Fuel and Emissions Systems System Descriptions (cont'd) Intake Air System Diagram This system supplies air for engine needs. A resonator in the air intake duct provides additional silencing as air is drawn into the system. AIR CLEANER ELEMENT

/ ' - - _ _J

ENGINE COOLANT

INTAKE MANIFOLD

0

_RESONATOR

From PGM·FI MAIN RELAY

YELl BLK

BLKI - - - - ¢ ECM/PCM BLU

,//L_ --1 VARIOUS

~ SENSORS

I

BLK

~ Idle Control System Diagram The idle speed of the engine is controlled by the Idle Air Control (lAC) valve: • After the engine starts, the lAC valve opens for a certain time. The amount of air is increased to raise the idle speed by about 150-300 rpm . • When the engine coolant temperature is low, the lAC valve is opened to obtain the proper fast idle speed. The amount of bypassed air is thus controlled in relation to engine coolant temperature.

ENGINE COOLANT

From

~~k' -----------~- RELAY ~~TNFI BLK

~

.'

BLKI - - - - - - ¢ ECM/PCM BLU

BLK

~

11-30

BACK

.~ VARIOUS

~,~SENSORS

Exhaust Gas Recirculation (EGR) System Diagram The EGR system reduces oxides of nitrogen (NOx) emissions by recirculating exhaust gas through the EGR valve and the intake manifold into the combustion chambers. The ECM/PCM memory includes the ideal EGR valve lift for varying operating conditions. The EGR valve position sensor detects the amount of EGR valve lift and sends it to the ECM/PCM. The ECM/PCM then compares it with the ideal lift in its memory (based on signals sent from other sensors). If there is any difference between the two, the ECM/PCM controls current to the EGR valve. EGRVAlVE POSITION SENSOR

- ~~b' -------1

----,

IBl~ EGR VALVE

ECM/PCM L -_ _

GRNI

<,,~

VARIOUS

~ SENSORS

BlK

L------PNK-------~

BlK

~

(cont'd)

BACK

11-31

Fuel and Emissions Systems System Descriptions (cont'd) Evaporative Emission (EVAP) Control Diagram The EVAP controls minimize the amount of fuel vapor escaping to the atmosphere. Vapor from the fuel tank is temporarily stored in the EVAP canister until it can be purged from the canister into the engine and burned. • The EVAP canister is purged by drawing fresh air through it and into a port on the intake manifold. The purging vacuum is controlled by the EVAP canister purge valve, which is open whenever engine coolant temperature is above 16JOF (75°C). • When vapor pressure in the fuel tank is higher than the set value of the EVAP two way valve, the valve opens and regulates the flow of fuel vapor to the EVAP control canister. • During refueling, the fuel tank vapor control valve opens with the pressure in the fuel tank, and feeds the fuel vapor to the EVAP canister.

_

'-;===-.--I-___~=-==~=~+__--------BLKI VEL ----_.

l

VELI

BLU

I

LTGRN GRNI BLK

I

From No. 6 ECU(ECM/PCM' _ .......... CRUISE CONTROL ------.... (1SA' (in the driver's under-dash fuse/relay box'

'--

EVAP CANISTER PURGE VALVE

II ====~J~~~ -......--""'I~EVAPCANISTER

~

¥Btilt

FUEL TANK

"'"~W~~~~~ _

__\-=-]

BLU LT GRNI

_

ECM/PCM

WHT

FILTER

REDI VEL

EVAP BVPASS \ SOLENOID VALVE EVAPCANISTER

BLK

/

FUEL AU CAP

11-32

-.L FUEL TANK VAPOR RECIRCULAT10N VALVE FUEL TANK VAPOR RECIRCULAT10N TUBE

BACK

//~ Y-'

VARIOUS SENSORS

Circuit Diagram ECM/PCM Circuit D." agram

MAP SENSOR

GRNlBLK'---- ,

....

ECTSENSOR

To CLIMATE CONTROL UNIT GRN/BLK'----.l IATSENSOR

TPSENSOR

EGRVALVE PosmON SENSOR

EGRVALVE

A

JUNCTION CONNECTOR GRNIBLK'

(cant'd)

BACK

11-33

Fuel and Emissions Systems Circuit Diagram (cont'd) ECM/PCM Circuit Diagram (cont'd) ( From page 11-33 )

*5

1---~CI6 P!\Q~Iii ___ . WH~-------------------------

----------------------------

--------------~~I GRN/BLK2-1 BLK/YEL

-1

-

PRIMARY *5 H02S (SENSOR 1)

C BLKlYEL

~1m GANIYEL'

BW/BLK2

dJ

§

BL~YEL

~

>--BRN/BLK' B

BAN/But'

SOLENOID VALVE"

-

II -----.

II

VTEC PRESSURE SWITCH"

~ ----~--------------.-~~~---------; IJU~N ____ I ~ G1111~

.

BRN/BLK'

CONNECTOR

BLKI

But'

'--

~

0

"'"

.........

G101

KS"

1-........---(C3

---------- RED/BLU .---------------------------------- --

~=====GR~=================F============~ C21 TDCM RED"---------------------+-----------t ~~~ ______ . BwI. ___________________________________ _

1---t-----{C8

·~~--W'~~~----------~---------~

~ ~~

. . . :. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ;. ~ ~ f" I DISTRIBUTOR

*4: FHA1, FHA4 engine *5: FHA1, F23A5 engine

11-34

BACK

[~ ®

}A: ;L: ':T~F

ALTC

_ _ WHTiGRN _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __I WHTlREo'

-

All

J-'-'''''----BLU/WHT'----------------.----+--:S::g

~I VSS 01

'--------------~---+-------i>!~;:~;CV

~----VEL'------------------~--~

r"''"'--- BLU/VEL --------------------------------11-------1

SHS· 2 r"'-'----GRN/Wiff-'---------------t----i

~S-H-C-·-2--GR~-------------------4_---_I

~ VALVEC·2

011

~_~~~ ______ RE07 _. _________________ ._ •• __________ ._.

012 NMSG·

2

WH~---------------t_--------iJ===~~ MAINSHAFT SPEED SENSOR 02

~----GR~------------------------------------~==~~ RED.------------------------1[r===:n

WHr~------------------------~-~ AfT CLUTCH PRESSURE CONTROL SOLENOIDO VALVE A 02

I~-'----::~'-------------------------------------------I~

AfT CLUTCH PRESSURE CONTROL SOLENOIDO VALVE B 02

(cont'd)

BACK

11-35

Fuel and Emissions Systems Circuit Diagram (cont'd) ECM/PCM Circuit Diagram (cont'd)

YELlBLK' BR No. 1 INJECTOR

YELlBLK' RED' No.2 INJECTOR

YELlBLK' BLU' No. 3 INJECTOR

YELlBLK' YEL' No.4 INJECTOR

H YELlBLK' BLKlBLU

-=

BLK' lAC VALVE

C103 IGP1

YELlBLK' JUNCTION CONNECTOR

IGP2

YELlBLK'

l-I~-..(iBl' 0P2Sw·2 BLU/BLK1 ---------------------1F--o·

I

2ND

~= ~RESSURE

~:.:....-BLU;wm2---------------IIF--U

I

3RD CLUTCH PRESSURE SWlTCH·2

RE~------------------••} »-==~-BLlr------------------..

11-36

BACK

To IMMOBIUZER UNIT

1-=

1

~~~~3[5J

AIR FUEL RAllO SENSOR (SENSOR 1)·3

C1D2

DI----~~~ 6=~ t - - - - - - GRN/R

AIR FUEL RAllO SENSOR RELAy·3

C203

T

REDI IW

~

o

GR~ORNI------------------------------------~-r-

MIL

...---YEL-L

0 C2~ MTRTW~GRti-O--YELlGRNZ~YELIGRti C101

C204

C1D2

ECT

GAUGE

C204

LKlIW

ILKlIW

wHf

NT' RED/ILK

RED/ILK

I------+~p

f------HR 1----4-IN D.

NK' u'

PNK' ILu'

ti

BRti

f------Io,

1-------l2 GAUGE ASSEMBLY ~

~~-------------8UVBW

L....f------------- RED/ILK

AIT GEAR POSmDN SWlTCH~

*2:AIT *3: F23M engl..

*6: 'OCI-Q2 m_l.

(cant'd)

BACK

11-37

Fuel and Emissions Systems Circuit Diagram (cont'd) ECM/PCM Circuit Diagram (cont'd)

C204

---1-;

rl- :- :-:- :- ~- =-=- =- =-=- =- =-~ -=- =- =-=- =- =-;- =- =-:- f 5B I

SECONDARY H02S (SENSOR 2)

L

N

l=::::....-GRNlWHT'·-- - - - - I

I------------I---=:::J I

-o!t=:::'JI :C101

~~-REDIYEL'---~

REDIYEL'

=1

I

ENGINE MOUNT

~0

~~"=~VALVE

=1

I


~~--BW/G~"---------------------1III====:J

CRUISE CONTROL UNIT

,

!~=:::"'-PNK

~WHT/YEL

-

""'"

I

IMM~LlZER

INDICATOR UGItT

1+ ToTACHOMETER

~~-Bw'

GAUGE ASSEMBLY C204

o

Bw'

[

TEST TACHOMETER CONNECTOR

II ~--------------------I:C===J

r-......._ _(A2B~:......_ WHT/REoZ ILU .2

MULTIPLEX CONTROL UNIT (DRIVER'S)

•

11-38

FANe From .....-WD).!.:=~-GRN'·---------------------44 RADIATOR FAN RELAY. RADIATOR FAN SWITCH

BACK

LTGRN/WHT--!~

LTGRN/WHT

r--

BLKlYEL--l~ EVAP

CANISlER VENT BHUTYALVE

YELl8W~~

f-.....-(j\29).:.:.::=-- LTGRN - - -

~':xz-==U~~l FTPSENSOR

aw'-----

-

~

:VEL=-=rrn

EVAPBVPA&S

SOLENOID YALVE

~

DRIVER'S UNDEA-DASH CONHECTOR B FllSfJRELAY BOX

YELl GRNI

1 6~02

~01

:?{

'--8

aw BLK'

- - GRN/8

==tE=~

lf--

r ffA.... 8

R

CONNEClOAK

8AN'-------------------~[

-

WKl'/BLK'------------------i·

-

C

- BWiOAN---------I

f--Nf---{U!}-====-

..... ~

~

CUT

:

RELAY

;

~

IGNITION SWITCH

D

I FUSES A: No. • BACK UP LIGHT INSTRUMENT LIGHT !7.sA)

I IIII

8: No. • ECUIECIIIPCIIl CRUISE CONTROL (1SA) C: No. 13 STAInER SIGNAL

!7,SA) D: No. 1 FUEL PUMP (1SA)

I

.', I \

Y

I

cr...... 11040)

(cont'd)

BACK

11-39

Fuel and Emissions Systems Circuit Diagram (cont'd) ECM/PCM Circuit Diagram (co nt'd) ( From page 11-39 ) ,-_~A,-

.------

r-----------1~

CONNECTOR I BRN'BLU/ORN _.

_ _~

!---'

1-

CONNECTOR~

REDIWHTBLKIYEL ,---WHT/BLK'~ 0202

CONNECTOR N

L ! I - - - - I - I - - W H T - - { ~1---

I WHT

CONNECTOR E

~

.- BLKlYEL

-{L----~_ DRIVER'S UNDER·DASH FUSEIRELA Y BOX

Q

C401 NE

GRY

I-I--

I

rl--+-- -

r=

E:~~LK'

WHT/GRN

DATAUNK CONNECTOR

BLK

G401

N

L..4----...

WHT/BLK'--fF-=ll

WHT/VEL-L~ BRAKE PEDAL POsmON SWITCH

,r-":"--=tQ

1

C102

9L.....--r--r-_Ir-WHT/~GN~C:HT/GRl

G5S2

C1m

, -,_.L

YEL/BLK'

'------+-+--+-_+_ BLK'

YEL/BLK'BLK'-

L -_ _~~~==~I

L..4-+-------~- REDIWHT-

1L.---1~--_+--BLU/ORN -lD--I-------l----+--C401

GRN/YEL

T

11-40

_

GRNlYEL L -_ _- / -_ _ BLKlYEL -

BACK

~ ..

I . ~~. ~~-_

,---..

PGM-FI

MAIN RELAY

1

0

D

CONNECTORC

~-~I--- BLKlYEL

1-C1_01__+-_____ ::::.

)..:..::::.._ _ WHTIYEL

BRN/BLK'

L--{]

E

YEL - - - - - / BRN/BLK'

C1112

To A/C . - - BLU/RED PRESSURE SWITCH

=t

CONNECTORH BLU/IiED

-------+--1----1---1-- BW/RED BRN/BLK' WHTIYEL

E!J L.-

CONNECTOIII BLKlYEL - - - [

I--+----...J

CONNECTOIIJ BRN/BLK'---f F ....._---, I---+-+-----IIED/BLU f-__............

---L

CONNECTORD YELlGRN - - - [ 1----------' PASSENGER'S UNDER-DASH FUSEIRELAY BOX

Q

L

T

L--++-+-----11-- WHTCONNECTOII C[ f-_....,;;;G~_--, CONNECTOR A

CONNECTOR B

C202

I

WHT/~EL

WHT/YEL

1-+...-..:=----1-- VEL

~C_~ _ _ _ _ _ _ _ _ _ _ :~:~

J

I - -......K- - -..

1---_ _0-_--+

YELlGRN

GRN/:JED'

H

1-_ _1- WHT/GRN - - - [ 1----0----1

L

[

1===:::::;--1

BLK CONNECTORD -

RED'

I---------t-RED'--[

G2II2 FUSES E : No. 13 CLOCK BACK UP t7.5Al F : No.6 LAF HEATER C20A> G: IG MAIN
BACK


BATTERY

G1

11-41

Fuel and Emissions Systems How to Set Readiness Codes Malfunction Indicator Lamp (MIL) indication (In relation to Readiness Codes)-F23A4 engine The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems. If the vehicle's battery has been disconnected or gone dead if the DTCs have been cleared, or if the ECM/PCM has been reset, these codes are reset. In some states, part of the emissions testing is to make sure these codes are set to complete. If all of them are not set to complete, the vehicle may fail the test. To check if the read i ness codes a re set, tu rn the ignititon switch ON (II), but do not start the engine. The MIL will come on for 15 - 20 seconds. If it then goes off, the readiness codes are set. If it blinks several times, one or more readiness codes are not set to complete. To set each code, drive the vehicle or run the engine as described in the following procedures.

Air Fuel Ratio (A/F) Sensor Monitor Code NOTE: • Do not turn the ignition switch OFF. • When the battery negative cable is disconnected, all readiness codes are cleared. Required condition: Ambient temperature between 20 - 95°F (-7 - 35°C). 1. Connect the scan tool to the Data Link Connector (DLC). 2. Start the engine. Hold it at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on. 3. Let the engine idle for 5 seconds. 4. Drive at a steady speed between 50-62 mph (80100 km/h) with the transmission in 04 position for about 2 minutes. 5. With the A/T in 04 position or MIT in 5th gear, decelerate from 62 mph (100 km/h) by completely releasing the throttle for at least 5 seconds. Ifthe engine is stopped during this procedure, repeat steps 4 and 5. 6. Check for the readiness code with the scan tool.

11-42

BACK

Catalytic Converter Monitor Code

EGR Monitor Code

NOTE: • Do not turn the ignition switch OFF. • When the battery negative cable is disconnected, all readiness codes are cleared. • When the ECM/PCM is cleared with the OBD II scan tool or Honda PGM Tester, all readiness codes are cleared.

NOTE: • Do not turn the ignition switch OFF. • When the battery negative cable is disconnected, all readiness codes are cleared. 1. Connect the scan tool to the Data Link Connector. 2. Start the engine, and hold it at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on.

Required condition: Ambient temperture between 20 - 95°F (-7 - 35°C).

1. Connect the scan tool to the Data Link Connector. 2. Start the engine. Hold it at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on. 3. Drive for about 10 minutes, without stopping, on a highway. Your speed can vary. 4. With the AfT in D4 position or MIT in 5th gear, drive at a steady speed between 50 -60 mph (80 -1 00 km/h) for 30 seconds.

3. Drive at a steady speed with the transmission in D4 position between 50-62 mph (80-100 km/h) for more than 10 seconds. 4. With the AfT in D4 position or MIT in 5th gear, decelerate from 62 mph (100 km/h) by completely releasing the throttle for at least 5 seconds. If the engine is stopped during this procedure, repeat steps 3 and 4. 5. Check for the readiness code with the scan tool.

5. Repeat step 4 three times. Between each repetition, close the throttle completely for 1-2 seconds. If the engine is stopped during this part of the procedure, repeat steps 3, 4, and 5. 6. Check for the readiness code with the scan tool.

(cont'd)

BACK

11-43

Fuel and Emissions Systems How to Set Readiness Codes (cont'd) EVAP Leak Monitor Code

H02S Monitor Code

NOTE: • When the battery negative cable is disconnected, all readiness codes are cleared. • When the ECM/PCM is cleared with the aBO II scan tool or Honda PGM Tester, all readiness codes are cleared. • If the engine is stopped between step 6 and 16, do the entire procedure again.

NOTE: • Do not turn the ignition switch OFF. • When the battery negative cable is disconnected, all readiness codes are cleared. Required condition: Ambienttemperature between 20-95°F (-7-35°C). 1. Connect the scan tool to the Data Link Connector.

1. Make sure the gasoline level is 60-90 percent of fuel tank capacity (not full). 2. Turn the ignition switch OFF.

2. Start the engine, and hold it at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on.

3. Let the vehicle sit more than 8 hours.

3. Letthe engine idle for 5 seconds.

4. Make sure the outside temperature is 20-95°F (-7 -35°C).

4. Drive at a steady speed between 50 - 62 mph (80100 km/h) for about 2 minutes.

5. Connect the scan tool to the Data Link Connector.

5. With the AfT in 04 position or MIT in 5th gear, decelerate from 62 mph (100 km/h) by completely releasing the throttle for at least 5 seconds. If the engine is stopped during this procedure, repeat steps 4 and 5.

6. Start the engine, and drive for about 15 minutes. 7. Keep the vehicle at a steady speed between 50-70 mph (80-114 km/h), without moving the accelerator pedal, for about 1 minute.

6. Check for the readiness code with the scan tool.

8. Stop the vehicle (do not stop engine).

H02S Heater Monitor Code

9. Repeat step 7 and 8 two more times.

NOTE: When the battery negative cable is disconnected, all readiness codes are cleared.

10. Check for the readiness code with the scan tool. If the readiness code does not set, go to step 11. 11. When ambient temperature is less than 32°F (O°C), hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on.

1. Connect the scan tool to the Data Link Connector. 2. Start the engine, and let it idle for 10 minutes. 3. Check for the readiness code with the scan tool.

12. Remove the fuel fill cap, then reinstall it. 13. Drive for about 20 minutes on a highway. 14. Keep the vehicle at a steady speed between 50-70 mph (80-114 km/h) without moving the accelerator pedal, for about 1 minute. 15. Stop the vehicle (do not stop the engine). 16. Repeat steps 14 and 15 two more times. 17. Check for the readiness code with the scan tool.

"-44

BACK

PGM-FI System Component Location Index ELECTRICAL LOAD DETECTOR (ELD) Troubleshooting, page 11-84 MANIFOLD ABSOLUTE

PRESSURE (MAP) SENSOR

Troubleshooting, page 11-47

INTAKE AIR TEMPERATURE (lAT) SENSOR Troubleshooting, page 11-50

THROTTLE POSITION (TP) SENSOR Troubleshooting, page 11-54 CRANKSHAFT POSITION/TOP DEAD CENTER (CKP/TDC) SENSOR Troubleshooting, page 11-73 KNOCK SENSOR Troubleshooting, page 11-72

CYLINDER POSITION (CYP) SENSOR Troubleshooting, page 11-88

PRIMARY HEATED OXYGEN SENSOR (PRIMARY H02S) OR AIR FUEL RATIO SENSOR (SENSOR 1) Troubleshooting, page 11-59 Replacement, page 11-99

ENGINE COOLANT TEMPERATURE (ECT) SENSOR Troubleshooting, page 11-52 VEHICLE SPEED SENSOR (VSS) (M/Tl Troubleshooting, page 11-75

SECONDARY HEATED OXYGEN SENSOR (SECONDARY H02S)

(SENSOR 2)

, _~7,y--- / /' ---, D~l:":' .'. ~"=-' : 'r 111 ---It:}: f.. ~ ~'f!-L--0:. ~

__ __

-'--

'::}/

\ \:....... "........... :--c..::

: E'

~

. ' L .. _i

~~, -----.;:::-

F23A5 ENGINE: 49ST, CANADA ('98-99 ,"-odels)

!l

-

Troubleshooting, page 11-62 Replacement, page 11-99

CO

,---{ / <0 ....)

""'11~...

-_ Except ... F23A5, ENGINE: 49ST, CANADA .o')

• • • ('9....

·,·b)

~.d..

I

,

"'\

~\~

(cont'd)

BACK

11-45

PGM-FI System Component Location Index (cont'd)

ENGINE CONTROL MODULE (ECMII POWERTRAIN CONTROL MODULE (PCM) DATA LINK CONNECTOR (DLC) General Troubleshooting Information, page 11-3 Troubleshooting, page 11-95

11-46

General Troubleshooting Information, page 11-3 Troubleshooting, page 11-90

BACK

DTC Troubleshooting OTC P0107: MAP Sensor Circuit Low Voltage

Is there approx. 5 V?


YES- Repair open in the wire between the ECM/ PCM (C19) and the MAP sensor.•

2. Check the MAP with the scan tool. NO-Substitute a known-good ECM/PCM and recheck (see page 11-3). If normal MAP readings are indicated, replace the original ECM/PCM .•

Is approx. 101 kPa (760 mmHg, 30 in.Hg) or 2.9 V indicated? YES-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the MAP sensor and the ECM/PCM .•

8. Check the MAP with the scan tool. Is approx. 2 kPa (15 mmHg, 0.6 in.Hg) or less, or V indicated?

o

NO-Go to step 3. YES - Go to step 9. 3. Turn the ignition switch OFF. NO- Replace the MAP sensor.. 4. Disconnect the MAP sensor connector. 9. Turn the ignition switch OFF. 5. Turn the ignition switch ON (II). 10. Disconnect ECM/PCM connector C (31 Pl. 6. Measure voltage between MAP sensor connector terminals No.1 and No.2. MAP SENSOR 3P CONNECTOR

11. Check for continuity between MAP sensor connector terminal No.3 and body ground. MAP SENSOR 3P CONNECTOR

SG1 (GRN/WHTI



Is there approx. 5 V? YES - Go to step 8.


NO-Go to step 7.

YES- Repair short in the wire between the ECM/ PCM (C17) and the MAP sensor.•

7. Measure voltage between ECM/PCM connector terminals C19 and C7.

NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). If normal MAP readings are indicated, replace the original ECM/PCM .•


SG1 (GRN/WHTI


BACK

11-47

PGM-FI System DTC Troubleshooting (cont'd) DTC P0108: MAP Sensor Circuit High Voltage

9. Measure voltage between MAP sensor 3P connector terminals No.1 and No.2.

1. Start the engine. Hold the engine at 3,000 rpm with no load (in park or neutral) until the radiator fan comes on, then let it idle.

MAP SENSOR 3P CONNECTOR

2. Check the MAP with the scan tool.

Is approx. 101 kPa (780 mmHg, 30 in.Hg) or higher or approx. 2.9 V indicated? YES - Go to step 3.

SG1 (GRN/WHT)

NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the MAP sensor and the ECM/PCM .•


Is there approx. 5 V? 3. Turn the ignition switch OFF. YES-Go to step 10. 4. Disconnect the MAP sensor connector.

s.

NO- Repair open in the wire between the ECMI PCM (C7) and the MAP sensor.•

Install a jumper wire between MAP sensor 3P connector terminals No.2 and No.3. MAP SENSOR 3P CONNECTOR

10. Turn the ignition switch OFF. 11. Install a jumper wire on ECM/PCM connector terminals between C7 and C17. ECM/PCM CONNECTOR C (31PI SG1(GRN/WHTI

I SG1 (GRN/WHT)

5 6 It 8 9 10 11 2 3 V 15 17 19 14 13 16 18 20 21 lL L/ L 23 24 25 26 2/7 28 29 30 lL

MAP (RED/GRN)

JUMPER WIRE

MAP (RED/GRN)


JUMPER WIRE Wire side of female terminals

6. Turn the ignition switch ON (II). 7. Check the MAP with the scan tool.

Is approx. 159 kPa (1,190 mmHg, 47in.Hg) or higher or 4.49 V or higher indicated?

l

12. Turn the ignition switch ON (II). 13. Check the MAP with the scan tool.

Is approx. 159 kPa (1, 190 mmHg, 47 in.Hg) or higher or 4.49 V or higher indicated?

YES-Go to step 8. NO- Replace the MAP sensor.•

YES-Substitute a known-good ECM/PCM and recheck (see page 11-S). If normal MAP readings are indicated, replace the original ECM/PCM .•

8. Remove the jumper wire.

NO- Repair open in the wire between the ECMI PCM (C17) and the MAP sensor.•

11-48

BACK

DTC P1128: MAP Sensor Signal Lower Than Expected 1. Turn the ignition switch ON (1/). 2. Check the MAP with the scan tool. Is 54.1 kPa (406 mmHg, 16.0 in.Hg) or higher indicated?

DTC P1129: MAP Sensor Signal Higher Than Expected 1. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then let it idle. 2. Check the MAP with the scan tool. Is 43.3 kPa (325 mmHg, 12.8 in.Hg) or less indicated?

YES-Intermittent failure, system is OK at this time .•


NO - Replace the MAP sensor..

NO - Replace the MAP sensor.•

BACK

11-49

PGM-FI System DTC Troubleshooting (cont'd) DTC P0112: IAT Sensor Circuit Low Voltage

8. Check the temperature reading on the scan tool. Be aware that if the engine is warm, the reading will be higher than ambient temperature. If the engine is cold, the IAT and ECT will have the same value.

1. Turn the ignition switch ON (II). 2. Check the IAT with the scan tool.

Is the correct ambient temperature indicated? Is 302°F (150°C) or higher (or H-Limit in Honda mode of PGM Tester), or 0 V indicated? YES-Go to step 3.

YES-Intermittent failure. system is OK at this time. Check for poor connections or loose wires at the IAT sensor and the ECM/PCM .•

NO-Goto step 8.

NO- Replace the IAT sensor.•

3. Disconnect the IAT sensor connector. 4. Check the IAT with the scan tool. Is 302°F(150°C) or higher (or H-Limit in Honda mode of PGM Tester), or 0 V indicated? YES - Go to step 5. NO- Replace the IAT sensor.• 5. Turn the ignition switch OFF. 6. Disconnect ECM/PCM connector C (31 Pl. 7. Check for continuity between IAT sensor 2P connector terminal No.2 and body ground. IAT SENSOR 2P CONNECTOR


Is there continuity? YES-Repair short in the wire between the ECM/ PCM (C25) and the IAT sensor.• NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). If normallAT readings are indicated. replace the original ECM/PCM .•

11-50

BACK

DTC P0113: IAT Sensor Circuit High Voltage

7. Connect ECM/PCM connector terminals C18 and C25 with a jumper wire.


ECM/PCM CONNECTOR C 131PI

Is -4°F (-20°C) or less (or L-Limit in Honda mode of PGM Tester), or 5 V indicated?

5 6 7 8 9 10 11 2 3 V L,( / 13 14 15 16 17 18 19 20 21 V 23 24 25 26 27 I~ 29 30 V

YES - Go to step 3.

IAT IRED/YELl

NO-Intermitent failure, system is OK atthis time. Check for poor connections or loose wires at the IAT sensor and the ECM/PCM .•

I

I

SG2IGRN/BLKI


3. Disconnect the IAT sensor connector. 4. Connect IATsensor 2P connector terminals No.1 and No.2 with a jumper wire.


IAT SENSOR 2P CONNECTOR

Is - 4°F (- 20°C) or less (or L-Limit in Honda mode of PGM Tester), or 5 V indicated?

SG2 IGRN/BLKI

YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). If normal voltage is indicated, replace the original ECM/PCM .•

JUMPER WIRE

NO- Repair open in the wire between the ECM/ PCM (C18, C25) and the IATsensor.•

IAT IRED/YELl Wire side of female terminals

5. Check the IAT with the scan tool. Is -4°F (-20°C) or less (or L-Limit in Honda mode of PGM Tester), or 5 V indicated? YES-Go to step 6. NO-Replace the IATsensor.• 6. Turn the ignition switch OFF.

BACK

11-51

PGM-FI System DTC Troubleshooting (cont'd) DTC P0116: ECT Sensor Range/Performance Problem

DTC P0117: ECT Sensor Circuit Low Voltage 1. Turn the ignition switch ON (II).

NOTE: If DTC P0117 and/or P0118 are stored at the same time as DTC P0116, troubleshoot those DTCs first, then recheck for DTC P0116.

2. Check the ECT with the scan tool. Is 302°F (150°C) or higher (or H-Limit in Honda mode of PGM Tester), or 0 V indicated?

1. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then let it idle.

YES - Go to step 3.

2. Check the ECT with the scan tool.

NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the ECT sensor and the ECM/PCM .•

Is 176- 200°F (80- 93°C) or 0.4-0.7 V indicated?

3. Disconnect the ECT sensor connector. YES -Intermittent failure, system is OK at this time. Check the thermostat and the cooling system .•

4. Check the ECT with the scan tool.

NO - Check the thermostat and the cooling system. If they are OK, replace the ECT sensor.•

Is 302°F (150°C) or higher (or H-Limit in Honda mode of PGM Tester), or 0 V indicated? YES - Go to step 5. NO - Replace the ECT sensor.. 5. Turn the ignition switch OFF. 6. Disconnect ECM/PCM connector C (31P). 7. Check for continuity between ECT sensor 2P connector terminal No.2 and body ground. ECT SENSOR 2P CONNECTOR


Is there continuity? YES-Repair short in the wire between the ECM/ PCM (C26) and the ECT sensor.• NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). If normal ECT readings are indicated, replace the original ECM/PCM .•

11-52

BACK

DTC P0118: ECT Sensor Circuit High Voltage



7. Connect ECM/PCM connector terminals C18 and C26 with a jumper wire.

2. Check the ECT with the scan tool. Is - 4°F (- 20°C) or less (or L-Umit in Honda mode of PGM Tester), or 5 V indicated?

ECM/PCM CONNECTOR C 131P)

8 9 10 5 6 7 11 2 3 V 15 17 19 13 14 16 18 20 21 / V/ 23 24 25 29 30 / 26 27 l~~

YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the ECT sensor and the ECM/PCM .•

ECT IRED/WHT)

L

SG21GRNI BLK)

JUMPER WIRE

3. Disconnect the ECT sensor connector. Wire side of female terminals

4. Connect ECT sensor 2P connector terminals No.1 and No.2 with a jumper wire. 8. Turn the ignition switch ON (II).

ECT SENSOR 2P CONNECTOR

9. Check the ECT with the scan tool. Is -4°F (-20°C) or less (or L-Umit in Honda mode of PGM Tester), or 5 V indicated?

SG2 IGRN/BLK) JUMPER WIRE

YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). If normal voltage is indicated, replace the original ECM/PCM .•

ECT IRED/WHT)

NO- Repair open in the wire between the ECM/ PCM (C18, C26) and the ECT sensor.• Wire side of female terminals

5. Check the ECT with the scan tool. Is - 4°F (- 20°C) or less (or L-Umit in Honda mode of PGM Tester), or 5 V indicated? YES-Go to step 6. NO - Replace the ECT sensor.•

BACK

11-53

PGM-FI System DTC Troubleshooting (cont'd) DTC P0122: TP Sensor Circuit Low Voltage 1. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then turn the ignition switch OFF.

9. At the sensor side, measure resistance between TP sensor 3P connector terminals No.1 and No.2 with the throttle fully closed.

TP SENSOR 3P CONNECTOR

2. Turn the ignition switch ON (II). 3. Check the throttle position with the scan tool.

Is there approx. 10% or 0.5 V when the throttle is fully closed and approx. 90% or 4.5 V when the throttle is fully opened?

TPS

YES-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the TP sensor and at the ECM/PCM ••


Is there approx. 0.5- 0.9 kQ ?



5. Disconnect the TP sensor connector.

NO- Replace the throttle body (The TP sensor is not available separately.) .•

6. Turn the ignition switch ON (II). 7. Measure voltage between TP sensor 3P connector terminals No.1 and No.3.

10. Measure resistance between TP sensor 3P connector terminals No.2 and No.3 with the throttle fully closed.


TPSENSOR 3P CONNECTOR

SG2 (GRN/BLKI

VCC2 (VEL/BLUI

TPS Wire side of female terminals



Is there approx. 4.5kQ ?

YES - Go to step 8.

YES- Go to step 11.

NO-Go to step 15.


8. Turn the ignition switch OFF. 11. Disconnect ECM/PCM connector (31 Pl.

11-54

BACK

12. At the wire harness side, check for continuity between TP sensor 3P connector terminal No.2 and body ground.

14. At the wire harness side, check for continuity between TP sensor 3P connector terminal No.2 and body ground.


TPSENSOR3PCONNECTOR





YES-Repair short in the wire between the ECMI PCM (C27) and the TP sensor.•

YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the prescribed voltage is now available, replace the original ECM/PCM .•

NO-Go to step 13. NO- Repair open in the wire between the ECMI PCM (C27) and the TP sensor.•

13. Connect ECM/PCM connector terminal C27 and body ground with a jumper wire.



V

1 2

/

3 5 6 7 8 9 10 1/ 13 14 15 16 17 18 19 20 21 26 27 28 23 25 29 30


V V

V

SG2 (GRN/BLK)

I 2 5 6 8 9 10 3 11 V t V 1/ 13 14 15 16 17 18 19 20 21 / 23 24 25 26 27 28 29 30 /

TPS (RED/BlK) JUMPER WIRE

--

VCC2 (VEl/BlU)

~



Is there approx. 5V? YES-Repair open in the wire between the ECMI PCM (C28) and the TP sensor.• NO- Substitute a known-good ECM/PCM and recheck (see page 11-5). If the prescribed voltage is now available, replace the original ECM/PCM .•

BACK

11-55

PGM-FI System DTC Troubleshooting (cont'd) DTC P1122: TP Sensor Signal Higher Than

DTC P1121: TP Sensor Signal Lower Than

Expected

Expected



2. Check the throttle position with the scan tool.


Is 16.5% (F23A 1, F23A4 engine) or 15.3% (F23A5 engine) or less indicated when the throttle is fully closed?

Is 14.1% (F23A1, F23A4 engine) or 13.3% (F23A5 engine) or higher indicated when the throttle is fully opened?

YES -Intermittent failure, system is OK at this time.•



NO - Replace the throttle body (The TP sensor is not available separately.) .•

11-56

BACK

DTC P0123: TP Sensor Circuit High Voltage


1. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then turn the ignition switch OFF.

ECM/PCM CONNECTOR C (31P) SG2 (GRN/BLK)


I 2 3 5 6 8 9 10 11 / V V 13 14 15 16 17 18 19 20 21 k" 23 24 25 29 30 V 26 27 28

r


Is there approx. 10% or 0.5 V when the throttle is fully closed and approx. 90% or 4.5 V when the throttle is fully opened? YES-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the TP sensor and at the ECM/PCM .•

VCC2 (VEL/BLU)

'Y.


Is there approx. 5 V? NO - Go to step 4. YES-Repair open in the wire between the ECMI PCM (C18) and the TP sensor.•

4. Turn the ignition switch OFF. 5. Disconnect the TP sensor connector.

NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the prescribed voltage is now available, replace the original ECM/PCM .•

6. Turn the ignition switch ON (II). 7. At the wire harness side, measure voltage between TP sensor 3P connector terminals No.1 and No.3. TP SENSOR 3P CONNECTOR

VCC2 (VEL/BLU)


Is there approx. 5 V? YES- Replace the throttle body (The TP sensor is not available separately) . • NO - Go to step 8.

BACK

11-57

PGM-FI System DTe Troubleshooting (cont'd) DTC P0128/P1486: Cooling System

1. Check the engine coolant level.

Malfunction /s the engine coo/ant leve/low? NOTE: If the OTCs listed below are stored at the same time as OTC P0128/P1486, troubleshoot those OTCs first, then recheck for P0128/P1486. P0107, P0108, P1128, P1129: MAP Sensor P1106, P1107, P1108: Barometric Pressure Circuit P1253, P1257, P1258, P1259: VTEC System (F23A1, F23A5 engine) P0401: EGR Flow Insufficient P1491: EGR Valve Lift Insufficient P1498: EGR Valve Position Sensor High Voltage P0116, P0117, P0118: Engine Coolant Temperature Circuit P0112, P0113: Intake Air Temperature Circuit P0500: Vehicle Speed Sensor P0335, P0336, P1359: Crankshaft Position Sensor P0300, P1399: Random Misfire P0301, P0302, P0303, P0304: Cylinder 1, 2, 3, or 4 Misfire Detected. P0505: Idle Control System Malfunction P1519: Idle Air Control Valve

YES-Refill the engine coolant. If necessary, check the cooling system .•

NO - Go to step 2. 2. Turn the ignition switch ON (11), and make sure the AlC is off. 3. Check the radiator fan.

OTC P0128/P1486 can set occasionally when the hood is opened.

11-58

BACK

Does the radiator fan keep running? YES-Check the radiator fan circuit with AlC model (see page 10-19) or without AlC model (see page 10-21), radiatorfan switch circuit (see page 10-23), and the radiator fan switch (see page 10-22). If the circuits and the switch are OK, substitute a known-good ECM/PCM and recheck (see page 11-5). Ifthe symptom/indication goes away, replace the original ECM/PCM .• NO-Test the thermostat (see page 10-9).•

DTC P0131: Primary H02S (Sensor 1) Circuit Low Voltage

11. Check for continuity between Primary H02S (Sensor 1) 4P connector terminal No.2 and body ground.

1. Resetthe ECM/PCM (see page 11-4). 2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on. 3. Check the Primary H02S (Sensor 1) output voltage with the scan tool during acceleration using wide open throttle.

PRIMARY H02S (SENSOR 11 4P CONNECTOR

PH02S(WHTI

3

4

Does the voltage stay at 0.5 V or less?

=

YES - Go to step 4.


NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the Primary H02S (Sensor 1) and atthe ECM/PCM .•

Is there continuity? YES- Repair short in the wire between the ECM/ PCM (C16) and the Primary H02S (Sensor 1) .•

4. Check the fuel pressure (see page 11-115).

Is it normal?

NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .•

YES- Go to step 5. NO- Repair the fuel supply system .• 5. Turn the ignition switch OFF. 6. Disconnect the Primary H02S (Sensor 1) 4P connector. 7. Start the engine and let it idle. 8. Check the Primary H02S (Sensor 1) output voltage with the scan tool.

Does the voltage stay at 0.5 V or less? YES-Go to step 9. NO- Replace the Primary H02S (Sensor 1) .• 9. Turn the ignition switch OFF. 10. Disconnect ECM/PCM connector C (31P).

BACK

11-59

PGM-FI System OTe Troubleshooting (cont'd) DTC P0132: Primary H02S (Sensor 1) Circuit High Voltage

7. Turn the ignition switch ON (II). 8. Check the Primary H02S (Sensor 1) output voltage with the scan tool.

1. Reset the ECM/PCM (see page 11-4).

Is there 0.9 V or more?

2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on.

YES - Go to step 9. NO-Replace the Primary H02S (Sensor 1).•

3. Check the Primary H02S (Sensor 1) output voltage with the scan tool.


Does the voltage stay at 0.9 V or more? 10. Connect ECM/PCM connector terminals C16 and C18 with a jumper wire.

YES - Go to step 4. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the Primary H02S (Sensor 1) and at the ECM/PCM .•


8 9 10 5 6 7 11 2 3 V V V 13 14 15 16 17 18 19 20 21 / 2R 27 12R 29 30 / 23 24 25

4. Turn the ignition switch OFF. 5. Disconnect the Primary H02S (Sensor 1) 4P connector.

SG2(GRNI BlK)

PH02S (WHT) '---

JUMPER WIRE

6. Connect Primary H02S (Sensor 1) 4P connector terminals No.1 and No.2 with a jumper wire.

Wire side of female terminals PRIMARY H02S (SENSOR 1) 4P CONNECTOR


JUMPER WIRE

12. Check the Primary H02S (Sensor 1) output voltage with the scan tool.

r--I ,----, '--

1

2

SG2(GRN/B lK)

L.....


rPHO 2S(WHT)

3

YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away replace the original ECM/PCM .•

4


NO-Repair open in the wire between the ECM/ PCM (C16) and the Primary H02S (Sensor 1) .•

11-60

BACK

DTC P0133: Primary H02S (Sensor 1) Slow Response DTC P1163: A/F Sensor (Sensor 1) Slow Response NOTE: • If DTC P0131, P0132 and/or P0135 are stored at the same time as DTC P0133, troubleshoot those DTCs first, then recheck for DTC P0133 . • If DTC P1162 is stored at the same time as DTC P1163, troubleshoot DTC P1162 first, then recheck for DTC P1163. 1. Resetthe ECM/PCM (see page 11-4). 2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on. 3. Test-drive under following conditions. • 55 mph (89km/n) steady speed

• AfT in D4 position (MIT in 5th gear) • Until readiness code or Temporary DTC P0133 and/or P1163 (F23A4 engine) comes on 4. Check for a Temporary DTC with the scan tool. Is Temporary DTC P0133 and/or P1163 indicated? VES- Replace the Primary H02S (Sensor 1) .• NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C101 (located under the under-hood fuse/relay box), the Primary H02S (Sensor 1) and the ECM/PCM .•

BACK

11-61

PGM-FI System DTC Troubleshooting (cont'd) DTC P0137: Secondary H02S (Sensor 2) Circuit Low Voltage-Except F23A4 SULEV Engine

10. Check for continuity between Secondary H02S (Sensor 2) 4P connector terminal No.2 and body ground. SECONDARY H02S ISENSOR 2) 4P CONNECTOR

1. Reset the ECM/PCM (see page 11-4). 2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on. 3. Check the Secondary H02S (Sensor 2) output voltage at 3,000 rpm with the scan tool.

SH02S IWHT/RED)

3

4

Does the voltage stay at 0.3 V or less? YES- Go to step 4. Terminal side of male terminals

NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C204 (located under the right side of the dash), C102 (located under the under-hood fuse/relay box), the Secondary H02S (Sensor 2), and the ECM/PCM .• 4. Turn the ignition switch OFF.

YES-Repair short in the wire between the ECM/ PCM (A23) and the Secondary H02S (Sensor 2) .• NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .•

5. Disconnect the Secondary H02S (Sensor 2) 4P connector. 6. Start the engine. 7. Check the Secondary H02S (Sensor 2) output voltage with the scan tool.

Does the voltage stay at 0.3 V or less? YES- Go to step 8. NO- Replace the Secondary H02S (Sensor 2) .• 8. Turn the ignition switch OFF. 9. Disconnect ECM/PCM connector A (32P).

11-62


BACK

DTC P0137: Secondary H02S (Sensor 2) Circuit Low Voltage-F23A4 SULEV engine

10. Check for continuity between Secondary H02S (Sensor 2) 4P connector terminal No.2 and body ground.

1. Reset the PCM (see page 11-4). 2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on.

SECONDARY H02S (SENSOR 2) 4P CONNECTOR

SH02S (WHT/RED)

3. Check the Secondary H02S (Sensor 2) output voltage with the scan tool during acceleration using wide open throttle.

3

4

Does the voltage stay at 0.6 V or more? YES-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C204 (located under the right side of the dash), C102 (located under the under-hood fuse/relay box), the Secondary H02S (Sensor 2), and the PCM . •

= Terminal side of male terminals

Is there continuity? YES-Repair short in the wire between the PCM (A23) and the Secondary H02S (Sensor 2) .•

NO-Go to step 4. 4. Turn the ignition switch OFF.

NO-Substitute a known-good PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original PCM .•

5. Disconnect the Secondary H02S (Sensor 2) 4P connector. 6. Start the engine. 7. Check the Secondary H02S (Sensor 2) output voltage with the scan tool. Does the voltage stay at 0.3 V or less? YES-Go to step 8. NO- Replace the Secondary H02S (Sensor 2) .• 8. Turn the ignition switch OFF. 9. Disconnect PCM connector A (32P).

BACK

11-63

PGM-FI System DTC Troubleshooting (cont'd) DTC P0138: Secondary H02S (Sensor 2) Circuit High Voltage-Except F23A4 SULEV engine

7. Turn the ignition switch ON (II). 8. Check the Secondary H02S (Sensor 2) output voltage with the scan tool.

1. Resetthe ECM/PCM (see page 11-4).

Is there 0.6 V or more? 2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on.

YES - Go to step 9. NO - Replace the Secondary H02S (Sensor 2) .•

3. Check the Secondary H02S (Sensor 2) output voltage at 3,000 rpm with the scan tool.

9. Turn the ignition switch OFF. 10. Connect ECM/PCM connector terminals A23 and C18 with a jumper wire.

Does the voltage stay at 0.6 V or more? YES - Go to step 4.

ECM/PCM CONNECTORS A (32PI

NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C204 (located under the right side of the dash), C102 (located under the under-hood fuse/relay box), the Secondary H02S (Sensor 2), and the ECM/PCM. •

8 9 10 / 1 5 6V Vl2 3 4 241 112113 14 15 V 17 18 19 20 21 V 23 2 25 26 27 28 29 30 / ~SH02S (WHTIRED)

JUMPER WIRE


SG2 (GRN/BLK)

C(31P)

5 6 8 9 10 11 2 3 V 17 20 13 14 15 16 18 19 21 V V/ 23 24 25 29 30 V 26 27 28

5. Disconnect the Secondary H02S (Sensor 2) 4P connector. 6. Connect Secondary H02S (Sensor 2) 4P connector terminals No.1 and No.2 with a jumper wire. SECONDARY H02S (SENSOR 214P CONNECTOR



JUMPER WIRE


2 SG2 (GRN/BLK)

SH02S (WHT/RED)

3

4

NO-Repair open in the wire between the ECM/ PCM (A23) and the Secondary H02S (Sensor 2) .•


11-64

YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/ndication goes away, replace the original ECM/PCM .•

BACK

DTC P0138: Secondary H02S (Sensor 2) Circuit High Voltage-F23A4 SULEV Engine


1. Reset the PCM (see page 11-4).



YES- Go to step 10.

3. Accelerate using wide open throttle. Then decelerate for at least 3 seconds with the throttle completely closed.


4. Check the Secondary H02S (Sensor 2) output voltage with the scan tool.

11. Connect PCM connector terminals A23 and C18 with a jumper wire.

NO- Replace the Secondary H02S (Sensor 2) .•

Does the voltage stay at 0.9 V or more?

PCM CONNECTORS

A (32PI

VI2 3 4

5 6 / 8 9 10 112113 14 15 / 17 18 19 20 21 lL' 23 25 26 27 2B 29 30 / ..J i2

YES - Go to step 5. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C204 (located under the right side of the dash), C102 (located under the under-hood fuse/relay box), the Secondary H02S (Sensor 2) and the PCM .•

SH02S (WHT/REDI C(31PI

SG2 (GRN/BLKI

,,/"1 24 I

r-JUMPERWIRE

V 2 3 1/

5 6 8 9 10 13 14 15 / 17 18 19 20 21 V 23 24 25 29 30 1/ 26 27 28

ILV



6. Disconnect the Secondary H02S (Sensor 2) 4P connector. 7. Connect Secondary H02S (Sensor 2) 4P connector terminals No.1 and No.2 with a jumper wire. SECONDARY H02S (SENSOR 21 4P CONNECTOR


Is there 0.9 V or more? JUMPER WIRE

YES-Substitute a known-good PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original PCM .•

2 SG2(GRN/BLKI

NO- Repair open in the wire between the PCM (A23) and the Secondary H02S (Sensor 2) .•

SH02S (WHT/REDI

3

4


BACK

11-65

PGM-FI System DTC Troubleshooting (cont'd) DTC P0139: Secondary H02S (Sensor 2) Slow Response-Except F23A4 SULEV Engine

DTC P0139: Secondary H02S (Sensor 2) Slow

Response-F23A4 SULEV engine


1. Reset the PCM (see page 11-4).



3. Check the Secondary H02S (Sensor 2) output voltage at 3,000 rpm with the scan tool.

3. Accelerate using wide open throttle. Then decelerate for at least 3 seconds with the throttle completely closed.

Does the voltage stay within 0.3- 0.6 V for 2 minutes?

4. Check the Secondary H02S (Sensor 2) output voltage with the scan tool.

YES - Replace the Secondary H02S (Sensor 2) .•

Does the voltage stay at 0.3 V or more? NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C204 (located under the right side of the dash), C102 (located under the under-hood fuse/relay box), the Secondary H02S (Sensor 2), and the ECM/PCM .•

11-66

BACK

YES - Replace the Secondary H02S (Sensor 2) .• NO -Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C204 (located under the right side of the dash), C1 02 (located under the under-hood fuse/relay box), the Secondary H02S (Sensor 2), and the PCM .•

DTC P0135: Primary H02S (Sensor 1) Heater Circuit Malfunction

7. Check for continuity between body ground and H02S 4P connector terminals No.3 and No.4 individually. H02S 4P CONNECTOR

DTC P0141: Secondary H02S (Sensor 2) Heater Circuit Malfunction

2

NOTE: Information marked with an asterisk ( * ) applies to DTC P0141.

3

4

1. Reset the ECM/PCM (see page 11-4). 2. Start the engine.

Is DTC P0135 or P0141 indicated? VES- Go to step 3. Wire side of female terminals

NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C204 (located under the right side of the dash), C101, C102 (located at the left side of the engine compartment), the Primary H02S (Sensor 1), the Secondary H02S (Sensor 2), and the ECM/PCM .•

Is there continuity? VES-Replace the H02S (Primary or Secondary *) (Sensor 1 or Sensor 2 * ).• NO- Go to step 8.

3. Check the No.6 ECU (ECM/PCM) CRUISE CONTROL (15A) fuse in the driver's under-dash fuse/relay box.

8. Turn the ignition switch ON (II). 9. Measure voltage between H02S 4P connector terminals, No.3 and No.4.

Is the fuse OK?

PRIMARY /SECONDARY* H02S (SENSOR 1/ SENSOR 2*) 4P CONNECTOR

VES- Go to step 4. NO- Replace the fuse and retest.

P02HTC (BLK/WHT), S02HTC (BLK/WHT)*

4. Turn the ignition switch OFF. 5. Disconnect the H02S (Primary or Secondary * ) (Sensor 1 or Sensor 2 * ) 4P connector. 6. At the H02S side, measure resistance between H02S 4P connector terminals No.3 and No.4. H02S 4P CONNECTOR

2

3


4

Is there battery voltage? YES-Go to step 10. Wire side of female terminals

NO- Go to step 13.

Is there 10- 40 Q (F23A4 SULEV engine: 2.020.0 Q)? VES- Go to step 7. NO-Replace the Primary H02S (Sensor 1) or Secondary H02S (Sensor 2) * .• (cont'd)

BACK

11-67

PGM-FI System DTC Troubleshooting (cont'd) 10. Turn the ignition switch OFF.


11. Disconnect ECM/PCM connector C (31 P) (ECM/PCM connector A, 32P) * .

15. Reconnect the H02S 4P connector.

12. Check for continuity between ECM/PCM connector terminal C1 (A8) * and body ground.

16. Disconnect ECM/PCM connector C (31 P) (ECM/PCM connector A, 32P) * . 17. Turn the ignition switch ON (II).

ECM/PCM CONNECTORS CI31PI

18. Measure voltage between ECM/PCM connector terminals 82 and C1 (A8) * . ECM/PCM CONNECTORS P02SHTC (BLK/WHTJ C (31PJ

S02SHTC IBLK/WHTI*

+


Is there continuity? YES-Repair short in the wire between the ECM/ PCM (C1, A8 * ) and the H02S (Primary or Secondary *) (Sensor 1, Sensor 2 * ).• NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .• 13. Measure voltage between H02S terminal No.4 and body ground.

t

r1 2 3 17

5 6 7

8 9 10

1/ 1/ 13 14 15 16 17 18 19 20 21 1/ 23 r7 25 2E 2728 29 30 1/ "'" PG1 (BLKJ

1 9 19

B(25PJ

3 4 5 1/ 7 81 10 11 12 13 14 r7 16 17 181 20 23 24 25 ~~ 2

A (32PI

S02SHTC (BLK/WHTJ*

1/12 3 4 8 9 10 /"1 5 6/ ~2T13 14 15 17 17 18 19 20217 23 24 1 25 26 27 28 29 30./ ~ Wire side of female terminals

Is there 0.1 V or less? YES-Repair open in the wire between the ECM/ PCM (C1, A8 * ) and the H02S (Primary or Secondary *) (Sensor 1, Sensor 2 * ).•

PRIMARY/SECONDARY* H02S (SENSOR 1/ SENSOR 2*1 4P CONNECTOR



Is there battery voltage? YES-Go to step 14. NO- Repair open in the wire between the No.6 ECU (ECM/PCM) CRUISE CONTROL (15A) fuse and the H02S.•

11-68

BACK

DTC P0171: Fuel System Too Lean

4. With a vacuum pump, apply vacuum to the EVAP canister purge valve from the intake manifold side.

DTC P0172: Fuel System Too Rich Does it hold vacuum? NOTE: If some of the OTCs listed below are stored at the same time as OTC P0171 and/or P0172, troubleshoot those OTCs first, then recheck for P0171 and/or P0172.

YES-Check the valve clearances and adjust if necessary.lfthe valve clearances are OK, replace the injectors .•

P0106, P0107, P0108, P1128, P1129: MAP Sensor P0135: Primary H02S (Sensor 1) Heater P0137, P0138: Secondary H02S (Sensor 2) P0141: Secondary H02S (Sensor 2) Heater P0401: EGR Flow Insufficient P1259: VTEC System (F23A1, F23A4 engine) P1491: EGR Valve Lift Insufficient P1498: EGR Valve Lift Sensor High Voltage

NO- Replace the EVAP canister purge valve .•

1. Check the fuel pressure (see page 11-115).

Is fuel pressure OK? YES - Go to step 2. NO - Check these items: • If the pressure is too high. Check the fuel pressure regulator and the fuel return line .• • If the pressure is too low. Check the fuel pump, the fuel feed line, the fuel filter, and the fuel pressure regulator .• 2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on. 3. Check the Primary H02S or Air Fuel Ratio (NF) Sensor (Sensor 1) output with the scan tool.

Does it stay at less than 0.3 V or more than 0.6 V? YES-Replace the Primary H02S or Air Fuel Ratio (NF) Sensor (Sensor 1).• NO-Goto step 4.

BACK

11-69

PGM-FI System DTC Troubleshooting (cont'd) OTC P0300: Random Misfire and Any Combination of the Following: OTC P0301: No.1 Cylinder Misfire OTC P0302: No.2 Cylinder Misfire OTC P0303: No.3 Cylinder Misfire OTC P0304: No.4 Cylinder Misfire NOTE: • If the misfiring is frequent enough to trigger detection of increased emissions during two consecutive driving cycles, the MIL will come on, and DTC P0300 (and some combination of P0301 through P0304) will be stored . • If the misfiring is frequent enough to damage the catalyst, the MIL will blink whenever the misfiring occurs, and DTC P0300 (and some combination of P0301 through P0304) will be stored. When the misfiring stops, the MIL will remain on. 1. Troubleshoot the following DTCs first, if any of them were stored along with the random misfire DTC(s): P0107, P0108, P1128, P1129: MAP Sensor P0171, P0172: Fuel metering P0401, P1491, P1498: EGR system P0505: Idle control system P1259: VTEC System (F23A1, F23A4 engine) P1361, P1362: TDC sensor P1381, P1382: CYP sensor P1519: lAC valve 2. Test-drive the vehicle to verify the symptom. 3. Find the symptom in the chart below, and do the related procedures and checks, in the order listed, until you find the cause. Symptom Random misfire only at low RPM and under load

Random misfire only during acceleration

Random misfire at high RPM and load, or under random conditions

11-70

1. 2.

Procedure Check fuel pressure (see page 11-115). Inspect the ignition distributor housing.

1. 2. 3. 4. 5. 1. 2. 3. 4. 5.

Inspect and test ignition wires (see page 4-25). Inspect the ignition distributor housing. Check fuel pressure (see page 11-115). Testthe ignition coil (see page 4-24). Test the ignition control module (see page 4-23). Check fuel pressure (see page 11-115). Inspect and test ignition wires (see page 4-25). Inspect the ignition distributor housing. Test the ignition coil (see page 4-24). Test the ignition control module (see page 4-23).

BACK

Also check for: • Low compression • Low quality fuel • Correct EGR valve function Malfunction in the VTEC system (F23A 1, F23A4 engine) (see page 6-7) Correct valve clearance (see page 6-14)

OTC P0301: No.1 Cylinder Misfire

6. Determine which cylinder(s) had the misfire.

OTC P0302: No.2 Cylinder Misfire

Does the misfire occur in the cylinder where the spark plug was exchanged?

OTC P0303: No.3 Cylinder Misfire YES- Replace the faulty spark plug .•

OTC P0304: No.4 Cylinder Misfire NO- Go to step 7. NOTE: If some of the DTCs listed below are stored at the some time as a misfire DTC, troubleshoot those DTCs first, then recheck for the misfire DTC. P0131, P0171, P0401: P1359, P1381,

7. Exchange the injector from the problem cylinder with one from another cylinder.

P0132: Primary H02S P0172: Fuel Supply System EGR System P1361, P1362: TDC Sensor P1382: CYP Sensor

8. Let the engine idle for 2 minutes. 9. Test-drive the vehicle several times in the range of the freeze data or under various conditions if there was no freeze data.

1. Start the engine, listen for a clicking sound from the injector in the problem cylinder.

Is DTC P0301, P0302, P0303, P0304, or Temporary DTC P1399 indicated?

Does it click?

YES-Go to step 10.

YES - Go to step 2.

NO-Intermittent misfire due to bad contact in the injector connector (no misfire at this time) .•

NO-Go to step 11. 10. Determine which cylinder(s) had the misfire. 2. After checking and recording the freeze data, do the ECM/PCM Reset Procedure. If there is no freeze data of misfiring, just clear the DTC.

Does the misfire occur in the cylinder where the injector was exchanged?

3. Exchange the spark plug from the problem cylinder with one from another cylinder. 4. Test-drive the vehicle several times in the range of the freeze data or under various conditions if there was no freeze data.

YES- Replace the faulty injector.• NO-Check the engine compression, and perform a cylinder leak down test.• 11. Check for an open or short in the harness between the ECM/PCM and the injector.

5. Check for a DTC or Temporary DTC with the scan tool.

Are the wires OK?

Is DTC P0301, P0302, P0303, P0304, or Temporary DTC P1399 indicated?

YES-Gotostep 12. NO- Repair open or short in the wire .•

YES - Go to step 6. 12. Install a known-good injector, and recheck. NO-Intermittent misfire due to spark plug fouling, etc. (no misfire at this time) .•

Does the injector click? YES- Replace the injector.• NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .•

BACK

11-71

PGM-FI System DTC Troubleshooting (cont'd) DTC P0325: KS Circuit Malfunction

7. Connect knock sensor connector terminal No.1 to body ground with a jumper wire.

1. Reset the ECM/PCM (see page 11-4). KNOCK SENSOR 1P CONNECTOR


~RED/BLU)

3. Hold the engine at 3,000 - 4,000 rpm for at least 60 seconds.

L--J


1

JUMPER WIRE

YES - Go to step 4. Wire side of female terminals

NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the knock sensor and at the ECM/PCM.

8. Check for continuity between ECM/PCM connector terminal C3 and body ground.



5. Disconnect the knock sensor connector.

KS (RED/BLU)

I

6. Check for continuity between ECM/PCM connector terminal C3 and body ground.

8 9 10 5 6 7 11 2 3 V 19 14 V / 13 15 16 17 18 20 21 1/ 23 24 25 26 27 28 29 30 1/

ECM/PCM CONNECTOR C (31P) KS (RED/BLU)

I

8 9 10 5 6 7 11 2 3 V 14 15 16 19 13 17 18 20 21 / VV 23 24 25 26 27 28 29 30 /

Q = Wire side of female terminals

Q

Is there continuity? YES-Go to step 9. Wire side of female terminals

NO-Repair open in the wire between the ECM/ PCM (C3) and the knock sensor. •

Is there continuity? 9. Substitute a known-good knock sensor and recheck. YES-Repair short in the wire between the ECM/ PCM (C3) and the knock sensor.•

Is DTC P0325 indicated? YES- Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .•

NO-Go to step 7.

NO - Replace the origi nal knock sensor (see page 724) .•

11-72

BACK

DTC P033S: CKP Sensor No signal

6. Check for continuity from body ground to each terminal indicated for the DTC(s) you retrieved.

DTC P0336: CKP Sensor Intermittent Interruption

P1361 or P1362 CKP/TDC SENSOR 4P CONNECTOR

DTC P1361:TDC 1 Sensor Intermittent Interruption

TOCP

DTC P1362: TDC 1 Sensor No Signal

=

=

1. Check for DTC P1359. If it is stored along with any of the DTCs listed above, troubleshoot it first, then troubleshoot the other DTCs.


P033S or P0336 CKP /TOC SENSOR 4P CONNECTOR

2. Reset the ECM/PCM (see page 11-4). 3. Start the engine. Is DTC P0335, P0336, P1361, or P1362 indicated?

=

YES-Go to step 4.

=



NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the CKP/TDC sensor and at the ECM/PCM .•

YES - Replace the CKP/TDC sensor (see page 6-55) .•

4. Turn the ignition switch OFF. NO- Go to step 7. 5. Disconnect the CKP/DTC sensor 4P connector, and measure resistance between its terminals at the locations shown for the DTC(s) you retrieved.

7. Reconnect the CKP/TDC sensor 4P connector.

P1361 or P1362 CKP/TOC SENSOR 4P CONNECTOR

TOCM

TOCP


P033S or P0336 CKP/TDC SENSOR 4P CONNECTOR

CKPP

Jib ~PM


Is there 1,850- 2,450 Q ? YES - Go to step 6. NO - Replace the CKP/TDC sensor (see page 6-55.

BACK

(cont'd)

11-73

PGM-FI System DTC Troubleshooting (cont'd) 8. Disconnect ECM/PCM connector C (31 P), and measure resistance between the terminals indicated for the DTC(s) you retrieved.

9. Check for continuity between the ECM/PCM connector terminal(s) to body ground as indicated for the DTC(s) you retrieved.

P033S or P0336 ECM/PCM CONNECTOR C (31 P)

P1361

ECM/PCM CONNECTOR C(31P)

TDCP (GRN)

P1361 or P1362 CKPP ECM/PCM CONNECTOR (BLU) C(31P)

Q Q

CKPP (BLU)

I 5 6 7 8 9 10 11 2 3 V V V 13 14 15 16 17 18 19 20 21 V 23 24 25 26 27 28 29 30 V

5 6 7 8 9 10 11 2 3 V 1/ / 13 14 15 16 17 18 19 20 21 1/ 23 24 25 26 27 28 129 3p V Wire side of female terminals

or P1362


T DCM (RED) P033S

=

or P0336 ECM/PCM CONNECTOR C (31 P)

CKPM (WHT)

8 9 10 5 6 7 11 2 3 V 14 15 17 19 13 16 18 20 21 / VV 23 24 25 26 27 28 2P 30 V

5 6 7 8 9 10 11 2 3 1/ 14 15 16 17 18 19 13 20 21 / I/" V 23 24 25 29 30 / 26 27 28



~ TDCP (GRN)

Is there 1,850- 2,450 Q ?


YES-Go to step 9.

YES- Repair short in the faulty sensor wire(s) .•

NO- Repair open in the faulty sensor wire(s) .•


11-74

BACK

"

DTC P0500: VSS Circuit Malfunction


1. Test-drive the vehicle.

12. Block the right front wheel. and slowly rotate the left front wheel.

2. Check the vehicle speed sensor reading with the scan tool.

13. Measure voltage between ECM connector terminals B20 and C23.

Is the correct speed indicated?

ECM CONNECTORS

YES -Intermittent failure. system is OK at this time. Check for poor connections or loose wires at the VSS and atthe ECM .•

B(25P)

1 9 19

NO - Go to step 3.

3 4 5 2 / 7 81 10 11 12 13 14 ;/ 16 17 181 23 24 25 20 ~~ LG1 (BRN/BLK) C(31P)


8 9 10 5 6 7 11 2 3 / 13 14 15 16 17 18 19 20 21 1/ 23 24 25 26 27 2B 29 30 /

IL' /

4. Block the rear wheels and set the parking brake.

~ VSS (BLU/WHT)

5. Raise the front of the vehicle. and make sure it is securely supported.



Does the voltage pulse between 0 V and 5 V?

7. Block the right front wheel. and slowly rotate the left front wheel.

YES-Substitute a known-good ECM and recheck (see page 11-5). If the symptom/indication goes away. replace the original ECM .•

8. Measure voltage between ECM connector terminals B20 and C23.

NO-Check these items:

ECM CONNECTORS

• A short or an open in the wire between the ECM (C23) and the VSS. • If the wire is OK. test the VSS (see page 22-69).

B(25PI

1 9 19

3 4 5 V 7 81 2 10 11 12 13 14 V 16 17 181 21 22 23 24 25 20

--

LG1 (BRN/BLKI C(31PI

5 6 7 8 9 10 11 2 3 ;/ 13 14 15 16 17 18 19 20 21 / 23 24 25 26272B 29 30 L

V /

~ VSS (BLU/WHT)


Does the voltage pulse between 0 V and 5 V? YES-Substitute a known-good ECM and recheck (see page 11-5). Ifthe symptom/indication goes away. replace the original ECM .• NO-Gotostep9. 9. Turn the ignition switch OFF. 10. Disconnect ECM connector C (31P).

BACK

11-75

PGM-FI System DTe Troubleshooting (cont'd) DTC P0560: ECM/PCM Back up Circuit Low Voltage

5. Measure voltage between ECM/PCM connector terminal B21 and body ground.

NOTE: Ifthe No. 13 CLOCK BACK UP (7.5A) fuse in the passenger's under-dash fuse/relay box is removed and the engine is started, the MIL will come on and the ECM /PCM will store DTC P0560. 1. Reset the ECM/PCM (see page 11-4).

ECM/PCM CONNECTOR B (25P)

1 9 19

2 10 20

2122 VBU (WHT/VEL)

2. Start the engine. Is DTC P0560 indicated? YES - Go to step 3.


NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the No. 13 CLOCK BACK UP (7.5A) fuse in the passenger's under-dash fuse/relay box and ECM/PCM .•

Is there battery voltage? YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .•

3. Turn the ignition switch OFF. 4. Inspectthe No. 13 CLOCK BACK UP (7.5A) fuse in the passenger's under-dash fuse/relay box .• Is the fuse OK? YES-Go to step 5. NO - Check for these problems . • Repair short in the wire between the ECM/PCM (B21) and No. 13 CLOCK BACK UP (7.5A) fuse in the passenger's under-dash fuse/relay box.• • Repair short in the wire in the back up circuit (see page 22-46) .•

11-76

BACK

NO- Repair open in the wire between the ECM/ PCM (B21) and the No. 13 CLOCK BACK UP (7.5A) fuse in the passenger's under-dash fuse/relay box .•

DTC P1106: BARD Sensor Range/Perfomance

DTC P1107: BARD Sensor Circuit Low Voltage

Problem DTC P1108: BARD Sensor Circuit High

Voltage

1. Resetthe ECM/PCM (see page 11-4). 2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then let it idle.

1. Resetthe ECM/PCM (see page 11-4). 2. Turn the ignition switch ON (II).

3. Test-drive with the AfT in 2nd position, or the MIT in 4th gear.

Is DTC P1107 or P110B indicated?

4. Accelerate for 5 seconds using wide open throttle.

YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM.

5. Check for a Temporary DTC with the scan tool. NO-Intermittent failure, system is OK at this time .•

Is Temporary DTC P1106 indicated? YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .• NO-Intermittent failure, system is OK at this time .•

BACK

11-77

PGM-FI System DTC Troubleshooting (cont'd) DTC P1149: A/F Sensor (Sensor 1)

Rangel

Performance Problem DTC P1165: A/F Sensor (Sensor 1) Rangel Performance Problem NOTE: If some of the DTCs listed below are stored at the same time as DTC P1149 or P1165, troubleshoot those DTCs first, then troubleshoot DTC P1149 or P1165. P0137, P0138: Secondary H02S (Sensor 2) P0141: Secondary H02S (sensor 2) Heater 1. Reset the ECM/PCM (see page 11-4). 2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on. 3. Test-drive under following conditions. • 55 mph (89 km/h) steady speed

• AfT in D4 position (MfT in 5th gear) • Until the readiness code or Temporary DTC P1149 (P1165) comes on

Is Temporary DTC P1149 (P1165) indicated? YES-Replace the Primary H02S (Sensor 1).• NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C102 (located under the under-hood fuse/relay box), the primary H02S relay, the primary H02S (Sensor 1), and the ECM/PCM .• 4. Check for a Temporary DTC with the scan tool.

11-78

BACK

DTC P1162: A/F Sensor (Sensor 1) Circuit Malfuncion

8. Connect ECM/PCM connector terminals C14 and C15 to body ground with a jumper wire.



2. Start the engine, and wait at least 2 minutes.

5 6 7 8 9 10 11 2 3 :/ V V 13 14 15 16 17 18 19 20 21 :/ 23 24 L~ 26 27 28 29 30 :/

Is DTe P1162 indicated? YES - Go to step 3.

PH02S+ (RED)

NO -Intermittent failure, system is OK at this time. Check for poor connections or loose wi res at the A/F Sensor (Sensor 1) and at the ECM/PCM .•

PH02S- (BLU)

JUM PER WIRE

JUMPER WIRE -~-

.....


3. Turn the ignition switch OFF. 4. Start the engine.

9. Check for continuity between A/F Sensor (Sensor

5. Measure voltage between ECM/PCM connector terminals C14 and 820, and between C15 and 820.

1) 4P connector terminal No.1, No.2, and body ground individually. A/F SENSOR (SENSOR 1) 4P CONNECTOR

ECM/PCM CONNECTORS B(25P)

1 9 19

/

PH02S- (BlU)

3 4 5 1/ 7 81 2 10 11 12 13 14V 1617 181 20 .EJ.f& 23 2~ 25 lG1 (BRN/BlK)

,.......--,---'-, I

2

PH02S+ (RED)

1+-----,

1---1-------1

3

4

C(31P)

3V 5 6 7 8 9 10 13 1415 16 1718 19 20 21V 23241$ 26 27 28 29 30 1/

1 2

VV ~(RED)


1

':::L

PH02S- (BLU)


Is there 2.5- 3.0 V?

Is there continuity? YES- Replace the A/F Sensor (Sensor 1) (see page

11-99).• YES- Go to step 6.

NO-Gotostep 10.

NO- Repair open in the wire between the A/F Sensor (Sensor 1) and the ECM/PCM (C14 or C15) .•

6. Turn the ignition switch OFF. 7. Disconnect the A/F Sensor 4P connector and ECMI PCM connector C (31 Pl.

(cont'd)

BACK

11-79

PGM-FI System DTC Troubleshooting (cont'd) DTC P1164: A/F Sensor (Sensor 1) Rangel Performance Problem

10. Turn the ignition switch OFF. 11. Disconnect the A/F Sensor 4P connector and ECM/ PCM connector C (31P).


12. Check for continuity between body ground and A/F Sensor (Sensor 1) 4P connector terminals No.2 and No.1.

2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on. 3. Check for a Temporary DTC with the scan tool.

A/F SENSOR (SENSOR 1) 4P CONNECTOR

PH02S- (BLU)

1--'--,--'--,1

Is Temporary DTC P1164 indicated?

PH02S+ (RED)

2

3

YES- Replace the A/F Sensor (Sensor 1) (see page 11-99).•

4

NO - Go to step 4. 4. Test-drive in 03 position. Starting at 1,600 rpm, accelerate using wide open throttle for at least 5 seconds. Then decelerate for at least 5 seconds with the throttle completely closed until the readiness code or Temporary DTC P1164 comes on.


Is there continuity? Is Temporary DTC P1164 indicated? YES- Repair short in the wire between the A/F Sensor (Sensor 1) and the ECM/PCM (C14 or C15) .•

YES- Replace the A/F Sensor (Sensor 1) (see page 11-99) .•

NO- Replace the A/F Sensor (Sensor 1) (see page 11-99) .•

11-80

BACK

NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C102 (located under the under-hood fuse/relay box), the A/F Sensor relay, the A/F Sensor (Sensor 1) and the ECM/PCM .•

DTC P1166: NF Sensor (Sensor 1) Heater Circuit Malfunction

5. Measure voltage between ECM/PCM connector terminals C13 and 820. ECM/PCM CONNECTORS


B (25P)

2. Start the engine.

1 9 19


2 345 V 7 8 10 11 12 13 14 / 16 17 181 20 ~[gg 23 24 25 LG1 (BRN/BLKI

YES - Go to step 3.

C (31P)

5 6 7 8 9 10 11 2 3 V V V 13 14 15 16 17 18 19 20 21 / 23 214 25 26 27 28 29 30 V

NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C102 (located under the under-hood fuse/relay box), A/F Sensor relay, the A/F Sensor (Sensor 1) and the ECM/PCM .•

J

4>

P02SHTC+ (WHT)


3. Check the following fuses:


• POWER SEAT (20A) fuse in the under-hood fuse/relay box. • No.4 ECU (ECM/PCM) CRUISE CONTROL (15A) fuse in the driver's under-dash fuse/relay box. • No.6 LAF HEATER (20A) in the passenger's under-dash fuse/relay box.

YES-Go to step 6. NO- Go to step 10. 6. Turn the ignition switch OFF. 7. Disconnect ECM/PCM connector 8 (25P).

Are any of the fuses blown? 8. Turn the ignition switch ON (II). YES- Repair short in the wire between the A/F Sensor relay and the fuses .•

9. Connect ECM/PCM connector terminal 816 to body ground with a jumper wire, then measure voltage between ECM/PCM connector terminals 819 and 820.

NO - Go to step 4. 4. Measure voltage between ECM/PCM connector terminals 819 and 820, 30 seconds after the ignition switch is turned ON (II).

ECM/PCM CONNECTOR B (25PI


1 9 19 P02SHTC (BLKIWHTI

2 10 20

lwJ

1 9 19

3 4 5 1/ 7 81 11 12 13 14 / 16 17 181 21 22 23 24 25 '--'--

10

20

r~ 'Y..

1 7 81 3 4 5 11 12 13 14 / 16 17 18J 21 22 23 24 25 '--'--

A"

2

LG1(BRN/BLKI

P02S HTC (BLK/WHTI

LG1 (BRN/BLKI

JUMPER WIRE

-=




YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). Ifthe symptom/indication goes away, replace the original ECM/PCM .•

Is there battery voltage? YES- Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .•

NO- Repair open or short in the wire between A/F Sensor (Sensor 1) and ECM/PCM (819) .• (cont'd)

NO- Go to step 5.

BACK

11-81

PGM-FI System DTC Troubleshooting (cont'd) 10. Turn the ignition switch OFF.


11. Disconnect ECM/PCM connector 8 (25P) and the A/F Sensor (Sensor 1) 4P connector.

14. Measure voltage between ECM/PCM connector terminals 816 and 820 ECM/PCM CONNECTOR B (25P)

12. Check for continuity between A/F Sensor (Sensor 1) 4P connector terminal No.3 and body ground. A/F SENSOR (SENSOR 1) 4P CONNECTOR

P02SHTC+ (BlK/WHT)

1 9 19

2 3

4

2 10 20

lG1 (BRN/BlK)

I

3 4 5 / 7 8 11 12 13 14 / 16 17 18 23 25 21 22 ~

*

P02SHTCR (GRN/RED)


/s there battery voltage? Terminal side of male terminals

YES-Repair open in the wire between the ECM/ PCM (C13) and the A/F Sensor (Sensor 1) or Secondary H02S (Sensor 2) .•

/s there continuity? YES- Repair short in the wire between the A/F Sensor (Sensor 1) and ECM/PCM (819) . • NO- Go to step 13.

NO-Go to step 15. 15. Check for continuity in the wires between A/F Sensor and the fuses.

/s there continuity? YES- The wires are OK. Replace the A/F Sensor relay .• NO-Repair open in the wire between the A/F Sensor relay and the fuses .•

11-82

BACK

DTC P1167: A/F Sensor (Sensor 1) Heater System Malfunction

5. Check for continuity between A/F Sensor (Sensor 1) 4P connector terminal No.1, No.2, and body ground individually.

NOTE: If DTC P1162 is stored at the same time as DTC P1167, troubleshoot DTC P1162 first, then troubleshoot DTC P1167. 1. Reset the ECM/PCM (see page 11-4).

A/F SENSOR (SENSOR 1) 4P CONNECTOR PH02S- (BLU) Ii---'--r--'--, PH02S+ (RED)

2 2. Start the engine. Wait for at least 80 seconds.

3

4

Is DTC P01167 indicated? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C1 02 (located under the under-hood fuse/relay box), the A/F Sensor relay, the A/F Sensor (Sensor 1), and the ECM/PCM .•



3. Disconnect the A/F Sensor 4P connector, and ECM/ PCM connector C (31P).

YES- Replace the A/F Sensor (Sensor 1) (see page 11-99) .•

4. Connect ECM/PCM connector terminals C14 and C15 to body ground with a jumper wire.

NO- Repair open or short in the wire between the A/F Sensor (Sensor 1) and the ECM/PCM (C14 or C15) .•


5 6 7 8 9 10 [1 2 3 V IV IV 13 14 15 16 17 18 19 20 21 V 23 24 :2p 26 27 28 29 30 V PH02S- (BLU)

PH02S+ (RED) JUM PER WIRE

JUMPER WIRE -~

--


BACK

11-83

PGM-FI System DTC Troubleshooting (cont'd) DTC P1297: ELD Circuit Low Voltage

8. Turn the ignition switch OFF. 9. Disconnect ECM/PCM connector A (32P).


10. Check for continuity between body ground and ECM/PCM connector terminal A30.

2. Start the engine. 3. Turn on the headlights.

ECM/PCM CONNECTOR A (32P)

Is DTC P1297 indicated? YES- Go to step 4. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C204 (located under the right side of dash), the ELD, and the ECM/PCM .• 4. Turn the ignition switch and the headlights OFF. Wire side of female terminals

5. Disconnect the ELD 3P connector. 6. Turn the ignition switch ON (II).


7. Measure voltage between body ground and ELD 3P connector terminal No.3.

YES-Repair short in the wire between the ECM/ PCM (A30) and the ELD.•

ELD 3P CONNECTOR



Is there approx. 5 V? YES - Replace the ELD.• NO-Goto step 8.

11-84

BACK

DTC P1298: ELD Circuit High Voltage

9. Connect ELD 3P connector terminal No.3 to body ground with a jumper wire.

1. Reset the ECM/PCM (see page 11-4). ELD 3P CONNECTOR

2. Start the engine. 3. Turn on the headlights.

/s DTC P1298 indicated? EL IGRN/RED)

YES - Go to step 4. JUMPER WIRE

NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C204 (located under the right side of dash), the ELD, and the ECM/PCM .•


4. Turn the ignition switch and headlights OFF.

10. Disconnect ECM/PCM connector A (32P).

5. Disconnect the ELD 3P connector.

11. Check for continuity between ECM/PCM connector terminal A30 and body ground.


ECM/PCM CONNECTOR A 132P)

7. Measure voltage between body ground and ELD 3P connector terminal No.1. ELD 3P CONNECTOR

2

3


=



YES-Go to step 12.

/s there battery voltage?

NO-Repair open in the wire between the ECM (A30) and the ELD.•

YES-Go to step 8. NO- Repair open in the wire between the No.6 ECU (PCM) CRUISE CONTROL (15A) fuse and the ELD.• 8. Turn the ignition switch OFF.

(cont'd)

BACK

11-85

PGM-FI System DTC Troubleshooting (cont'd) 12. Check for continuity between ELD 3P connector terminal No.2 and body ground.

ELD 3P CONNECTOR


Is there continuity? YES-Go to step 13. NO-Repair open in the wire between ELD connector terminal No.2 and G202 .• 13. Reconnect the ELD 3P connector. 14. Start the engine and let it idle. 15. While measuring voltage between ECM/PCM connector terminals A30 and 820, turn the headlights on (low). ECM/PCM CONNECTORS A (32P)

8 9 10 / ' 5 6V Vl2 3 4 112113 14 15 17 17 18 192021 V 23 24 25 26 27 28 2930 / ...lL EL (GRN/RED) B(25P)

1 9 19

2 3 4 5 V 7 81 10 11 12 13 14 V 16 17 181 20 ~~ 23 24 25

~ LG1(BRN/BLK) Wire side of female terminals

Does the voltage drop? YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). Ifthe symptom/indication goes away, replace the original ECM/PCM .• NO-Replace the ELD.•

11-86

BACK

DTC P1359: CKP/TDC Sensor Circuit Malfunction 1. Reset the ECM/PCM (see page 11-4). 2. Start the engine.

Is DTC P1359 indicated? YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the CKPrrOC sensor and the ECM/PCM .• 3. Check for poor connections or loose wires between the CKPrrOC sensor and the ECM/PCM.

Are the connections OK? YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .• NO-Repair as necessary.•

BACK

11-87

PGM-FI System DTC Troubleshooting (cont'd) DTC P1381: CYP Sensor Intermittent Interruption

7. For the F23A 1 or F23A4 engine, measure resistance between distributor 4P connector terminals No.3 and No.4. For the F23A5 engine, measure resistance between the distributor 4P connector terminals No.2 and No.4.

DTC P1382: CYP Sensor No Signal 1. Reset the ECM/PCM (see page 11-4).

DISTRIBUTOR 4P CONNECTOR


F23A1, F23A4 ENGINE

Is Dre P1381, and/or P1382 indicated?

F23A5 ENGINE

ffiBj CYPP

~

YES- Go to step 3. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the distributor and the ECM/PCM .•

CYPP

~

CYPM

1

2

3

4 CYPM


3. Check for poor connections at the ignition (spark plug) wires.

Is there 800-1,500 Q ? Are the wires OK? YES- Go to step 8. YES-Go to step 4. NO-Replace the ignition distributor housing .• NO-Correct as necessary.• 4. Check the condition of the ignition wires (see page 4-25).

Are the wires OK?

8. For the F23A 1 or F23A4 engine, check for continuity between body ground and the distributor connector terminals No.3 and No.4 individually. For the F23A5 engine, check for continuity between body ground and the distributor connector terminals No.2 and No.4 individually.

YES- Go to step 5.

DISTRIBUTOR 4P CONNECTOR

NO- Replace the ignition wires.• F23A1, F23A4 ENGINE

F23A5 ENGINE

5. Turn the ignition switch OFF. 3

6. Disconnect the distributor 4P connector. CYPM

=

=


Is there continuity? YES-Replace the ignition distributor housing .• NO - Go to step 9. 9. Reconnect the distributor 4P connector. 10. Disconnect ECM/PCM connector C (31P).

11-88

BACK

11. Measure resistance between ECM/PCM connector terminals C29 and C30. ECM/PCM CONNECTOR C (31P)

1 2 3 [7

V

5 6 7 8 9 10 IV 13 14 15 16 17 18 19 20 21 / 29 30 / 23 24 25 26 27 28 evpp (YEll

CYPM (BLK)

~ Q


Is there 800- 1,500 Q ? YES-Go to step 12. NO- Repair open in the wire between the ECM/ PCM (C29, C30) and the distributor.• 12. Check for continuity between body ground and ECM/PCM connector terminal C29. ECM/PCM CONNECTOR C (31P)

8 9 10 5 6 7 1 2 3 [7 IVIV 13 14 15 16 17 18 19 20 21 iV 29 30 / 26 27 28 23 24 25

fPP{VEL =


Is there continuity? YES-Repair short in the wire between the ECM/ PCM (C29) and the distributor.. NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). Ifthe symptom/indication goes away, replace the original ECM/PCM .•

BACK

11-89

PGM-FI System DTC Troubleshooting (cont'd) OTC P1607: ECM/PCM Internal Circuit

Malfunction 1. Resetthe ECM/PCM (see page 11-4). 2. Turn the ignition switch ON (II). 3. Wait 30 seconds. Is DTC P1607 indicated?

YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .• NO- Go to step 4. 4. Turn the ignition switch OFF. 5. Turn the ignition switch ON (II). 6. Wait 10 seconds. Is DTC P1607 indicated?

YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .• NO-Intermittent failure, system is OK at this time .•

11-90

BACK

MIL Circuit Troubleshooting 1. Connect an aBO II scan tool/Honda PGM Tester (see page 11-3).

YES-If the MIL always come on and stays on, go to step 16. But if the MIL sometimes works normally, first check for these problems.

2. Turn the ignition switch ON (II), and read the aBO II scan tool/Honda PGM Tester.

An intermittent short in the wire between the ECM/PCM (A10) and the Data Link Connector (OLC). • An intermittent open in the wire between the ECM/PCM (A21) and the OLC. o An intermittent short in the wire between the ECM/PCM (A 18) and the gauge assembly. o

Does the OBD II scan tool/Honda PGM Tester communicate with the ECM/PCM? YES-Go to step 3. NO-Go to troubleshooting "OLC Circuit Troubleshooting" (see page 11-95).

NO-If the MIL is always off, go to step 6. But if the MIL sometimes works normally, first check for these problems.

3. Check the aBO II scan tool/Honda PGM Tester for OTCs.

o

Are any DTCs indicated? YES-Go to the OTC Troubleshooting index.

o

NO - Go to step 4.

o


o o

5. Turn the ignition switch ON ("), and watch the Malfunction Indicator Lamp (MIL). o

Does the MIL come on and stay on for more than 20 seconds after turning the ignition switch ON (II)?

o

A loose No.9 BACK UP LIGHT, INSTRUMENT LIGHT (7.5A) fuse in the driver'S under-dash fuse/ relay box. A loose ACG S (15A) fuse in the under-hood fuse/relay box. A loose No.1 FUEL PUMP (15A) fuse in the driver's under-dash fuse/relay box. A poor connection at ECM/PCM terminal A 18. An intermittent open in the GRN/ORN wire between the ECM/PCM (A 18) and the ga uge assembly. An intermittent short in the wire between the ECM/PCM (C19) and the MAP sensor. An intermittent short in the wire between the ECM/PCM (C28) and the TP sensor, EGR valve position sensor, or Fuel Tank Pressure (FTP) Sensor.

6. Check the low oil pressure light.

Is the low oil pressure light on? YES-Go to step 7. NO-Check for these problems. o

o

A blown No.9 BACK UP LIGHT, INSTRUMENT LIGHT (7.5A) fuse in the driver's under-dash fuse/ relay box. A short or open in the wire between the No.9 BACK UP LIGHT, INSTRUMENT LIGHT (7.5A) fuse and the gauge assembly.

(cont'd)

BACK

11-91

PGM-FI System MIL Circuit Troubleshooting (cont'd) 10. Turn the ignition switch OFF, then disconnect ECM/ PCM connector C (31 P), and check for continuity between body ground and ECM/PCM connector terminals C19 and C28 individually.

7. Try to start the engine.

Does the engine start? YES - Go to step 8.


NO-Goto step 10.

1 2 3V 5 6 7 8 9 10 V V 13 14 15 16 17 18 19 20 21 1/ 23 24 25 29 30 1/ 26 27 28

8. Turn the ignition switch OFF, and connect ECM/PCM connector terminal A18 to body ground with a jumper wire.

,yn


VCC2 (VEL/BLUI

5 6 1/ 8 9 10 / 1 VJ2 3 4 112113 14 15 V 17 18 19 20 21 1/ 23 24 1 32 25 26 27 12s 29 30 1/

VCC1 (VEL/RED)



MIL (GRN/ORN) JUMPER WIRE

YES-Goto step 11.

_.... =

NO-Go to step 12.


11. Disconnect the 3P connector from each of these sensors, one at a time, and check for continuity between body ground and ECM/PCM connector terminal C19 and C28 individually.


Is the MIL on? YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). Ifthe symptom/indication goes away, replace the original ECM/PCM .•

• • • •

NO-Check for an open in the wires between the ECM/PCM (A18) and the gauge assembly. Also check for a blown MIL bulb.•

MAP Sensor EGR valve position sensor FTP sensor TP sensor

Is there continuity? YES- Repair the short to body ground in the wire between the ECM/PCM (C19) and the MAP sensor, or the ECM/PCM (C28) and the TP sensor, EGR valve position sensor, or FTP sensor. • NO - Replace the sensor that made continuity to body ground go away when disconnected .• 12. Disconnectthe injectors and lAC valve connectors.

11-92

BACK

13. Turn the ignition switch ON (II), and measure voltage between body ground and ECM/PCM connector terminals 81 and 89 individually.

14. Reconnect the connectors to the sensors, then reconnect ECM/PCM connector C (31 Pl.

ECM/PCM CONNECTOR B (25P) IGP1 (VEl/BlK) r-

':i

':i

1 9 19

2 10 20

3 4 5 1/ 7 81 11 12 13 14 1/ 16 17 181 21 22 23 24 25

15. Turn the ignition switch ON (11), and measure voltage between body ground and ECM/PCM connector terminals 82, 810, 820, and 822 individually. ECM/PCM CONNECTOR B (25P)

~__~~P~G1(Bl~K=)~~~

1 9 19

IGP2 (VEl/BlK)

=

':i


-

YES-Go to step 14.

o

-

lG2 (BRN/BlK)

=

=


Is there less than 1.0 V?

NO - Check for these problems:

o

lG1 (BRN/ BlK)

PG2 (BlK)


o

7 8

2 10 20

An open in the wire(s) between the PGM-FI main relay and ECM/PCM connector terminals 81 and 89. Poor connections at the PGM-FI main relay. A faulty PG M-FI main relay (see page 11-112). If necessary, repair or replace the relay.•

YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .•

NO- Repair the open in the wire(s) that had more than 1.0 V between G101 and the ECM/PCM (82, 810, 820,822) .•

(cont'd)

BACK

11-93

PGM-FI System MIL Circuit Troubleshooting (cont'd) 16. Turn the ignition switch OFF, then turn it back ON (II), and measure voltage between ECM/PCM connector terminal A 10 and body ground. ECM/PCM CONNECTOR A (32P)


Is there about 5 V?

YES- Go to step 17. NO- Repair short in the wire between the OLC and the ECM/PCM (A10) .• 17. Turn the ignition switch OFF, disconnect ECM/PCM connector A (32P), then turn the ignition switch ON (II). Does the MIL stay on? YES - Repair short in the wire between the gauge

assembly and the ECM/PCM (A18) .•

NO- Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .•

11-94

BACK

OLC Circuit Troubleshooting If the ECM/PCM does not communicate with the OBO II scan tool, Honda PGM Tester, or I/M test equipment, do this troubleshooting procedure.

3. Measure voltage between OLC terminals No.5 and No. 16. DATA LINK CONNECTOR (DLC)

1. Measure voltage between OLC terminal No. 16 and body ground. DATA LINK CONNECTOR (DLC)


Is there battery voltage? Terminal side of female terminals

YES-Go to step 4. NO- Repair open in the wire between OLC terminal No.5 and body ground (G101) .•

Is there battery voltage? YES - Go to step 2.

4. Turn the ignition switch ON (II). NO- Repair open in the wire between OLC terminal No. 16 and the ACGS (15A) fuse in the under-hood fuse/relay box .•

5. Measure voltage between OLC terminals No.5 and No.7.

2. Measure voltage between OLC terminals No.4 and

DATA LINK CONNECTOR (DLC)

No. 16. DATA LINK CONNECTOR (DLC)




YES- Go to step 10.

Is there battery voltage? NO - Go to step 6.

YES - Go to step 3. 6. Turn the ignition switch OFF. NO- Repair open in the wire between OLC terminal No.4 and body ground (G401) .•

(cont'd)

BACK

11-95

PGM-FI System OLC Circuit Troubleshooting (cont'd) Is there continuity?

7. Disconnect ECM/PCM connector A (32P). Make sure the OBD II scan tool or Honda PGM Tester is disconnected from the DLC.


8. Check for continuity between DLC terminal No.7 and body ground.

NO-Repair open in the wire between DLC terminal No.7 and the ECM/PCM (A21). After repairing the wire, check the DTC with the OBD " scan tool/ Honda PGM Tester and go to the DTC Troubleshooting index.•


10. Turn the ignition switch OFF. 11. Disconnect ECM/PCM connector A (32P). Make sure the OBD II scan tool or Honda PGM Tester is disconnected from the DLC. 12. Turn the ignition switch ON (II).


13. Measure voltage between DLC terminals No.5 and No.7.

Is there continuity? YES- Repair short to ground in the wire between DLC terminal No.7 and the ECM/PCM (A21). After repairing the wire, check the DTC with the OBD II scan tool/Honda PGM Tester and go to the DTC Troubleshooting index .•


NO- Go to step 9. 9. Check for continuity between DLC terminal No.7 and ECM/PCM terminal A21. ECM/PCM CONNECTOR A (32P)


~R~-:-::+--,J..:::.5+:6===*+--4-.!:~"I---'~~-I Wire side of ~~~~~~~~~~~~~~

female terminals

Is there 0 V?

K-LiNE (GRV)



NO- Repair short to power in the wire between the DLC terminal No.7 and the ECM/PCM (A21). After repairing the wire, check the DTC with the OBO " scan tool/Honda PGM Tester and go to the DTC Troubleshooting index .•


11-96

BACK

Injector Replacement 1. Relieve fuel pressure (see page 11-115). 2. Disconnect the connectors from the injectors (A), the EGR valve (8), and the EVAP canister purge valve (C).

c H

_______ G 12N·m 11.2 kgf·m, 8.7Ibf·ft)

_---D

3. Disconnect the vacuum hoses and fuel return hose from the fuel pressure regulator (D) and EVAP canister purge valve. Place a rag or shop towel over the hoses before disconnecting them. 4. Disconnect the fuel hose (E) from the fuel rail (F). 5. Remove the retainer nuts (G) from the fuel rail and harness holder (H). 6. Remove the EVAP canister purge valve, and disconnect the PCV valve (I). 7. Disconnect the fuel rail.

8. Remove the injectors from the fuel rail.

(cont'd)

BACK

11-97

PGM-FI System Injector Replacement (cont'd) 9. Slide new cushion rings (A) onto the injectors (B).

c

D

/

A

B

E

10. Coat new a-rings (C) with clean engine oil, and put them on the injectors. 11. Insert the injectors into the fuel rail (D). 12. Coat new seal rings (E) with clean engine oil, and press them into the intake manifold. 13. Install the injectors into the intake manifold. 14. Install and tighten the retainer nuts. 15. Connect the fuel hose to the fuel rail with new washers. 16. Connect the vacuum hoses and fuel return hose to the fuel pressure regulator and EVAP canister purge valve. 17. Install the connectors on the injectors, EGR valve, and EVAP canister purge valve. 18. Install the EVAP canister purge valve and PCV valve. 19. Turn the ignition switch ON (II), but do not operate the starter. After the fuel pump runs for approximately 2 seconds, the fuel pressure in the fuel line rises. Repeat this 2 or 3 times, then check for fuel leakage.

11-98

BACK

Primary H02S and A/F Sensor Replacement

Secondary H02S Replacement

Special Tools Required 02 sensor wrench SNAP-ON YA8875 or SP Tools 93750 or equivalent, commercially available

Special Tools Required 02 sensor wrench SNAP-ON YA8875 or SP Tools 93750 or equivalent, commercially available

1. Disconnect the primary H02S or A/F Sensor 4P connector, then remove the primary H02S or A/F Sensor (A).

1. Disconnect the secondary H02S 4P connector, then remove the secondary H02S (A).

A

A 44 N·m (4.5 kgf·m, 33 Ibf·ft)

2. Install the primary H02S or A/F Sensor in the reverse order of removal.

44 N·m (4.5 kgf·m, 33 Ibf·ft)

2. Install the secondary H02S in the reverse order of removal.

BACK

11-99

Idle Control System Component Location Index

IDLE AIR CONTROL (lAC) VALVE

POWER STEERING PRESSURE (PSP) SWITCH

Troubleshooting. page 11-102

Troubleshooting. page 11-108

11-100

BACK

DTC Troubleshooting DTC P0505: Idle Control System Malfunction

7. Put your finger on the lower port (AI in the throttle body.

NOTE: If DTC P1519 is stored at the same time as DTC P0505, troubleshoot DTC P1519 first, then recheck for DTC P0505. 1. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then let it idle. 2. Check the engine speed at idle under no-load conditions: headlights, blower fan, rear defogger, radiator fan, and air conditioner off.

Is it 700± 50 rpm? YES-Intermittent failure, system is OK at this time.•

Does the engine speed drop?

NO-If the idle speed is less than 650 rpm, go to step 3; if it's 750 rpm or higher, go to step 4.

YES-Adjust the idle speed (see page 11-110). If it's impossible, replace the lAC valve .• NO- Check for vacuum leaks, make sure the throttle valve is completely closed, and repair as necessary .•

3. Disconnect the 3P connector from the lAC valve.

Does the engine speed increase or fluctuate? YES-Adjustthe (base) idle speed (see page 11110). If it's impossible, clean the ports in the throttle body.• NO - Replace the lAC valve .• 4. Turn the ignition switch OFF. 5. Remove the intake air duct from the throttle body. 6. Start the engine and let it idle.

BACK

11-101

· Idle Control System DTC Troubleshooting (cont'd) DTC P1519: lAC Valve Circuit Malfunction

8. Check for continuity between body ground and lAC valve 3P connector terminal No.1.

1. Resetthe ECM/PCM (see page 11-4). lAC VALVE 3P CONNECTOR

2. Turn the ignition switch ON (II). /s DTC P1519 indicated?

3

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the lAC valve and the ECM/PCM .•

=



4. Disconnect the lAC valve 3P connector. /s there continuity?

5. Turn the ignition switch ON (II). YES-Go to step 9. 6. At the wire harness, measure voltage between lAC valve 3P connector terminal No.2 and body ground.

NO- Repair open in the wire between the lAC valve and G101 .•

lAC VALVE 3P CONNECTOR

9. Disconnect ECM/PCM connector 8 (25P). 10. Check for continuity between body ground and ECM/PCM connector terminal 823. ECM/PCM CONNECTOR B (25P)

1 9 19


2 10 20

V

IACV IBLKIBLU,


V

7 8 3 4 5 11 12 13 14 16 17 18 21 22 23 24 25

?

YES-Go to step 7. NO-Repair open in the wire between the lAC valve and the PGM-FI main relay.•



7. Turn the ignition switch OFF. YES-Repair short in the wire between the lAC valve and the ECM/PCM (823) .• NO-Go to step 11.

11-102

BACK

15. Measure voltage between body ground and ECM/ PCM connector terminal 823.

11. Connect lAC valve 3P connector terminal No.3 to body ground with a jumper wire. lAC VALVE 3P CONNECTOR


2

3

1 9 19

IACV (BLK/BLUI JUMPER WIRE

2 10 20

/

7 8 3 4 5 16 17 18 11 12 13 14 23 24 25 21 22

V

lACY IBLKJBlU'

~

=

=



12. Check for continuity between ECM/PCM connector terminal 823 and body ground.



1 9 19

2 10 20

/

7 8 3 4 5 11 12 13 14 16 17 18 21 22 23 24 25

V

lACY IBlK/BlU,


NO-Replace the lAC valve.•

?


Is there continuity? YES-Go to step 13. NO- Repair open in the wire between the lAC valve and the ECM/PCM (823) .• 13. Reconnect the lAC valve 3P connector. 14. Turn the ignition switch ON (II).

BACK

11-103

Idle Control System AIC Signal Circuit Troubleshooting 1. Turn the ignition switch OFF. 2. Disconnect the AlC pressure switch connector.

8. Momentarily connect ECM/PCM connector terminals A 17 and 820 with a jumper wire several times.


A (32P)

ECM/PCM CONNECTORS

5 6 1/ 8 9 10 / VI2 3 4 24 112J13 14 15 V 17 18 19 20 21 lL 23 25 26 27 28 29 30 V ~

4. Measure voltage between ECM/PCM connector terminals A27 and 820. A (32P)

ECM/PCM CONNECTORS

5 6/ 8 9 10 VI2 3 4 L12j13 14 15 / 17 18 19 20 21 1/ 23 25 2627 28 29 30 / 32 ACS (BLU/RED)

ACC(RED) B(25P)

/"1

1 9 19

24 I

-

2 10 20

2 10 20

'---

LG1 (BRN/BLK)

B(25P)

1 9 19

3 4 5 V 7 81 11 12 13 14 ~ 16 17 181 21 22 23 24 25

JUMPER WIRE

3 4 5 / 7 81 11 12 13 14 1/ 16 17 18J 23 24 25 ~g


Is there a clicking noise from the AlC compressor clutch?

~LG1 (BRN/BLK)

YES-Go to step 9.


NO-Goto step 15.

Is there approx. 5V? 9. Start the engine. YES-Go to step 5. 10. Turn the blower switch ON. NO-Go to step 12. 11. Turn the AlC switch ON. 5. Turn the ignition switch OFF.

Does the AlC operate? 6. Reconnect the AlC pressure switch connector. YES- The air conditioning signal is OK.• 7. Turn the ignition switch ON (II). NO-Gotostep 16. 12. Turn the ignition switch OFF. 13. Disconnect ECM/PCM connector A (32P)

11-104

BACK

Is there a clicking noise from the Ale compressor clutch?

14. Check for continuity between body ground and ECM/PCM connector termi nal A27. ECM/PCM CONNECTOR A (32P)

YES- Repair open in the wire between the ECM/ PCM (A 17) and the AlC clutch relay.• NO-Check the AlC system for other symptoms.• 16. Measure voltage between ECM/PCM connector terminals A27 and 820. A (32P)

ECM/PCM CONNECTORS

5 6V [7[2 3 4 8 9 10 -;7 24 f12T13 14 15 17 17 18 19 20 21 V 23 25 26 27 28 29 30 1/ ~


ACS (BLU/RED) B(25P)


1 9 19

YES-Repair short in the wire between the ECM/ PCM (A27) and the AlC pressure switch .•

3 4 5 2 7 7 81 10 11 12 13 14 7 16 17 181 20 21 22 23 24 25 '---

~BRN/RLK) NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the prescribed voltage is now available, replace the original ECM/PCM. If not, check the AlC system for other symptoms.• 15. Momentarily connect under-hood fuse/relay box 16 P connector terminal No. 11 to body ground with a jumper wire several times. NOTE: The under-hood fuse/relay box 16P connector is on the bottom of the fuse box. When you unbolt and invert the fuse box, leave the upper cover on to prevent short circuits.

I


Is there less than 1.0 V? YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM. If not, inspect the air conditioning system .• NO- Repair open in the wire between the ECM/ PCM (A27) and the AlC pressure switch .•

UNDER-HOOD FUSE/RELAY BOX CONNECTOR D (16P)

7 ACC (RED)

JUMPER WIRE


BACK

11-105

Idle Control System Alternator FR Signal Circuit Troubleshooting 1. Disconnect the 4P connector from the alternator.

12. Connect the alternator 4P connector terminal No.4 to body ground with a jumper wire.

2. Turn the ignition switch ON (II). ALT 4P CONNECTOR

3. Measure voltage between ECM/PCM connector terminals 820 and C5. ECM/PCM CONNECTORS

B(25P)

1 9 19

r-. 1 2 ALTF( WHT/RED)

3

3 4 5 V 7 8 2 10 11 12 1314 V 16 17 18 23 24 25 20 J1~ LG1 (BRN/BLK)

Y..

4 JUMPER WIRE

C (31P) ALTF (WHT/RED) _.L..

=

t


1 2 3 1/ 5 6 7 8 9 10 13 14 15 16 17 18 19 20 21 1/ 23 24 25 29 30 V 26 27 28

VV

13. Check for continuity between body ground and ECM/PCM connector terminal C5.

Wire side of female terminals ECM/PCM CONNECTOR C (31P)

Is there approx. 5V?

I ALTF (WHT/RED)

YES-Go to step 4.

8 9 10 5 6 7 1 2 3V 1/1/ 13 14 15 16 17 18 19 20 21 1/ 29 30 / 23 24 25 26 27 28


Q

5. Reconnect the alternator 4P connector.

=



Is there continuity? 7. Measure voltage between ECM/PCM connector terminals 820 and C5.

YES- Troubleshoot the charging circuit (see page 4-29) .•

Does the voltage decrease when the headlights and rear window defogger are turned on?

NO- Repair open in the wire between the ECM/ PCM (C5) and the alternator..

YES - The ALT FR signal is OK .• 14. Turn the ignition switch OFF. NO - Go to step 8.

15. Disconnect the negative cable from the battery.

8. Turn the ignition switch OFF. 16. Disconnect ECM/PCM connector C (31 Pl. 9. Disconnect the negative cable from the battery. 10. Disconnect ECM/PCM connector C (31 Pl. 11. Disconnect the ALT 4P connector.

11-106

BACK

Starter Switch Signal Circuit Troubleshooting 17. Check for continuity between body ground and ECM/PCM connector terminal C5. ECM/PCM CONNECTOR C 131P)

1 ALTF /WHT/RED)

Q

1 2 3 1/ 5 6 7 8 9 10 V V 13 14 15 16 17 18 19 20 21 1/ 23 24 25 26 27 28 29 30 V

=

NOTE: • MIT: Clutch pedal be pressed • AfT: Transmission in Park or neutral 1. Measure voltage between ECM/PCM connector terminals A24 and 820 with the ignition switch in the start position (III). ECM/PCM CONNECTORS A/32P)

VI 2 3 4 5 6 V 8 9 112113 14 15 V 17 18 19 20 21 V 25 26 27 28 29 30 V


L

24

STS IBLU/ORN) B125P)


':i

YES- Repair short in the wire between the ECM/ PCM (C5) and the alternator.• NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the prescribed voltage is now available, replace the original ECM/PCM .•

-

10 23 32

1 9 19

2 3 4 5 1/ 7 81 10 11 12 13 14 V 16 17 181 20 21 22 23 24 25 I LG1 /BRNiBLK)


/s there battery voltage? YES- The starter switch signal is OK.• NO - Go to step 2. 2. Inspectthe No. 13 STARTER SIGNAL (7.5 A) fuse in the driver's under-dash fuse/relay box.

/s the fuse OK? YES - Repair open in the wire between the ECM/ PCM (A24) and the No. 13 STARTER SIGNAL (7.5 A) fuse.• NO- Repair short in the wire between the ECM/ PCM (A24) and the No. 13 STARTER SIGNAL (7.5 A) fuse or the PGM-FI main relay. Replace the No. 13 STARTER SIGNAL (7.5 A) fuse .•

BACK

11-107

Idle Control System PSP Switch Signal Circuit Troubleshooting 9. At the harness side, connect PSP switch 2P connector terminals No.1 and No.2 with a jumper wire.

1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A26 and 820.

PSP SWITCH 2P CONNECTOR ECM/PCM CONNECTORS

A132P)

8 9 10 / 5 6 1/ V/2 3 4 24 112113 14 15'/ 17 18 19 20 21 V 23 25 2627 28 29 30 V ~

JUMPER WIRE

PSPSWIGRN) B125P)

':i.

1 9 19


345 2 / 7 81 10 11 12 13 14 '/ 16 17 18-1 21 22 23 24 25 20

--

I LG1 IBRN/BLK)

10. Measure voltage between ECM/PCM connector terminals A26 and 820.


Is there less than 1.0 V? Is there less than 1.0 V? YES-Go to step 3. YES - Replace the PSP switch .• NO - Go to step 6. NO-Check for an open in the wire between the ECM/PCM (A26) and the PSP switch, or an open in wire between the PSP switch and G302 .•

3. Start the engine. 4. Turn the steering wheel to full lock position.

11. Turn the ignition switch OFF. 5. Measure voltage between ECM/PCM connector terminals A26 and 820.


12. Disconnectthe PSP switch 2P connector. 13. Turn the ignition switch ON (II).

YES- The PSP switch signal is OK.• NO-Go to step 11. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II).

11-108

BACK

Brake Pedal Position Switch Signal Circuit Troubleshooting 14. Measure voltage between ECM/PCM connector terminals A26 and 820. 1. Check the brake lights. ECM/PCM CONNECTORS

A (32P)

8 9 VI2 3 4 5 6 / 112113 14 15 V 17 18 19 20 21 V 28 29 30 V 25 26 27

-

10 23 32

Are the brake lights on without pressing the brake pedal?

/ 24

YES -I nspect the brake pedal position switch (see page 19-5) .•

PSPSW(GRN)

NO- Go to step 2.

B(25P)

'Y.

1 9 19

2 10 20

3 4 5 V 7 81 11 12 13 14 / 16 17 181 21 22 23 24 25

I

'---

LG1 (BRN/BLK) Wire side of female terminals

2. Press the brake pedal.

Do the brake lights come on? YES - Go to step 3.


NO - Go to step 4.

YES - Replace the PSP switch .•

3. Measure voltage between ECM/PCM connector terminals A32 and 820 with the brake pedal pressed.

NO-Go to step 15.

ECM/PCM CONNECTORS

15. Turn the ignition switch OFF. 16. Disconnect ECM/PCM connector A (32P). 17. Check for continuity between body ground and ECM/PCM connector terminal A26. ECM/PCM CONNECTOR A (32P) Wire side of female terminals

8 9 3 4 5 6V \12\13 14 15 / 17 18 19 20 21 / 28 29 30 V 25 26 27

V\2

10 23 32

/\ 24 I

PSPSW(GRN)

Is there battery voltage? YES- The brake pedal position switch signal is OK.• NO- Repair open in the wire between the ECM/ PCM (A32) and the brake pedal position switch .•

Q =

4. Inspectthe STOP (20A) fuse in the under-hood fuse/relay box. Wire side of female terminals

Is the fuse OK? Is there continuity? YES- Repair short in the wire between the ECM/ PCM (A26) and the PSP switch .• NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the prescribed voltage is now available, replace the original ECM/PCM . •

YES-Repair open in the wire between the brake pedal position switch and the STOP (20 A) fuse. Inspect the brake pedal position switch (see page 19-5) .• NO-Repair short in the wire between the ECM/ PCM (A32) and the STOP (20 A) fuse. Replace the STOP (20 A) fuse .•

BACK

11-109

Idle Control System Idle Speed Adjustment Adjust idle speed using the Honda PGM Tester procedure, if possible. If not, use the following procedure.

5. Adjust the idle speed, if necessary, by turning the idle adjusting screw (A) 1/4-turn clockwise or counterclockwise. NOTE: Do not turn the idle adjusting screw more than 1/4-turn without checking the idle speed.

NOTE: • Leave the lAC valve connected. • Before setting the idle speed, check these items: - The MIL has not been reported on. -:- Ignition timing - Spark plugs - Air cleaner - PCV system • On Canadian models, pull the parking brake lever up. Start the engine, then check that the headlights are off.

A

1. Disconnect the EVAP canister purge valve 2P connector. 2. Connect a tachometer, or connect the Honda PGM Tester (A) or an OBD II scan tool to the Data Link Connector (DLC) (B) located under the driver's side ofthe dashboard.

6. After turning the idle adjusting screw 1/4-turn, check the idle speed again. If it is out of spec, turn the idle adjusting screw 1/4-turn again. 7. Let the engine idle for 1 minute with the heater fan switch on HI and the air conditioner on, then check the idle speed.

NOTE: • Do not turn the idle adjusting screw when the air conditioner is on . • If the idle speed is not within specification, see Symptom Troubleshooting Index. 3. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then let it idle.

8. Reconnect the EVAP canister purge valve 2P connector.

4. Check the idle speed with no-load conditions: headlights, blower fan, rear defogger, radiator fan, and air conditioner off.

11-110

BACK

Fuel Supply System Component Location Index FUEL FILL CAP

/

FUEL TANK Replacement, page 11-125

FUEL PUMP

Test, page 11-117 Replacement, page 11-124

FUEL TUBE/QUICK-CONNECT FITTINGS Precautions, page 11-120 Removal, page 11-120 Installation, page 11-119

FUEL FILTER

Replacement, page 11-123 FUEL GAUGE SENDING UNIT Test/Replacement, page 11-129

FUEL FEED LINE Inspection, page 11-118 FUEL RETURN LINE Inspection, page 11-118 FUEL VAPOR LINE Inspection, page 11-118

FUEL PRESSURE REGULATOR

Replacement, page 11-123

PGM-FI MAIN RELA V Troubleshooting, page 11-112

BACK

11-111

Fuel Supply System PGM-FI Main Relay Circuit Troubleshooting 1. Turn the ignition switch OFF, then disconnect the PGM-FI main relay 7P connector.

4. Check for a blown ACG S (15A) fuse in the underhood fuse/relay box.

Is the fuse blown?

2. Check for continuity between body ground and PGM-FI main relay 7P connector terminal No.3.

YES-Repair the short in the wire between the PGM-FI main relay and the ACG S (15A) fuse .•

PGM-FI MAIN RELAY 7P CONNECTOR

3

2

4

5

6

NO-Repairthe open in the wire between the PGMFI main relay and the ACG S (15A) fuse .•

PG1IBLK)

7

5. Turn the ignition switch ON (II), and measure voltage between body ground and PGM-FI main relay 7P connector terminal No.5. PGM-FI MAIN RELAY 7P CONNECTOR

= 2

3

456

7


Is there continuity? YES - Go to step 3. NO-Repair open in the wire between the PGM-FI main relay and G101 .•


3. Measure voltage between body ground and PGM-FI main relay 7P connector terminal No.7.



YES-Go to step 7.

4

2 5

6

3 7

NO-Go to step 6. BAT IWHT/GRN)

6. Check for a blown No.1 FUEL PUMP (15A) fuse in the driver's under-dash fuse/relay box.

Is the fuse blown?

=

YES-Repair the short in the wire between the PGM-FI main relay and the No.1 FUEL PUMP (15A) fuse .•


NO-Repair the open in the wire between the PGMFI main relay and the No.1 FUEL PUMP (15A) fuse .•

Is there battery voltage? YES - Go to step 5. NO-Go to step 4.

11-112

BACK

7. Push the clutch pedal in, or shift to Park, then turn the ignition switch to the START (III) position, and measure voltage between body ground and PGM-FI main relay 7P connector terminal No.2.

10. Check for continuity between PGM-FI main relay 7P connector terminal No.1 and ECM/PCM connector terminal A15. PGM-FI MAIN RELAY 7P CONNECTOR

PGM-FI MAIN RELAY 7P CONNECTOR STS IBLU/ORN)

2 4

5

3 6

7


Q

9

10 23 32

24





YES-Go to step 9.

YES- Go to step 11.

NO - Go to step 8.

NO- Repair open in the wire between the PGM-FI main relay and the ECM/PCM (A 15) .•

8. Check for a blown No. 13 STARTER SIGNAL (7.5A) fuse in the driver's under-dash fuse/relay box.

11. Reconnect ECM/PCM connector A (32P) and the PGM-FI main relay 7P connector.

Is the fuse blown?

12. Turn the ignition switch ON (II), and measure voltage between ECM/PCM connector terminals 81 and 820, and between 89 and 820.

YES-Repair the short in the wire between the PGM-FI main relay and the No. 13 STARTER SIGNAL (7.5A) fuse .•

ECM/PCM CONNECTOR B (25P)

NO - Repai r the open in the wi re between the PG MFI main relay and the No. 13 STARTER SIGNAL (7.5A) .• 9. Turn the ignition switch OFF, and disconnect ECM/ PCM connector A (32P).

l'GP1 (YEL/BLK) IGP2 (YEL/BLK)

f f

1 9 19

2 10 20

/1

3 4 5

/

7 81 16 17 181 23 24 25

11 12 13 14 /

21 22

LG1 (BRN/BLK)



YES-Gotostep 13. NO-Check for an open in the wires between the PGM-FI main relay and the ECM/PCM (81, 89). If the wires are OK, replace the PGM-FI main relay .• (cont'd)

BACK

11-113

Fuel Supply System PGM-FI Main Relay Circuit Troubleshooting (cont'd) 13. Turn the ignition switch OFF, then ON (II) again, and measure voltage between the ECM/PCM connector terminals A15 and 82 within the first 2 seconds after the ignition switch is turned ON (II).

A (32PI

15. Connect battery power to the PGM-FI main relay 7P connector terminal No.2, and connect ground to the PGM-FI main relay 7P connector terminal No.1. Then check for continuity between the PGM-FI main relay 7P connector terminals No.5 and No.4.

ECM/PCM CONNECTORS

8 9 5 6V Vl2 3 4 [12 113 14 15 V 17 18 19 20 21 V 25 12~ 27 28 29 30 V FLR (GRN/YELI

~ 1 9 19

2 10 20

10 23 32

NOTE: Use the terminal numbers shown. Ignore the terminal numbers molded into the relay.

/

No.2

24

----

B(25PI

3 4 5 / 7 81 11 12 13 14 / 16 17 181 23 24 25 21 22 '---'---

ToIG1

Wire side of female terminals To GROUND

Is there 1.0 V or less? To ST. SWITCH

YES- The PGM-FI main relay may be faulty. Go to step 14.

To ECM/PCM (A15)

To FUEL PUMP


NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the prescribed voltage is now available, replace the original ECM/PCM .•

YES-Goto step 16. NO- Replace the PGM-FI main relay and retest.•

14. Remove the PGM-FI main relay.

16. Connect battery power to the PGM-FI main relay 7P connector termi nal No.5, and connect ground to the PGM-FI main relay 7P connector terminal No.3. Then check for continuity between the PGM-FI main relay 7P connector terminals No.7 and No.6.

Is there continuity? YES-Go to step 17. NO- Replace the PGM-FI main relay and retest.• 17. Connect battery power to the PGM-FI main relay 7P connector terminal No.6, and connect ground to the PGM-FI main relay 7P connector terminal No.1. Then check for continuity between the PGM-FI main relay 7P connector terminals No.5 and No.4.

Is there continuity? YES- The PGM-FI main relay is OK.• NO- Replace the PGM-FI main relay and retest .•

11-114

BACK

Fuel Pressure Relieving

Fuel Pressure Test

Before disconnecting fuel lines or hoses, release pressure from the system by loosening the fuel pulsation damper on top of the fuel rail.

• Fuel pressure gauge 07406-0040001 • Fuel pressure gauge attachment 07VAJ-0040100


1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery.

1. Relieve the fuel pressure. 2. Use a wrench to remove the fuel pulsation damper from its fitting, then attach the fuel pressure gauge attachment.

3. Remove the fuel fill cap. 07VAJ-0040100

4. Use a wrench on the fuel pulsation damper (A) at the fuel rail.

3. Attach the fuel pressure gauge.

B

5. Place a rag or shop towel (B) over the fuel pulsation damper. 6. Slowly loosen the fuel pulsation damper one complete turn. NOTE: Replace all washers whenever the fuel pulsation damper is loosened or removed.

B

c 4. Disconnect the vacuum hose (A) from the fuel pressure regulator (B) and pinch it closed with a clamp (C).

(cant'd)

BACK

11-115

Fuel Supply System Fuel Pressure Test (cont'd) 5. Start the engine and let it idle.

10. Reconnect the vacuum hose, remove the pressure gauge, and reinstall the fuel pulsation damper with a new washer. Tighten the fuel pulsation damper to 22 N·m (2.2kgf·m, 16 Ibf·ft).

• Ifthe engine starts, go to step 7. • If the engine does not start, go to step 6. 6. Check to see if the fuel pump is running: remove the fuel fill cap and listen to the fuel fill port while an assistant turns the ignition switch ON (II). You should hear the pump run for about 2 seconds when the ignition is turned ON (II). • If the fuel pump runs, go to step 7. • If the fuel pump does not run, test it (see page 11117). 7. Read the pressure gauge (with the fuel pressure regulator vacuum hose disconnected and clamped). The pressure should be 320-370 kPa (3.3-3.8 kgf/cm2, 47 - 54 psi). • If the pressure is OK and engine is running, go to step 8. If the engine is not running, repair the cause, then continue this test. • If the pressure is out of spec, go to step 9. 8. With the engine running, unpinch and reconnect the vacuum hose, and read the gauge again. The pressure should be 260-310 kPa (2.7-3.2 kgf/cm 2, 38-46 psi). • If the fuel pressure is OK, the test is complete. • If the pressure is out of spec, go to step 9. 9. Disconnect the vacuum hose from the pressure regulator again while you watch the pressure gauge. The pressure should rise when you disconnect the hose. • If the pressure did not rise, replace the fuel pressure regulator (see page 11-123). • If the pressure rose, but a" your readings were lower than specified, check for a clogged fuel filter and for leaks in the fuel lines. • If the pressure rose, but a" your readings were higher than specified, check for a pinched or clogged fuel return hose or line.

11-116

BACK

NOTE: Disassemble and clean the fuel pressure gauge attachment thoroughly after use.

Fuel Pump Test If you suspect a problem with the fuel pump, check that the fuel pump actually runs; when it is ON, you will hear some noise if you listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is first turned on. If the fuel pump does not make noise, check as follows:

5. Turn the ignition switch ON (II). 6. Check that battery voltage is available between the fuel pump 5P connector terminal No.5 and body ground when the ignition switch is turned ON (II). • If battery voltage is available, check the fuel pump ground. If the ground is OK, replace the fuel pump (see page 11-124). • If there is no voltage, check the wire harness (see page 11-112).

1. Remove the trunk floor (see page 20-78). 2. Remove the access panel from the floor. 3. Turn the ignition switch OFF, then disconnect the fuel pump 5P connector.

FUEL PUMP 5P CONNECTOR

4. Connect the PGM-FI main relay 7P connector terminals No.4 and No.5 with a jumper wire. FUEL PUMP IBLK/YELl


1

2

4

5

3

6

7


FUEL PUMP IBLK/YEL)

IG1 IRED/WHT) '----


BACK

11-117

Fuel Supply System Fuel Line Inspection Check the fuel system lines, hoses, and fuel filter for damage, leaks, or deterioration. Replace any damaged parts.

22 N·m 12.2 kgf·m, 16 Ibf·ft)

37 N·m 13.8 kgf·m, 27 Ibf·ft)

11-118

BACK

Check all hose clamps, and retighten them if necessary. • : Do not disconnect the hose from the line at these points.

B

[:;

VB

To • FUEL /'" • PRESSURE / /" , ~ REGULATOR / To EVAPORATIVE B EMISSION (EVAPI CANISTER PURGE VALVE

A

B

10-15mm (0.39-0.59 in.1

Clamp in the middle.

BACK

11-119

Fuel Supply System Fuel Tube/Quick-Connect Fittings Precaution The fuel tube/quick-connect fittings assembly connects the in-tank fuel pump to the fuel feed line and the fuel return line. When removing or installing the fuel pump and fuel tank, it is necessary to disconnect or connect the quick-connect fittings. Pay attention to following: • The fuel tubes (A) and quick-connect fittings (B) are not heat-resistant; be careful not to damage them during welding or other heat-generating procedures. • The fuel tubes and quick-connect fittings are not acid-proof; do not touch them with a shop towel that was used for wiping battery electrolyte. Replace them if they came into contact with electrolyte or something similar.

Fuel Tube/Quick-Connect Fittings Removal 1. Disconnectthe battery negative cable. 2. Remove the fuel fill cap. 3. Relieve fuel pressure (see page 11-115). 4. Check the fuel quick-connect fittings for dirt, and clean them if necessary. 5. Hold the connector (A) with one hand, and squeeze the retainer tabs (B) with the other hand to release the tabs from the locking pawls (C). Pull the connector off.

• When connecting or disconnecting the fuel tubes and quick-connect fittings, be careful not to bend or twist them excessively. Replace them if they are damaged. A disconnected quick-connect fitting can be reconnected, but the retainer on the mating line cannot be reused once it has been removed from the line. Replace the retainer when • replacing the fuel pump. • replacing the fuel filter. • replacing the fuel feed line. • replacing the fuel return line. • it has been removed from the line. • it is damaged.

SANOH

TUBE COLOR BLACK

RETAINER COLOR WHITE

TOKAI SANOH

BLACK

YELLOW

MANUFACTURER

TUBE FEED TUBE (BOTH SIDES) RETURN TUBE (BOTH SIDES)

A B

11-120

BACK

NOTE: • Be careful notto damage the line (D) or other parts. Do not use tools. • If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. • Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.

Fuel Tube/Quick-Connect Fittings Installation 6. Check the contact area (A) ofthe line (B) for dirt and damage. o Ifthe surface is dirty, clean it. o If the surface is rusty or damaged, replace the fuel pump, fuel filter, fuel feed line and fuel return line.

B

7. To prevent damage and keep foreign matter out, cover the disconnected connector and line end with plastic bags (A).

1. Check the contact area (A) of the line (8) for dirt or damage, and clean it if necessary.

2. Insert a new retainer (A) into the connector (B) if the retainer is damaged, or after o replacing the fuel pump. o replacing the fuel filter. o replacing the fuel feed line. o replacing the fuel return line . • removing the retainer from the line.

NOTE: o The retainer cannot be reused once it has been removed from the line. Replace the retainer when - replacing the fuel pump. - replacing the fuel filter. - replacing the fuel feed line. - replacing the fuel return line. - it has been removed from the line. - it is damaged.

B

(cont'd)

BACK

11-121

Fuel Supply System Fuel Tube/Quick-Connect Fittings Installation (cont'd) 3. Before connecting a new fuel tube/quick-connect fitting assembly (A), remove the old retainer from the mating line.

Reconnection to existing retainer:

A

5. Make sure the connection is secure and that the pawls are firmly locked into place; check visually and by pulling the connector.

o 4. Align the quick-connect fittings with the line (A), and align the retainer (B) locking pawls with the connector (C) grooves. Then press the quickconnect fittings onto the line until both retainer pawls lock with a clicking sound. NOTE: If it is hard to connect, put a small amount of new engine oil on the line end. Connection with new retainer:

c

/ /"

11-122

6. Reconnect the battery negative cable, and turn the ignition switch ON (II). The fuel pump will run for about two seconds, and fuel pressure will rise. Repeat 2 or 3 times, and check that there is no leakage in the fuel supply system.

BACK

Fuel Pressure Regulator Replacement

Fuel Filter Replacement After making sure that the fuel pump and the fuel pressure regulator are OK, replace the fuel filter whenever fuel pressure drops below the specified value (320-370 kPa, 3.3-3.8 kgf/cm 2, 47-54 psi with the fuel pressure regulator vacuum hose disconnected and pinched).

1. Place a shop towel under the fuel pressure regulator, then relieve fuel pressure (see page 11115). 2. Disconnect the vacuum hose and fuel return hose.

1. Remove the fuel tank unit (see page 11-124). 3. Remove two 6 mm retainer bolts (A) and the fuel pressure regulator (B).

2. Remove the fuel filter (A).

A

12N·m 11.2 kgf·m, 9lbf.ftl

I

~

~

4. Apply clean engine oil to a new O-ring (C), and carefully install it into its proper position.

D

3. Install the parts in the reverse order of removal with a new base gasket, then check these items:

5. Install the fuel pressure regulator and the 6 mm retainer bolts. 6. Reconnect the vacuum hose and fuel return hose. 7. Turn the ignition switch ON (II), but do not operate the starter. After the fuel pump runs for approximately 2 seconds, the fuel pressure in the fuel line rises. Repeat this 2 or 3 times, then check for fuel leakage.

BACK

• When connecting the wire harness, make sure the connection is secure and the terminal (B) is firmly locked into place. • Check that the tab of the clamp (C) does not interfere with the wire harness. • Do not push the lower part of the suction filter (D). • When installing the fuel gauge sending unit (E), make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist it excessively.

11-123

Fuel Supply System Fuel Pump Replacement 8. Remove the bracket (A), the fuel filter (B), the fuel gauge sending unit (C), the hose (D), and the wire harness (E).

1. Remove the trunk floor (see page 20-78). 2. Remove the access panel from the floor. 3. Turn the ignition switch OFF, then disconnect the fuel pump 5P connector. 4. Remove the fuel cap. 5. Relieve the fuel pressure (see page 11-115). 6. Disconnect the quick-connect fittings from the fuel pump. 7. Remove the bolts (A), and the fuel tank unit (B). A

4N·m (0.4 kgf·m, 3 Ibf·ft)

\ A

9. When connecting the fuel pump, make sure the connection is secure and the suction filter (H) is firmly connected to the fuel pump (I). 10. Install the parts in the reverse order of removal with a new base gasket, then check these items: • When connecting the wire harness, make sure the connection is secure and the terminal (F) is firmly locked into the place. • Check that the tab of the clamp (G) does not interfere with the wire harness. • Do not push the lower part of the suction filter. • When installing the fuel gauge sending unit, make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist it excessively.

11-124

BACK

Fuel Tank Replacement Removal

8. Remove the fuel line cover (A). Disconnect the fuel fill neck tube (8), the fuel tank vapor recirculation tube (C) and the fuel tank vapor control signal tube (D) from the fuel fill lines (E).

1. Relieve the fuel pressure (see page 11-115). 2. Remove the fuel fill cap.

A

3. Drain the fuel tank: Remove the fuel tank unit (see page 11-124). Using a hand pump, hose, and container suitable for gasoline, draw the fuel from the fuel tank. 4. Remove the trunk floor and the access panel (A) from the floor. Disconnect the fuel tank 5P connector (8). D

9. Disconnect the fuel tank vapor vent tube (A) and the quick-connect fittings (8). Disconnect the hose (C). Remove the hose from the line holder (D). Disconnect the hose (E) from the EVAP two way valve (F). Remove the line holder (G). F

5. Loosen the rear wheel nuts slightly, then raise the vehicle and make sure it is securely supported. Remove the rear wheels. 6. Release the parking brake. 7. Remove the catalytic converter (see page 9-5).

D

'" D

G

(cont'd)

BACK

11-125

Fuel Supply System Fuel Tank Replacement (cont'd) 10. Ifthe vehicle has ABS, disconnectthe wheel sensor 2P connectors (A); if not, go to step 11.

13. Hook the caliper body (A) on to the damper spring (B). Go to step 16.

A

A

11. Remove the stabilizer bar (A), the heat shield (B) and the parking brake cable bracket (C). S

14. Disconnect the brake line (A) from the wheel cylinder (B). A

15 N·m (1.5 kgf·m. 11lbf·ftl

B

22 N·m (2.2 kgf·m, 16lbf·ftl

12. If the vehicle has rear drum brakes, go to step 14. If it has rear disc brakes, remove the clip (A) and parking brake cable (B), two caliper bolts (C), caliper body (D), and brake hose bracket (E).

11-126

15. Remove the brake drum and brake shoes. Remove the two mounting bolts for the parking brake cable from the backing plate, then remove the parking brake cable using a 12 mm offset wrench.

BACK

Installation

16. Remove the flange bolt (A).

~

1. Install the fuel tank straps (A), and tighten the bolts (8). Install the lines to the fuel line holder (C).

~

B 3BN·m 13.9kgf.m,

//

A

~lb\i~~rG~ A

59 N·m 16.0 kgf.m, 43 Ibf·ft)

2. Place the jack, or support, under the rear suspension sub frame. Install the rear suspension sub frame, aligning the pins (A) with the holes in the rear suspension sub frame.

18. Remove the bolts (A) and the fuel tank straps (8).

A

A

A

3. Install the remaining parts in the reverse order of removal. 4. If equipped with drum brakes, bleed the brake system after installing the brake hose (see page 19-7). If not, go to step 5. 5. After installation, adjust the wheel alignment (see page 18-5).

c

B

19. Remove the lines from the fuel line holder (C). 20. Lift the fuel tank out of the sub frame.

BACK

11-127

Fuel Supply System Fuel Gauge Test NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram (see page 22-60). 1. Check the No.9 BACK UP LIGHT INSTRUMENT LIGHT (7.5 A) fuse in the driver's under-dash fuse/ relay box before testing.

7. Turn the ignition switch OFF. 8. Connect fuel pump 5P connector terminals No. 1 and No.2 with a jumper wire, then turn the ignition switch ON (II). FUEL PUMP 5P CONNECTOR

2. Turn the ignition switch OFF. JUMPER WIRE

3. Remove the spare tire lid.

(VEl/BLU)

4. Remove the access panel from the floor. (BlK)

5. Disconnect the fuel pump 5P connector. 6. Measure voltage between fuel pump 5P connector terminals No.1 and No.2 with the ignition switch ON (II). There should be between 5 and8 v. o o

If the voltage is OK, go to step 6. If the voltage is not as specified, check for:


9. Check that the pointer of the fuel gauge starts moving toward the "F" mark.

- an open in the YEl/BLU or BlK wire. - poor ground (G552).

o

o


If the pointer of the fuel gauge does not move at all, replace the gauge. If the pointer moves, the gauge is OK; inspect the fuel gauge sending unit (see page 11-129).

NOTE: o Turn the ignition switch OFF before the pointer reaches "F" on the gauge dial. Failure to do so may damage the fuel gauge. o The fuel gauge is a bobbin (cross-coil) type, so the fuel level is continuously indicated even when the ignition switch is OFF. The pointer moves more slowly than that of a bimetal type.


11-128

BACK

Fuel Gauge Sending Unit Test/Replacement 1. Remove the spare tire lid.

8. Measure the resistance between the No.1 and No. 2 terminals with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the following readings, replace the fuel gauge sending unit (A).

2. Remove the access panel from the floor. 3. Turn the ignition switch OFF, then disconnect the fuel pump 5P connector.

Float Position Resistance ( Q )

4. Remove the fuel fill cap. 5. Relieve the fuel pressure (see page 11-115). 6. Disconnect the quick-connect fittings from the fuel pump.


7. Remove the bolts (A) and the fuel tank unit (B). A 4N·m

.L~~~~

1.\'..'''' Ibl·ft] 3

9. Install the parts in the reverse order of removal with a new base gasket and new quick connect fittings, then check these items: • When connecting the wire harness, make sure the connection is secure and the terminal (B) is firmly locked into place. • Check that the tab of the clamp (C) does not interfere with the wire harness. • Do not fold over the lower part of the mesh filter (D).

• When installing the fuel gauge sending unit (A), make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist it excessively.

D

BACK

11-129

Fuel Supply System Low Fuel Indicator Light Test NOTE: For the low fuel indicator circuit diagram, see page 22-60.

8. Connect the fuel pump 5P connector terminals No. 1 and No.3 with a jumper wire.

1. Check the No.9 BACK UP LIGHT INSTRUMENT LIGHT (7.5 A) fuse in the driver's under-dash fusel relay box before testing.

o

o

If the light comes on, replace the fuel gauge sending unit (see page 11-129). If the light does not come on, check for: - an open in the LT GRN/RED wire between the fuel gauge sending unit and the fuel gauge assembly. - a blown bulb. - a poor ground (G552).

2. Park the vehicle on level ground. 3. Drain the fuel tank: Remove the fuel return line from the fuel pressure regulator, and attach a suitable hose to the regulator fitting. Place the other end of the hose in a container suitable for gasoline. Start the engine, and run it until the tank is empty (the engine stalls).


4. Add less than 8.5 a(2.2 U.S. Gal, 1.8Imp. Gal) of fuel, and turn the ignition switch ON (II). The low fuel indicator light should come on within 4 minutes. o

If the light comes on within 4 minutes, go to step

JUMPER WIRE IBLKI

9. o

If the light does not come on within 4 minutes, go to step 5.

ILT GRN/REDI


5. Remove the spare tire lid. 9. Add 4 aof fuel (1.1 U.S. Gal, 0.9 Imp. Gal). The light should go off within 4 minutes.

6. Remove the access panel from the floor.

7. Turn the ignition switch OFF, then disconnect the fuel pump 5P connector.

11-130

BACK

Intake Air System Component Location Index

AIR CLEANER Replacement, page 11-133 THROTTLE BODY

Test, page 11-132

THROTTLE CABLE

Adjustment, page 11-134

R~moval/lnstallation,

page 11-135 Disassembly/Reassembly, page 11-136

11-131

Intake Air System Throttle Body Test

Intake Air Bypass Control Valve Test

NOTE: • Do not adjust the throttle stop screw. It is preset at the factory. • If the Malfunction Indicator Lamp has been reported on, check for Diagnostic Trouble Codes (DTCs) (see page 11-3). 1. With the engine off, check the throttle cable operation.The cable should move without binding or sticking.

1. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then let it idle. 2. Disconnect the air assist hose (A) from the lAC valve (8) then connect it to a vacuum pump/gauge (C). D

• If the cable is OK, go to step 2. • If the cable binds or sticks, check it and its routing. If it's faulty, reroute it or replace it and adjust it (see page 11-134), then go to step 2.

2. Operate the throttle lever by hand to see if the throttle valve and/or shaft are too loose or too tight. • If there is excessive play in the throttle valve shaft, or any binding in the throttle valve at the fully closed position, replace the throttle body. •. If the throttle valve and shaft are OK, go to step 3. 3. Connect a scan tool to the Data Link Connector. 4. Turn the ignition switch ON (II).

5. Check the throttle position with the scan tool. There should be approx. 10% when the throttle is fully closed and approx. 90% when the throttle is fully opened.

3. Start the engine, then let it idle. 4. Check the vacuum.

• If the throttle position is correct, the throttle body is OK. • If the throttle position is not correct, replace the throttle body.

Is there any vacuum YES-Go to step 5. NO- Repair the air assist hose.• 5. Disconnect the air assist hose from the vacuum pump/gauge, then connect the air assist hose, the lAC valve and the vacuum pump/gauge by using a three-way joint (D). 6. Disconnect the lAC valve 3P connector. 7. Check the vacuum.

Is there vacuum above 40 kPa (300 mmHg, 12 in. Hg)? YES-Replace the lAC valve .• NO-The intake air bypass control system is OK.•

11-132

BACK

Air Cleaner EI ementReplacement AIRCLEA NER HOUSING COVER

AIR CLEANER HOUSING

BACK

11-133

Intake Air System Throttle Cable Adjustment 1. Push the throttle link (A) toward the throttle lever (8) until there is no clearance.

A

B

2. Check cable free play at the throttle linkage. Cable deflection (A) should be 10-12 mm (3/8-1/2 in.).

e

A

3. If deflection (A) is not within spec (10-12 mm, 3/8 -1/2 in.), loosen the locknut (8), turn the adjusting nut (C) until the deflection is as specified, then retighten the locknut. 4. With the cable properly adjusted, check the throttle valve to be sure it opens fully when you push the accelerator pedal to the floor. Also check the throttle valve to be sure it returns to the idle position whenever you release the accelerator pedal.

11-134

BACK

Throttle Body Removal/Installation NOTE: • Do not adjust the throttle stop screw. • After reassembly, adjust the cruise control cable (see page 4-541 and the throttle cable (see page 11-1341. • The TP sensor is not removable.

TPsENsOR

MAP SENSOR

22N·m 12.2 kgf·m, 16 Ibf·ftl

THROTTLE CABLE

BACK

11-135

Intake Air System Throttle Body DisassemblyIReassembly

O-RING

THROTTLE POSITION SENSOR

11-136

BACK

Catalytic Converter System DTC Troubleshooting DTC P0420: Catalyst System Efficiency Below Threshold NOTE: If some of the OTCs listed below are stored at the same time as OTC P0420, troubleshoot those OTCs first, then recheck for OTC P0420. P0137, P0138: Secondary H02S (Sensor 2) P0141: Secondary H02S (Sensor 2) Heater 1. Reset the ECM/PCM (see page 11-4). 2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on. 3. Except F23A4 SULEVengine: Test-drive at 40-55 mph (64-88 km/h) for approx. 2 minutes. Then decelerate for at least 3 seconds with the throttle completely closed. Then reduce the vehicle speed to 35 mph (56 km/h), and try to hold it until the scan tool indicates FAIL or PASS as the TWC test result. F23A4 SULEV engine: Test-drive at 50-55 mph (80 -88 km/h) for approx. 2 minutes. Then decelerate for at least 4 seconds with the throttle completely closed. Then accelerate to 55 mph (88 km/h), and try to hold it until the scan tool indicates FAIL or PASS as the TWC test result. Is the test result FAIL? YES - Check the three way catalytic converter (TWC). If necessary, replace the TWC.• NO-Intermittent failure, system is OK at this time .•

BACK

11-137

EGRSystem DTC Troubleshooting DTC P0401: EGR Insufficient Flow

DTC P1491: EGR Valve Insufficient Lift


,. Resetthe ECM/PCM (see page 11-4).

2. Test-drive under the following conditions. Then check for a Temporary DTC with the scan tool.


o o

Without any electrical load. Decelerate from 55 mph (88 km/h) for at least 5 seconds.

3. Check for a Temporary DTC with the scan tool. 4. Test-drive the vehicle for approx. 10 minutes. Try to keep the engine speed in the 1,700- 2,500 rpm range.

Is Temporary OTC P0401 indicated? YES-Clean the intake manifold EGR port with carburetor cleaner. Clean the passage inside the EGR valve with carburetor cleaner, or replace the EGRvalve.•

Is Temporary OTC P1491 indicated? YES-Go to step 5.

NO-Intermittent failure, go to step 3.

NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the EGR valve and the ECM/PCM .•

3. Turn the ignition switch OFF. 4. Disconnect the EGR valve 6P connector.


5. Connect the battery positive terminal to EGR valve connector terminal No.4.

6. Disconnect the EGR valve 6P connector. 7. Start the engine and let it idle.

EGR VALVE 6P CONNECTOR

8. Measure voltage between EGR valve 6P connector terminals No.4 and No.6. EGR VALVE 6P CONNECTOR

E-EGR

PG1

1 2 3

4 E-EGRIPNKI


6. Start the engine and let it idle, then connect the battery negative terminal to EGR valve 6P connector terminal No.6.

6 PG11BLKI


Did the engine stall or run rough?


YES-Intermittent failure, system is OK atthis time .•

YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). Ifthe symptom/indication goes away, replace the original ECM/PCM .•

NO- Clean the intake manifold EGR port with carburetor cleaner. Clean the passage inside the EGR valve with carburetor cleaner, or replace the EGR valve.•

11-138

BACK

NO-Go to step 9.



14. At the sensor side, measure resistance between EGR valve 6P connector terminals No.1 and No.2.

10. Turn the ignition switch ON (II). 11. Measure voltage between EGR valve 6P connector terminals No.2 and No.3.


EGR VALVE 6P CONNECTOR EGRL (WHT/BLKI

SG2 (GRN/BLKI

VCC2 (VEL/BLUI

SG2 (GRN/BLKI

4 6 '-----I

':i. l - - - - - ' Terminal side of male terminals


Is the resistance 100 kQ or more?


YES- Replace the EGR valve.•

YES-Go to step 13.

NO- Go to step 15.

NO-Gotostep 12.

15. Measure resistance between EGR valve 6P connector terminals No.1 and No.3.



ECM/PCM CONNECTOR C (31 PI SG2 (GRN/BLKI

EGRL (WHT/BLKI

5 6 1 2 3/ 8 9 10 / / 13 14 15 16 17 18 19 20 21 V 23 24 25 26 27 28 29 30 1/ VCC2 (VEL/BLUI

':i.

VCC2 (VEL/BLUI


Wire side offemale terminals

Is there 100 kQ or more?


YES- Replace the EGR valve .•

YES- Repair open in the wire between the EGR valve and the ECM/PCM (C18, C28) .•

NO-Go to step 16. 16. Reconnect the EGR valve connector.



(cont'd)

BACK

11-139

EGRSystem OTe Troubleshooting (cont'd) 21. Check for continuity between ECM/PCM connector terminal C6 and body ground.




IEGRl (WHT/BlK)

':i

EGRL (WHT/BLK)

SG2 (GRN/BLK)

1 2 3 1/ 5 6 7 8 9 10 V 1/ 13 14 15 16 17 18 19 20 21 V 23 24 25 29 30 V 26 27 28

I 8 9 10 1 2 3V 5 6 17 L! ~ 13 14 15 16 17 18 19 20 21 1/ 23 24 25 29 30 1/ 26 27 28

Q



Is there continuity? Is there approx. 1.2 V? YES - Go to step 22. YES - Go to step 19. NO-Repair open in the wire between the EGR valve and the ECM/PCM (C6) .•

NO- Repair short in the wire between the EGR valve and the PCM (C8) .•

22. Disconnect the EGR valve 6P connector. 19. Turn the ignition switch OFF. 20. Connect EGR valve 6P connector terminal No.1 to body ground with a jumper wire.

23. Connect the battery positive terminal to EGR valve 6P connector terminal No.4 with a jumper wire. EGR VALVE 6P CONNECTOR


I ..--1

2

3

4

1/

6

E-EGR

EGRL (WHT/BLK)

PG1

JUMPER WIRE -'-



24. Start the engine and let it idle, then connect the battery negative terminal to EGR valve 6P connector terminal No.6 with a jumper wire. Does the engine stall or run rough? YES - Go to step 25. NO- Replace the EGR valve .• 25. Turn the ignition switch OFF. 26. Disconnect ECM/PCM connector B (25P).

11-140

BACK


30. Check for continuity between ECM/PCM connector terminal 87 and body ground.

28. Connect EGR valve 6P connector terminal No.4 to body ground with a jumper wire. ECM/PCM CONNECTOR B 125P) EGR VALVE 6P CONNECTOR

-

1

E-EGRIPNK)

2

/

4

3

I

1 9 19

6

E-EGRIPNK )

2 10 20

Q

345 V 7 81 1112 13 14V 1617 181 ~~ 23 24 25

JUMPER WI RE

=

-=....



Is there continuity? 29. Check for continuity between ECM/PCM connector terminal 87 and body ground.

NO-Go to step 31.

ECM/PCM CONNECTOR B 125P) E-EGRIPNK) 1

9 19

2 10 20

YES-Repair short in the wire between the EGR valve and the ECM/PCM (87) .•

I

31. Check for continuity between EGR valve 6P connector terminal No.6 and body ground.

345 V 7 81 1112 1314 / 16 17 18/ ~~ 23 24 25


_....JUMPER WIRE

2

=

3

4


Is there continuity? YES-Go to step 30. Wire side of female terminals

NO-Repair open in the wire between the EGR valve and the ECM/PCM (87) .•

Is there continuity? YES-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .• NO- Repair open in the wire between the EGR valve and G101 .•

BACK

11-141

EGRSystem DTC Troubleshooting (cont'd) DTC P1498: EGR Valve Position Sensor Circuit High Voltage


1. Resetthe ECM/PCM (see page 11-4). ECM/PCM CONNECTOR C (31PI

2. Start the engine. SG2 (GRN/BLKI

Is OTe P1498 indicated? YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the EGR valve and the ECM/PCM .•

1 2 3/ 5 6 8 9 10 / / 13 14 15 16 17 18 19 20 21 / 23 24 25 29 30 / 26 27 28


VCC2 (VEL/BLUI

'Y


4. Disconnect the EGR valve 6P connector.

Is there approx. 5 V? 5. Turn the ignition switch ON (II). 6. Measure voltage between EGR valve 6P connector terminals No.2 and No.3.

NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). Ifthe symptom/indication goes away, replace the original ECM/PCM .•


SG2 (GRN/BLKI

VCC2 IVEL/BLUI

4

'-----;'Y t - - - - ' Wire side of female terminals

Is there approx. 5 V? YES-Replace the EGR valve .• NO-Goto step 7.

11-142

YES-Repair open in the wire between the EGR valve and the ECM/PCM (C18) .•

BACK

PCVSystem PCV Valve Inspection and Test 1. Check the PCV valve (A), hoses (8), and connections for leaks or restrictions.

2. At idle, make sure there is a clicking sound from the PCV valve when the hose between the PCV valve and intake manifold is lightly pinched (A) with your fingers or pliers. If there is no clicking sound, check the PCV valve grommet for cracks or damage. If the grommet is OK, replace the PCV valve and recheck.

BACK

11-143

Evaporative Emission Control System Component Location Index

EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE

FUEL TANK VAPOR CONTROL VALVE Test, page 11-160 Replacement, page 11-162

EVAPORATIVE EMISSION (EVAP) CANISTER

EVAPORATIVE EMISSION (EVAP) CANISTER VENT SHUT VALVE

EVAPORATIVE EMISSION (EVAP) BYPASS SOLENOID VALVE EVAPORATIVE EMISSION (EVAP) TWO-WAY VALVE Test, page 11-159

11-144

FUEL TANK PRESSURE SENSOR

BACK

OTe Troubleshooting DTC P0451: FTP Sensor Range/Performance

6. Disconnect the hose between the EVAP two way valve and the FTP sensor at the EVAP two way valve end.

Problem Special Tools Required Vacuum Pump/Gauge. 0-30 in. Hg A973X-041-XXXXX

7. Connect a vacuum pump to the open end of that hose.

1. Remove the fuel fill cap. 2. Turn the ignition switch ON (II). 3. Monitor FTP sensor voltage with the Honda PGM Tester. or measure voltage between ECM/PCM connector terminals A29 and C18. ECM/PCM CONNECTORS


SG2 (GRN/BLK)


9. Monitor FTP sensor voltage with the Honda PGM Tester. or measure voltage between PCM connector terminals A29 and C18. and carefully squeeze the vacuum pump slowly. ECM/PCM CONNECTORS

Is there approx. 2.5 V?

YES-Go to step 4. NO-Replace the FTPsensor.• 4. Turn the ignition switch OFF. 5. Open the fuel vent assembly cover (A) in front of the EVAP canister. SG2 (GRN/BLK)


10. The voltage should smoothly drop from approx. 2.5 V down to approx. 1.5 V. STOP applying vacuum when the voltage drops to approx. 1.5 V or damage to the FTP sensor may occur. Does the voltage drop to approx. 1.5 V and hold?

A

YES-Check for misrouted.leaking. or broken FTP sensor vacuum lines. If the vacuum lines are OK. substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away. replace the original ECM/PCM .• NO-Replace the FTPsensor.•

BACK

11-145

Evaporative Emission Control System DTC Troubleshooting (cont'd) OTC P0452: FTP Sensor Circuit Low Voltage

6. Turn the ignition switch OFF. 7. Reinstall the fuel fill cap.

1. Check the vacuum lines of the FTP sensor for misrouting, leakage, breakage, or clogging.

8. Disconnect the FTP sensor 3P connector.

Are the vacuum lines OK? 9. Turn the ignition switch ON (II). YES-Go to step 2. 10. Measure voltage between FTP sensor 3P connector terminals No.1 and No.2.

NO- Repair or replace vacuum lines as necessary .•

FUEL TANK PRESSURE SENSOR 3P CONNECTOR

2. Resetthe ECM/PCM (see page 11-4). 3. Remove the fuel fill cap. 4. Turn the ignition switch ON (II). 5. Monitor FTP sensor voltage with the Honda PGM Tester, or measure voltage between body ground and ECM/PCM connector terminal A29.

SG2 (GRN/BLK)



8 9 5 6/ 2 3 4 12 13 14 15 1/ 17 18 19 20 21 / 28 29 30 V 25 26 27

/

,

10 23 32

/ 24

Is there approx. 5 V? YES- Go to step 11.

PTANKILT GRN)

NO-Repair open in the wire between the FTP sensor and the ECM/PCM (C28) .•


Is there approx. 2.5 V? YES-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the FTP sensor and the ECM/PCM .•

NO - Go to step 6.

11-146

BACK

11. Measure voltage between FTP sensor 3P connector terminals No.2 and No.3. FTP SENSOR 3P CONNECTOR

DTC P0453: FTP Sensor Circuit High Voltage 1. Check the vacuum lines of the FTP sensor for misrouting, leakage, breakage, or clogging.

Are the vacuum lines OK? YES - Go to step 2. NO- Repair or replace vacuum lines as necessary.• 2. Resetthe ECM/PCM (see page 11-4). 3. Remove the fuel fill cap. Wire side of female terminals


Is there approx. 5 V? YES - Replace the FTP sensor.•

5. Monitor FTP sensor voltage with the Honda PGM Tester, or measure voltage between body ground and ECM/PCM connector terminal A29.

NO- Go to step 12. ECM/PCM CONNECTOR A (32P)

12. Turn the ignition switch OFF. 13. Disconnect ECM/PCM connector A (32P). 14. Check for continuity between FTPsensor3P connector terminal No.3 and body ground.

VI2

8 9 3 4 5 6 / 112113 14 15 / 17 18 19 20 21 / 28 29 30 1/ 25 26 27

10 / 1 23 24 1 32

fAN" III GRNI

FTPSENSOR3PCONNECTOR


Is there approx. 2.5 V?

=

YES-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the FTP sensor and the ECM/PCM .•


NO - Go to step 6.

Is there continuity? YES-Repair short in the wire between the FTP sensor and the ECM/PCM (A29) .• NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/indication goes away, replace the original ECM/PCM .•

(cont'd)

BACK

11-147

Evaporative Emission Control System DTC Troubleshooting (cont'd) 6. Turn the ignition switch OFF.

11. Measure voltage between FTP sensor 3P connector terminals No.2 and No.3.

7. Reinstall the fuel fill cap.

FTP SENSOR 3P CONNECTOR

8. Disconnect the FTP sensor 3P connector. 9. Turn the ignition switch ON (II). 10. Measure voltage between FTP sensor 3P connector terminals No.1 and No.2. FTP SENSOR 3P CONNECTOR


Is there approx. 5 V? YES-Replace the FTPsensor.• NO-Go to step 12. Wire side of female terminals

12. Measure voltage between ECM/PCM connector terminals A29 and C18. ECM/PCM CONNECTORS

Is there approx. 5 V? YES- Go to step 11. NO-Repair open in the wire between the FTP sensor and the ECM/PCM (C28) .•


Is there approx. 5 V? YES-Repair open in the wire between the FTP sensor and ECM/PCM (A29) .• NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). If the system/indication goes away, replace the original ECM/PCM.

11-148

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DTC P1456: EVAP Control System Leakage (Fuel Tank System)

EVAP Bypass Solenoid Valve Test

1NOTICE 1 The fuel system is designed to allow specified maximum vacuum and pressure conditions. Do not deviate from the vacuum and pressure tests as indicated in these procedures. Excessive pressure/ vacuum would damage the EVAP components or cause eventual fuel tank failure

3. Disconnect the vacuum hose from the EVAP twoway valve (A), and connect a vacuum pump to the hose.

Special Tools Required Vacuum Pump/Gauge, 0 -- 30 in. Hg A973X-041-XXXXX This is a two-trip code; once cleared, it cannot be reproduced in one trip. Also, certain specific driving and ambient conditions must occur before the ECM/ PCM will complete the system checks. Additional test drives may still not meet the specific conditions needed to reproduce the code. Follow these troubleshooting procedures carefully to ensure the integrity of the system and to confirm the cause of the problem or code. NOTE: Fresh fuel has a higher volatility that will create greater pressure/vacuum. The optimum condition for testing is fresh fuel and less than a full tank of fuel. If possible, to assist in leak detection, add one gallon of fresh fuel to the tank (as long as it will not fill the tank), just before starting these procedures. Fuel fill cap check 1. Check the fuel fill cap. It must be a gray or black OEM cap and be tightened at least 3 "clicks" to properly seal the system.

A973X-041-XXXXX

4. With the Honda PGM Tester in the EVAP test mode, turn on the bypass solenoid, or connect ECM connector terminal A3 to body ground with a jumper wire. ECM/PCM CONNECTOR A (32P)

5 6V V]2 3 4 8 9 10 ,/"1 20 21 15 17 18 19 112113 V V 23 24 1 28 29 30 V 125 26 27 ~

*

2WBS(BLU) JUMPER WIRE -'-

=

Is the correct fuel fill cap installed and properly tightened?


YES-Go to step 2. NO-Replace or tighten the cap .• 2. Check the fuel fill cap seal. Is the fuel fill cap seal missing or damaged? YES - Replace the fuel fill cap (gray or black colored cap) .• NO- The fuel fill cap is OK. Go to step 3.

(cont'd)

BACK

11-149

Evaporative Emission Control System DTe Troubleshooting (cont'd) 5. Turn the ignition switch ON (II).

10. Turn the ignition switch ON (II)

6. Apply vacuum to the hose.

11. Measure voltage between EVAP bypass solenoid valve 2P connector terminal No.1 and body ground.

Does the valve hold vacuum? EVAP BYPASS SOLENOID VALVE 2P CONNECTOR

VES- Go to step 7. NO-The EVAP bypass solenoid valve/EVAP twoway valve is OK. Go to step 12. 7. Turn the ignition switch OFF. 8. Disconnectthe EVAP bypass solenoid valve 2P connector. 9. Check for continuity between EVAP bypass solenoid valve 2P connector terminal No.2 and body ground.


EVAP BYPASS SOLENOID

VALVE 2P CONNECTOR


Is there continuity? Is there battery voltage? VES-Gotostep 10. NO-Repair open in wire between the EVAP bypass solenoid valve and ECM/PCM (A3) .•

VES- Replace the EVAP bypass solenoid valve (A) and the O-rings (B) .• NO- Repair open in the wire between the EVAP bypass solenoid valve and No.6 ECU (ECM/PCM) CRUISE CONTROL (15A) fuse .•

11-150

BACK

12. Plug the upper port (A) of the EVAPtwo-way valve.

Vacuum Hoses and Connections Test 14. Perform the fuel tank vapor control valve test (see page 11-160).

A

Is the fuel tank vapor control valve normal? YES-Go to step 15. NO - Replace the fuel tank vapor control valve .•

~X""_XXXXX

15. Tighten the fuel cap 3 "clicks", then monitor fuel tank pressure readings with the Honda PGM Tester. 16. Start the engine. Let the engine idle for 5 minutes. 17. Check the FTP sensor reading.

13. While monitoring the FTPsensorvoltage with the Honda PGM Tester, or measuring the voltage between PCM connector terminals A29 and C18, slowly pump vacuum until the voltage drops to approximately 1.5 volts.

J

I

B

ECM/PCM CONNECTORS

C F

Is the reading above 0.53 kPa (0.16 in. Hg 4 mm Hg) pressure, or approx 3V ?


YES - Substitute a known-good ECM/PCM and retest (see page "-5). If the symptom/indication goes away, replace the original ECM/PCM .•

SG2 (GRN/BlK)

Does the voltage drop to 1.5 V and hold for at least 20 seconds?

NO-Check the following parts for leaks:

YES - The EVAP bypass solenoid valve/EVAP twoway valve is OK. Go to step 22. NO-Repair leakage from the EVAP bypass solenoid valve, EVAP two-way valve, FTP sensor, orO-rings.•

• • • • • • • • • •

Fuel tank (A) Fuel fill cap (B) Fuel fill pipe (C) Fuel tank vapor control valve (0) Fuel tank vapor recirculation valve (E) Fuel tank vapor recirculation tube (F) Fuel tank vapor signal tube (G) Fuel tank vapor vent tube (H) EVAP two-way valve (I) FTP sensor (J) - Repair or replace any leaking parts.•

BACK

11-151

Evaporative Emission Control System DTC Troubleshooting (cont'd) DTC P1457: EVAP Control System Leakage (EVAP Canister System)

EVAP Canister Purge Valve Test

INOTICE I The fuel system is designed to allow specified maximum vacuum and pressure conditions. Do not deviate from the vacuum and pressure tests as indicated in these procedures. Excessive pressure/ vacuum would damage the EVAP components or cause eventual fuel tank system failure.

1. Disconnect the vacuum hose from the EVAP canister purge valve (A), and connect the vacuum pump to the hose.

Special Tools Required Vacuum pump/gauge, 0 - 30 in.Hg A973X-041-XXXXX This is a two-trip code; Once cleared, it cannot be reproduced in one trip. Also certain specific driving and ambient conditions must occur before the ECM/PCM will complete the system checks. Additional test drives may still not meet the specific conditions needed to reproduce the code. Follow these troubleshooting procedures carefully to ensure the integrity of the system and to comfirm the cause of the problem or code.

2. Turn the EVAP canister purge valve on with the Honda PGM Tester, then connect ECM/PCM connector terminal A6 to body ground with a jumper wire.

NOTE: Fresh fuel has a higher volatility that will create greater pressure/vacuum. The optimum condition for testing is fresh fuel, and there must be less than a full tank of fuel. If possible, to assist in leak detection, add one gallon of fresh fuel to the tank (as long as it will not fill the tank), just before starting these procedures.


(CS (RED/VEL) 5 6V 8 9 10 /12L13 14 15 V 17 18 19 20 21 1/ 23 32 25 26 27 28 29 30 V

V/2 3 4

-

JUMPER WIRE -"-



11-152

BACK

// 24 /


4. Apply vacuum to the hose.

9. Measure voltage between EVAP canister purge valve 2P connector terminal No.1 and body ground.

Does the valve hold vacuum? YES-Go to step 5.

EVAP CANISTER PURGE

VALVE 2P CONNECTOR

NO- The EVAP canister purge valve is OK. Go to step 10. 5. Turn the ignition switch OFF.

IG1 (BlK/VEl)

S. Disconnect the EVAP canister purge valve 2P connector. 7. Check for continuity between EVAP canister purge valve 2P connector terminal No.2 and body ground. EVAP CANISTER PURGE VAlVE2PCONNECTOR


Is there battery voltage? YES - Replace the EVAP canister purge valve .• NO-Repair open in the wire between the EVAP canister purge valve and No. S ECU (ECM/PCM) CRUISE CONTROL (15A) fuse .•


Is there continuity? YES - Go to step 8. NO-Repair open in the wire between the EVAP canister purge valve and ECM/PCM (AS) .•

(cont'd)

BACK

11-153

Evaporative Emission Control System OTC Troubleshooting (cont'd) EVAP Bypass Solenoid Valve Test 10. Disconnect the vacuum hose from the EVAP twoway valve (A), and connect a vacuum pump to the hose.

Is there continuity? A973X-041-XXXXX

YES-Go to step 16. NO- Replace the EVAP bypass solenoid valve (A) and O-rings (8) .•

11. Turn the ignition switch ON (II). 12. Apply vacuum to the hose.

16. Disconnect ECM/PCM connector A (32P).

Does the valve hold vacuum? YES - The EVAP bypass solenoid valve/EVAP twoway valve is OK. Go to step 18.

17. Check for continuity between EVAP bypass solenoid valve 2P connector terminal No.2 and body ground.

NO-Go to step 13.

EVAP BYPASS SOLENOID VALVE 2P CONNECTOR

13. Turn the ignition switch OFF. 14. Disconnect the EVAP bypass solenoid valve 2P connector. 15. Check for continuity between EVAP bypass solenoid valve 2P connector terminal No.2 and body ground. EVAP BYPASS SOLENOID VALVE2PCONNECTOR


Is there continuity? YES-Repair short in the wire between the EVAP bypass solenoid valve and ECM/PCM (A3) .• NO-Substitute a known-good ECM/PCM and recheck (see page 11-5). Ifthe symptom/indication goes away, replace the original ECM/PCM .• Wire side of female terminals

11-154

BACK

EVAP Canister Vent Shut Valve Test


18. Disconnect the vacuum hose from the EVAP canister filter (A), and connect a vacuum pump to the hose.

23. Disconnect the EVAP canister vent shut valve 2P connector. 24. Check for continuity between EVAP canister vent shut valve 2P connector terminal No.2 and body ground. EVAP CANISTER VENT SHUT VALVE2PCONNECTOR

= 19. With the Honda PGM Tester in the EVAP test mode, turn on the bypass solenoid, or connect ECM/PCM connector terminal A4 to body ground with a jumper wire.


Is there continuity? YES - Go to step 25.

ECM/PCM CONNECTOR A 132PI

NO- Repair open in the wire between the EVAP canister vent shut valve and ECM/PCM (A4) .•

I VSV ILT GRN/WHTI VI2 3 4

5 6/ 8 9 10 / 1 l12113 14 15 V 17 18 19 20 21 / 23 24 I 25 26 27 28 29 30 1/ ~

JAMPERWIRE -'-

=


20. Turn the ignition switch ON (II) 21. Apply vacuum to the hose.

Does the valve hold vacuum? YES- The EVAP canister vent shut valve is OK. Go to step 27. NO-Goto step 22.

(cont'd)

BACK

11-155

Evaporative Emission Control System DTC Troubleshooting (cont'd) 25. Turn the ignition switch ON (II).

Canister System Leak Test

26. Measure voltage between EVAP canister vent shut valve 2P connector terminal No.1 and body ground.

27. Turn the ignition switch OFF. 28. Connect two three-way tee fittings (A) into the hose from the EVAP canister to the EVAP two-way valve. Connect the FTP sensor to one of the tee fittings and the vacuum pump to the other.

EVAP CANISTER VENT SHUT VALVE 2P CONNECTOR

IG1 (BlK/YELI


29. Remove the vent hose from the EVAP canister vent shut valve (A) and plug the port (B) to seal the fresh air vent for the EVAP canister.

A

Is there battery voltage? YES - Replace the EVAP canister vent shut valve (A) and O-ring (B) .• NO-Repair open in the wire between the EVAP canister vent shut valve and No.6 ECU (ECM/PCM) CRUISE CONTROL (15A) fuse .• 30. Turn the ignition switch ON (II).

11-156

BACK

31. While monitoring the Fuel Tank Pressure sensor voltage with the Honda PGM Tester, or measuring voltage between ECM/PCM connector terminals A 29 and C18, slowly pump the vacuum pump. ECM/PCM CONNECTORS

36. Turn the ignition switch ON (II). 37. While monitoring FTPsensorvoltagewiththe Honda PGM Tester, or measuring voltage between ECM/PCM connector terminals A29 and C18, slowly pump the vacuum pump. ECM/PCM CONNECTORS

SG2 IGRN/BLK)

Wire side of female terminals SG2 IGRN/BLKI


32. Continue to pump until the voltage drops to about 1.5 V. Make sure your vacuum pump has no leak.

38. Continue to pump vacuum until the voltage drops to about 1.5 V.

33. Monitor the voltage for 20 seconds.

Does the voltage drop to about 1.5 V and hold for at least 20 seconds?

39. Check the voltage for 20 seconds.

Does the voltage drop to about 1.5 V and hold for least 20 seconds?

YES -I nspect the EVAP canister vent shut valve line and connections .•

YES-Inspect the fuel tank vapor line and connections for vacuum leaks.•

NO - Go to step 34.

NO- Go to step 40.

34. Turn the ignition switch OFF. 35. Disconnect the quick-connect fitting (A) from the EVAP canister, and cap the canister port (B).

B

(cont'd)

BACK

11-157

Evaporative Emission Control System DTC Troubleshooting (cont'd) 40. Turn the ignition switch OFF. 41. Disconnectthe purge line hose (A) from the canister at the metal line and cap the canister port

44. Continue to pump until the voltage drops to about 1.5 V. Make sure the engine coolant temperature is still above 95°F (35°C) and your vacuum pump has no leak.

(B).

45. Monitor the voltage for 20 seconds. Does the voltage drop to about 1.5 V and hold for at least 20 seconds? YES -Inspect the EVAP canister purge valve line and connections for vacuum leaks. If they are OK, do the EVAP two-way valve test, and fuel tank vapor control valve test (see page 11-160) .• NO- Replace the EVAP canister.•

42. Turn the ignition switch ON (II). 43. While monitoring FTP sensor voltage with the Honda PGM Tester, or measuring voltage between ECM/PCM connector terminals A29 and C18, slowly pump the vacuum pump. ECM/PCM CONNECTORS

SG2 (GRN/BLK)


11-158

BACK

EVAP Two Way Valve Test Special Tools Required • Vacuum pump/gauge, 0 - 30 in.Hg A973X-041-XXXXX • Vacuum/pressure gauge, 0- 4 in.Hg 07JAZ-0010008

5. Slowly pressurize the vapor line while watching the gauge. The pressure should stabilize momentarily above 1.0 kPa (8 mmHg, 0.3 in.Hg).

1. Remove the fuel fill cap. 2. Disconnect the vapor line from the EVAP two-way valve (A), and connect the line to aT-fitting (8) from the vacuum gauge and the vacuum pump as shown.

• If the pressure momentarily stabilizes (valve opens) above 1.0 kPa (8 mmHg, 0.3in.Hg), the valve is OK. • Ifthe pressure stabilizes below 1.0 kPa (8 mmHg, 0.3 in.Hg), install a new valve and retest.

07 JAZ-001 0008

---------

/ A

A973X-041-XXXXX

3. Apply vacuum slowly and continuously while watching the gauge. The vacuum should stabilize momentarily at 0.8 - 2.1 kPa (6 - 16 mmHg, 0.2 - 0.6 in.Hg). If the vacuum stabilizes (valve opens) below 0.8 kPa (6 mmHg, 0.2 in.Hg) or above 2.1 kPa (16 mmHg, 0.6 in.Hg), install a new valve and retest. 4. Move the vacuum pump hose from the vacuum fitting to the pressure fitting, and move the vacuum gauge hose from the vacuum side to the pressure side (A) as shown.

A973X-041-XXXXX

BACK

11-159

Evaporative Emission Control System Fuel Tank Vapor Control Valve Test Valve Test


Vacuum pump/gauge, 0 - 30 in.Hg A973X-041-XXXXX 1. Make sure the fuel tank is less than half full.

Float Test 2. Remove the fuel fill cap. 1. Make sure the fuel tank is less than half full. 3. Remove the left rear inner fender. Disconnect the fuel tank vapor signal tube (A).

2. Remove the fuel fill cap to relieve the fuel tank pressure, then reinstall the cap. 3. Remove the left rear inner fender. Disconnect the fuel tank vapor recirculation tube (A), and connect a vacuum pump to the vapor recirculation tube.

A

4. Disconnect the vacuum hose (A) from the EVAP canister (8), and then plug the ports with plugs (e). A

D

4. Plug the line (8). 5. Apply vacuum to the fuel tank vapor recirculation tube (A) . • If the vacuum holds, replace the fuel tank vapor control valve (see page 11-162). • If the vacuum does not hold, the float is OK. Go to step 1 of the valve test.

A973X-041XXXXX

E A

5. Disconnect the vacuum hose (D) from the EVAP canister vent shut valve (E), and connect a hose (F) and a vacuum pump to the EVAP canister vent shut valve. 6. Pump the vacuum pump 80 times . • If the vacuum holds, go to step 7 . • If the vacuum does not hold, go to step 10.

11-160

BACK

9. Fill the fuel tank with fuel, then check for fuel in the two way valve and fuel tank vapor recirculation hose (B).

7. Connect a second vacuum pump to the fuel tank vapor signal tube (A).

NOTE: At either location, tiny droplets of fuel are normal. • If fuel runs out of the hoses at either location, replace the fuel tank vapor control valve. • If fuel does not run out of the hoses at either location, the fuel tank vapor control system is normal.

A

8. Apply vacuum to the fuel tank vapor signal tube, then check the vacuum on the pump in step 6. • If the vacuum holds, replace the fuel tank vapor control valve (see page 11-162) . • If the vacuum is released, the EVAP canister vent shut valve is OK. Go to step 10.

Check for fuel running out.

10. Disconnect the fuel tank vapor hose quick disconnect from the EVAP canister, then plug the port on the canister. Reapply vacuum (80 pumps). • If the vacuum holds, replace the fuel tank vapor vent shut valve (see page 11-162). • If the vacuum does not hold,inspectthe EVAP canister vent shut valve O-ring. If the O-ring is OK, replace the EVAP canister and repeat step 4.

BACK

11-161

Evaporative Emission Control System Fuel Tank Vapor Control Valve Replacement 1. Remove the fuel tank (see page 11-125). 2. Remove the fuel tank vapor control valve (A) from the fuel tank (8).

3. Replace the base gasket (C). 4. Install the fuel tank vapor control valve (A). 5. Install the fuel tank (see page 11-125).

11-162

BACK

Transaxle Clutch Special Tools ............................................................. Component Location Index ..................................... Clutch Pedal and Clutch Switch Adjustment .......... Clutch Master Cylinder Replacement ..................... Slave Cylinder Replacement .................................... Clutch Replacement ..................................................

12-2 12-3 12-4 12-5 12-6 12-7

Manual Transmission ....... .................. ........... 13-1 MIT Differential ............................................. 13-53 Automatic Transmission .............................. 14-1 AIT Differential.......... .................................... 14-198 Drivelinel Axle .......... ...................................... 16-1

Clutch Special Tools Ref. No.

CD ® ®

cD

Tool Number 07JAF-PM7011A 07 LAB-PVOO 100 or 07924-PD20003 07LAF-PT00110 07936-3710100

CD

12-2

Description Clutch Alignment Disc Ring Gear Holder Clutch Alignment Shaft Remover Handle

®

®

BACK

Qty

1 1 1 1


PEDAL PIN

~RESERVOIR HOSE

""

CLUTCH MASTER CYLINDER Replacement, page 12-5

LOCK PIN

CLUTCH PEDAL Adjustment, page 12-4

/

CLUTCHUNE

FLYWHEEL Inspection, step 1 on page 12-9 Removal, step 1 on page 12-9 Installation, step 1 on page 12-9 DOWEL PIN CLUTCH DISC Removal, page 12-7 Installation, step 1 on page 12-10

~

MIT ASSEMBLY

PRESSURE PLATE Removal, page 12-7 Installation, step 1 on page 12-10

SLAVE CYLINDER Replacement, page 12-6 RELEASE BEARING Replacement, step 1 on page 12-11

BACK

12-3

Clutch Clutch Pedal and Clutch Pedal Position Switch Adjustment NOTE: • To check the clutch switch (see page 4-49). • The clutch is self-adjusting to compensate for wear. • If there is no clearance between the master cylinder piston and push rod, the release bearing is held against the diaphragm spring, which can result in clutch slippage or other clutch problems.

1. Loosen locknut (A), and back off the clutch switch (8)(or adjusting bolt) until it no longer touches the clutch pedal (C). H 9.8 N·m (1.0 kgf·m. 7.2Ibf·ftl

5. Turn the clutch switch (8) in an additional 3/4 to 1 turn. 6. Tighten locknut (A). 7. Loosen locknut (H) and the clutch interlock switch (I ).

8. Press the clutch pedal to the floor. 9. Release the clutch pedal 15 - 20 mm (0.59 - 0.79 in.) from the fully pressed position, and hold it there. Adjust the position of the clutch interlock switch (I) so that the engine will start with the clutch pedal in this position. 10. Tighten locknut (H).

c D 7N·m (0.7 kgf·m. 5lbf·ftl

2. Loosen locknut (D), and turn the push rod (E) in or out to get the specified stroke (F) and height (G) at the clutch pedal.

Clutch Pedal Stroke: 141-151 mm (5.6-5.9 in.) Clutch Pedal Height: 190 mm (7.5 in.) 3. Tighten locknut (D). 4. Turn the clutch switch (8) in until it contacts the clutch pedal (C).

12-4

BACK

Clutch Master Cylinder Replacement NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

6. Remove the retaining clip (AI. Disconnect the clutch line (BI, and remove the a-ring (el. Plug the end of the clutch line with a shop towel to prevent brake fluid from coming out.

1. Remove the brake fluid from the clutch master cylinder reservoir (AI with a syringe. A

\ B

7. Remove the clutch master cylinder (DI, then remove the reservoir hose (EI from the clutch master cylinder (DI.

2. Disconnect the reservoir hose (BI from the clutch master cylinder reservoir. Plug the end of the reservoir hose with a shop towel to prevent brake fluid from coming out.

8. Install the clutch master cylinder in the reverse order of removal. Install the new a-ring. Tighten the master cylinder mounting nuts to 13 N·m (1.3 kgf·m, 9.4 Ibf·ftl. 9. Bleed the clutch hydraulic system (see step 5 on page 12-61.

3. Remove the clutch master cylinder reservoir. 4. Remove the power relay (el. 5. Pry out the lock pin (AI, and pull the pedal pin (BI out of the yoke. Remove the nuts (el. C

I~

A

/

B

.. .wmit

BACK

12-5

Clutch Slave Cylinder Replacement NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

3. Remove the slave cylinder (A) and a-ring (B). Plug the end of the clutch line with a shop towel to prevent brake fluid from coming out.

1. Remove the mounting bolts (A), the slave cylinder (B), and clutch line mounting bolt (e).

~

(PIN 08798-9002)

4. Install the slave cylinder in the reverse order of removal. Install the new a-ring. Apply Super High Temp Urea Grease (PIN 08798-9002) to the push rod of the slave cylinder. Tighten the slave cylinder mounting bolts to 23 N·m (2.3 kgf·m, 17 Ibf·ft). 5. Bleed the clutch hydraulic system. Tighten the bleeder screw to 8 N·m (0.8 kgf·m, 6 Ibf·ft). 2. Remove the roll pin. NOTE: Be careful not to damage the slave cylinder by overtightening the bleeder screw. • Attach a hose to the bleeder screw (A), and suspend the hose in a container of brake fluid. • Make sure there is an adequate supply offluid at the clutch master cylinder, then slowly pump the clutch pedal until no more bubbles appear at the bleeder hose. • Refill the clutch master cylinder with fluid when done. • Always use only Genuine Honda DOT 3 brake fluid.

A

12-6

BACK

Clutch Replacement 3. Install the special tools.

Special Tools Required • Clutch alignment shaft 07LAF-PT00110 • Clutch alignment disc 07JAF-PM7011A • Remover handle 07936-3710100 • Ring gear holder 07LAB-PV00100 or 07924-PD20003

\,

Pressure Plate and Clutch Disc Removal 1. Assemble the special tools as shown. Assemble the Clutch Alignment Disc with side marked" A" facing the diaphragm spring. 2. Check the diaphragm spring fingers for height using the special tools and a feeler gauge (A). If the height is more than the service limit, replace the pressure plate. Standard (New): Service Limit:

0.6 mm (0.02 in.) max. 0.8 mm (0.03 in.)

4. To prevent warping, unscrew the pressure plate mounting bolts (A) in a crisscross pattern in several steps, then remove the pressure plate (B). 5. Inspect the pressure plate (A) surface for wear, cracks, and burning. B

07936-3710100

6. Inspect the fingers of the diaphragm spring (B) for wear at the release bearing contact area.

(cont'd)

BACK

12-7

Clutch Clutch Replacement (cont'd) 7. Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (e). If the warpage is more than the service limit, replace the pressure plate. Standard (New): Service Limit:

10. Measure the clutch disc thickness. Ifthe thickness is less than the service limit, replace the clutch disc. Standard (New):

0.03 mm (0.001 in.) max. 0.15 mm (0.006 in.)

Service Limit:

8.4-9.0 mm (0.33-0.35 in.) max. 6.0 mm (0.24 in.)

11. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth is less than the service limit, replace the clutch disk.

8. Remove the clutch disc and special tools.

Standard (New): Service Limit:

1.65-2.25 mm (0.065-0.089 in.) max. 0.8 mm (0.03 in.)

9. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc is burned black or oil soaked, replace it.

B

12-8

BACK

Flywheel Removal

Flywheel Inspection 1. Inspect the ring gear teeth for wear and damage.

1. Install the special tool.

2. Inspect the clutch disc mating surface on the flywheel for wear, cracks and burning. 3. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel and recheck the runout. Standard (New):

Service Limit:

0.05 mm (0.002 in.) max. 0.15 mm (0.006 in.)

07LAB-PV00100 or 07924-PD20003

2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel.

Flywheel Installation A

1. Align the hole in the flywheel with the crankshaft dowel pin, and install the flywheel. Install the mounting bolts finger-tight. 2. Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps. FlVWHEEl MOUNTING BOLT TORQUE: 103 N·m (10.5 kgf·m, 76Ibf·ft)

(cont'd)

BACK

12-9

Clutch Clutch Replacement (cont'd) Clutch Disc and Pressure Plate Installation

4. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring.

1. Install the ring gear holder. 07LAF-PT00110

PRESSURE PLATE MOUNTING BOLT TORQUE: 25 N·m (2.6 kgf·m, 19Ibf·ft)

A

~

(PIN 08798-9002)

3. Install the pressure plate (A) and the mounting bolts (8) finger-tight.

\,-

5. Remove the special tools. 6. Make sure the diaphragm spring fingers are all the same height.

A

12-10

BACK

Release Bearing Replacement

4. Apply Super High Temp Urea Grease (PIN 087989002) to the release fork (A), the release fork bolt (8), the release bearing (C), and the release bearing guide (D) in the shaded areas.

1. Remove the release fork boot (A) from the clutch housing (8).

B

D

2. Remove the release fork (C) from the clutch housing (8) by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E). 3. Check the release bearing for play by spinning it by hand. If there is excessive play, replace the release bearing with a new one. NOTE: The release bearing is packed with grease. Do not wash it in solvent.

1.0-1.69 (0.04-0.06oz)

5. With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing. 6. Align the detent of the release fork (A) with the release fork bolt (8), then press the release fork over the release fork bolt (B) squarely. 7. Install the release fork boot (E), make sure the boot seals around the release fork and clutch housing. 8. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (8), and that the release bearing slides smoothly. B

BACK

12-11

BACK

Transaxle Manual Transmission Special Tools ................................ 13-2 Transmission Fluid Inspection and Replacement ..................... 13-3 Back-up Light Switch Test .......... 13-3 Transmission Removal ............... 13-4 Transmission Insta"ation ........... 13-10 Shift Arm Replacement ............... 13-18 Transmission Disassembly ........ 13-21 Reverse Shift Fork Clearance Inspection ................................. 13-25 Mainshaft Assembly Clearance Inspection ................................. 13-26 Mainshaft Disassembly .............. 13-28 Mainshaft Inspection ................... 13-29 Mainshaft Reassembly ............... 13-30 Countershaft Assembly Clearance Inspection ................................. 13-32 Countershaft Disassembly ......... 13-34 Countershaft Inspection ............. 13-35 Countershaft Reassembly .......... 13-36 Shift Forks Clearance Inspection ................................. 13-39 Shift Forks Disassembly/ Reassembly .............................. 13-40

Synchro Sleeve and Hub Inspection and Reassembly Synchro Ring and Gear Inspection ................................ . Countershaft Bearing Replacement ............................ Mainshaft Bearing and Oil Seal Replacement ............................ Mainshaft Thrust Clearance Adjustment .............................. . Transmission Reassembly ........ . Gearshift Mechanism Replacement ........................... .

13-41 13-41 13-43 13-44 13-45 13-48 13-52

MIT Differential Component Location .................. . Backlash Inspection .................... . Final Driven Gear/Carrier Replacement ........................... . Carrier Bearings Replacement .. . Oil Seal Replacement ................. . Carrier Bearing Outer Race Replacement and Preload Adjustment .............................. .

BACK

13-53 13-54 13-54 13-55 13-55

13-57

1:9]

Manual Transmission Special Tools Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

DescriPtion Tool Number Driver Attachment 07GAD-PG40100 Mainshaft Holder 07GAJ-PG20110 **® 07GAJ-PG20130 Mainshaft Base **@ Driver Attachment 07HAD-SF10100 CD Preload Inspection Tool 07HAJ-PK4020 1 ® Oil Seal Driver Attachment 07 JAD-PH80 101 ® IJ) Pilot, 28 x 30 mm 07 JAD-PH80400 Bearing Attachment 07LAD-PW50601 ® Adjustable Bearing Puller, 25-40 mm 07736-AO 1OOOB *® @ Attachment, 42 x 47 mm 077 46-00 10300 @ Attachment, 52 x 55 mm 077 46-0010400 @ Attachment, 62 x 68 mm 077 46-0010500 @ Driver, 40 mm I.D. 077 46-0030 100 Attachment, 35 mm 1.0. 077 46-0030400 ® @ Driver 077 49-0010000 @ Oil Seal Driver 07947-6890100 * Must be used with commercially available 3/8"- 16 Slide Hammer. ** Part of Mainshaft Inspection Tool Set, 07GAJ-PG2010A. Ref.No.

CD

@ CD

(55) P' ®

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I

Transmission Fluid Inspection and Replacement

Back-Up Light Switch Test 1. Disconnect the back-up light switch (A) connectors. A

~'8Iw.ftl

,. Park the vehicle on level ground. and turn the engine OFF. 2. Remove the oil filler plug (A) and washer (B). check the condition of the fluid. and make sure the fluid at the proper level (C).

c

/ 2. Check for continuity between the terminals (B). There should be continuity when the shift lever into reverse. 3. If the transmission fluid is dirty. remove the drain plug (D) and drain the fluid. Cover the front and rear beams with a shop towel (E) to catch any spilled fluid.

3. If necessary. replace the switch.

4. Reinstall the drain plug (D) with a new washer (F). and refill the transmission fluid to the proper level.

Oil Capacity 1.9 A (2.0 US qt, 1.7 Imp qt) at fluid change 2.0 A (2.1 US qt, 1.8 Imp qt) at overhaul

Always use Genuine Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because it does not contain the proper additives. 5. Reinstall the oil filler plug with a new washer (B).

BACK

13-3

Manual Transmission Transmission Removal 4. Remove the engine wire harness clamp.


Engine hanger, A and Reds AART1256 or equivalent, commercially available NOTE: Use fender covers to avoid damaging painted surfaces. 1. Disconnect the negative (-) cable first, then the positive (+) cable from the battery. Remove the battery. 2. Remove the intake air duct (A) and air cleaner housing (8).

5. Carefully remove the slave cylinder (A) and clutch line clamp (8) so as not to bend the clutch line. Do not operate the clutch pedal once the slave cylinder has been removed.

B

3. Remove the battery tray.

13-4

BACK

6. Disconnect the starter cables (A), then remove the starter motor (8). A

9. First remove the cable bracket (A), then disconnect the cables (8) from the top of the transmission housing. Carefully remove both cables and the bracket together so as not to bend the cables.

:::L}f-----A B

10. Disconnect the vehicle speed sensor (VSS) connector.

B

8. Remove the transmission ground cable (8) and starter cable clamp (C).

(cont'd)

BACK

13-5

Manual Transmission Transmission Removal (cont'd) 13. Remove the front engine mount bracket 3 mounting bolts.

11. Remove the rear engine mount bracket brace.

14. Raise vehicle and make sure it is securely supported. 12. Remove the engine wire harness (A) and two upper transmission mounting bolts (B).

15. Drain transmission fluid with a shop towel covering the front and rear beams to catch any spilled fluid (see page 13-3). 16. Remove the splash shield.

B

13-6

BACK

17. Remove the cotter pins (A), and loosen the castle nuts (8), then separate the ball joints and lower arms (C) on both sides (see step 3 on page 18-17).

20. Remove the intermediate shaft. Coat all the precision finished surfaces with clean engine oil grease. Tie bags over the shaft end.

~

18. Remove the both damper forks (D). 19. Pull the driveshafts out of the intermediate shaft and differential (see page 16-3). Coat all the precision finished surfaces with clean engine oil grease. Tie bags over the driveshaft ends.

,, ..~

/~"

\

21. Remove the engine stiffener.

(

',,-

(cont'd)

BACK

13-7

Manual Transmission Transmission Removal (cont'd) 24. Make reference marks (A) on the rear beam (B) and front beam (C), then remove the front beam.

22. Remove the radius rod mounting bolts from the lower arm (A).

~

B

c

23. Remove the power steering cooler line (A) from the front beam (B). A

c 25. Lift and support the engine/transmission assembly with an engine hanger (P/N AAR-T-1256, available through the American Honda Tool and Equipment Program, or equivalent).

26. Place a floor jack under the transmission, and raise the transmission just enough to take weight off of the mounts.

13-8

BACK

27. Remove the transmission mount bracket (A) and transmission mount (8).

28. Remove the transmission mount stud bolt (C) on the transmission housing.

30. Remove the two rear engine mount bracket (A) mounting bolts (8). B

31. Remove the rear side transmission mounting bolt (C).

29. Remove the intake manifold bracket. 32. Remove the front side transmission mounting bolt.

(cont'd)

BACK

13-9

Manual Transmission Transmission Removal (cont'd)

Transmission Installation

33. Pull the transmission away from the engine until it clears the mainshaft, then lower it on the transmission jack. Take care not to bend the clutch line.

1. Check that the dowel pins are installed in the clutch housing. 2. Install the slave cylinder bracket on the transmission assembly~

34. Remove the slave cylinder bracket from the transmission.


35. Remove the boot (A), the release fork (B), and the release bearing (C) from the transmission (0). D

3. Apply Super High Temp Urea Grease (PIN 087989002) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (0) in the shaded areas.

':AIM

OF=;:::;.~~

0.4-1.0 9 (0.01-0.04 ozl

B

1.0-1.6 9 (0.04-0.06 ozl

4. Install the release bearing (C), release fork (A), and boot (E) on the transmission (F).

13-10

BACK

5. Place the transmission on the transmission jack. and raise it to the engine level.

9. Install the transmission mount stud bolt (A) on the transmission housing.

6. Install the front side transmission mounting bolt. 12 x 1.25 mm 64 N·m 16.5 kgf·m. 47 Ibf·tt)

I 50mm 11.97 in.)

7. Install the rear side transmission mounting bolt (A). A 12 x 1.25 mm 64 N·m 16.5 kgf·m. 47 Ibf·tt)

C 12 x 1.25 mm 54 N·m 15.5 kgf·m. 40 Ibf·tt)

~ ®

B

10. Raise the transmission. install the transmission mount (8) and transmission mount bracket (C).

8. Install the 2 rear engine mount bracket (8) new mounting bolts (C).

• Torque mounting bolts and nut in the sequence shown . • Make sure the bushings are not twisted or offset.

CD ® ® CD

12 x 1.25 mm 64 N·m (6.5 kgf·m. 47 Ibf·ft) Temporary tightening 10 x 1.25 mm 38 N·m (3.9 kgf·m, 28Ibf·ft) 12 x 1.25 mm 54 N·m (5.5 kgf·m. 40 Ibf·ft)

(cont'd)

BACK

13-11

Manual Transmission Transmission Installation (cont'd) 11. Remove the engine/transmission hanger.

13. Install the power steering cooler line (A) in the line clamps (B). A

12. Install the front beam (A) in its original position by aligning the marks (B) you made in the removal procedure.

14. Install both radius rods (A) with new mounting bolts on the lower arm (B).

B

14x 1.5mm 103N·m (10.5 kgf·m, 75.9 Ibf·ftl

13-12

12x1.25mm 64N·m (6.5 kgf·m, 47 Ibf·ftl

BACK

17. Install the intermediate shaft (see page 16-26).

15. Install the engine stiffener. .

12x1.2Smm 64N·m 16.S kgf·m, 47 Ibf·ftl

~

10x 1.2Smm 39 N·m (4.0 kgf·m, 29lbf·ftl

; '- I

. f

(/ /

10x 1.2Smm 44 N·m 14.S kgf·m, 33 Ibf·ftl

16. Install the intake manifold bracket.

18. Install the driveshafts with new set rings (see page 16-20).

8x 1.2Smm 22 N·m 12.2 kgf·m, 16 Ibf·ftl

(cont'd)

BACK

13-13

Manual Transmission Transmission Installation (cont'd) 19. Install the damper forks (A) with new locknuts (B). 10x 1.25 mm 43 N·m (4.4 kgf·m, 32 Ibf·ftl

22. Install the washer (A) and the front engine mount bracket mounting bolts (B). B


/-~ "

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~

;:~~-4:1LH7_/--:~51/'

L ....

~.!.

E

F

12x 1.25mm 49-59N·m (5.0-6.0 kgf·m, 36-43 Ibf·ftl

A

B 12x 1.25mm 64 N·m (6.5 kgf·m, 47lbf·ftl

20. Install the ball joints (C) onto the lower arms (D), and install the castle nuts (E) and cotter pins (F).

23. Install the engine wire harness (A) and two upper transmission mounting bolts (B). A


B


13-14

BACK

26. Install the cable bracket (A) and cables (8). Turn the shift lever boot (C) so the hole is facing down.

24. Install the rear engine mount bracket brace.

8x 1.25 mm

27~~ftl

~ ~

L

~

~

-A

c

(PIN 08798-90021 10x 1.25 mm


25. Connect the vehicle speed sensor (VSS) connector.

27.

6x1.0mm 9.8 N·m (1.0 kgf·m,

7.2Ibf·ftl

28. Connect the back-up light switch connectors (C).

(cont'd)

BACK

13-15

Manual Transmission Transmission Installation (cont'd) 29. Install the starter motor (A), then connect the starter cables (B). Make sure that the crimped side ofthe ring terminal is facing out.

31. Install the engine wire harness clamp. 6x 1.0mm 9.8 N·m 11.0 kgf·m, 7.2Ibf·ftl

8x1.25mm B

9 NZ~ k~.m'~7

~·ftJ

32. Install the battery bracket.

9. ~'\k~'"" 7.21. . 6x1.0mm

ffl

10x 1.25 mm 38 N·m 13.9 kgf·m, 271bf.ftl

12x1.25mm 64 N·m 16.5 kgf·m, 47lbf·ftl

30. Apply Super High Temp Urea Grease (PIN 087989002) to the end of the slave cylinder rod. Install the slave cylinder (A) and clutch line clamp (B). Take care not to bend the clutch line. 6x 1.0 mm 9.8 N·m 11.0 kgf·m, 7.2Ibf·ftl

8x1.25mm 22 N·m 12.2 kgf·m,

'.,bI·ftJ

~

13-16

BACK

)

. .

33. Install the intake air duct (AI and air cleaner housing (81.

35. Install the battery. Connect the positive (+ I cable first, then the negative (- I cable to the battery. 36. Refill the transmission fluid (see page 13-31. 37. Test drive the vehicle. 38. Check the clutch operation. 39. Check the transmission for noise and smooth operation. 40. Check the front wheel alignment (see page 18-5). 41. Loosen the three mounting bolts on the front engine mount bracket, then retorque them to 38 N·m (3.9 kgf·m, 27 Ib·ftl.Make sure the bushings are not twisted or offset. 42. Enter the anti-theft code for the radio, then enter the customer's radio station presets.

34. Turn the breather cap so that the "F" mark points toward the front of the vehicle.

BACK

13-17

Manual Transmission Shift Arm Replacement Exploded View SELECT LEVER

~

6x1.0mm 12 N·m (1.2 kgf·m. 9Ibf.ft)

(PIN 08798-9002)

SHIFT ARM 8x 1.0 mm 28 N·m (2.9 kgf·m.

21'\

INTERLOCK BOLT 39 N·m (4.0 kgf·m. 29 Ibf·ftl

SELECT ARM

~

(PIN 08798-9002)

~

~

~

/

5 x 22 mm SPRING PIN Replace.

SHIFT LEVER BOOT

~ (PIN 08798-9002)

SHIFT LEVER SHAFT

13-18

BACK

,~--INTERLOCK

NOTE: The shift arm cover can be removed and installed with the transmission in the vehicle.

3. Remove the reverse lock cam (A) from the shift arm cover (B).

1> @

1. With the transmission installed, remove the shift arm cover assembly (A). 6x 1.0mm 12N·m,

6X1.0mm 15N·m

11.5 kgf.m, 11lbf·ftl

~~A

11.2 kgf·m, 9lbf·ftl

~ 8x 14mm

2. Remove the spring pin (A), then remove the select lever (B), select arm (e) and springs (D).

4. Remove the oil seal (A) from the shift arm cover (B).

~ (PIN 08798-90021

~

A

B

(cont'd)

BACK

13-19

Manual Transmission Shift Arm Replacement (cont'd) 5. Bend the tab of the lock washer (A), then remove the bolt (B).

8. Install the shift arm assembly in the reverse order of removal, and note these items.

B 8x 1.0mm

• During reassembly, grease all sliding parts. • Use only Super High Temp Urea Grease (PIN 08798-9002). • Apply liquid gasket (PIN 08718-0001) to the interlock bolt threads before reassembly. • Turn the shift lever boot so the hole is facing down. • Use liquid gasket (PIN 08718-0001). • Remove the dirty oil from the sealing surface. • Seal the entire circumference of the bolt holes to prevent oil leakage. • If 20 minutes have passed after applying liquid gasket. reapply it and assemble the housings. Allow it to cure at least 20 minutes after assembly before filling the transmission with oil.

·····:LlQUID

GASKET

6. Remove the interlock bolt (C). 7. Remove the shift lever shaft (A), shift arm (B), and interlock (C).

~ (PIN 08798-9002)

13-20

BACK

Transmission Disassembly Exploded View - Gears, Shafts and Clutch Housing

.........

I.

.........

@ @

/'"

I

..................

Ii i

..............

'........... _._._._._._._.-1

CD CLUTCH HOUSING ®OILSEAL ® 14 x 20 mm DOWEL PIN ® OIL GUIDE PLATE ® NEEDLE BEARING ® RETAINING PLATE

(j) MAGNET

® REVERSE IDLER GEAR SHAFT ® REVERSE IDLER GEAR

@OILSEAL @ BALL BEARING @ SPRING WASHER @WASHER @ REVERSE SHIFT FORK

@ SHIFT FORK ASSEMBLV @ MAINSHAFT ASSEMBL V @ COUNTERSHAFT ASSEMBLV @ DIFFERENTIAL ASSEMBL V

(cont'd)

BACK

13-21

Manual Transmission Transmission Disassembly (cont'd) Exploded View - Transmission Housing

r'-'-'-'-'-'-'-'1

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.

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a

L._._._._/

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CD SHIFT ARM ASSEMBLV ® OIL GUTTER PLATE

@78mmSHIM @ OIL GUIDE PLATE ®WASHER Replace. @ BACK·UP LIGHT SWITCH ® SET SCREW

13-22

®WASHER Replace. ® SPRING L. 26 mm /1.02 in.) @STEEL BAU O.D. 5/16 in. ® FRONT TRANSMISSION HANGER @32 mm SEALING BOLT @WASHER Replace. @ REVERSE IDLER GEAR SHAFT BOLT @OILSEAL

BACK

@DRAINPLUG @WASHER Replace. @ OIL FILLER PLUG @WASHER Replace. @REARTRANSMISSION HANGER ® TRANSMISSION HOUSING

6. Remove the 32 mm sealing bolt (A) .

Note the following during disassembly: • Ifthe transmission housing or clutch housing are replaced, the bearing preload must be adjusted . • Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench. 1. Remove the shift arm cover assembly (see page 1318). 2. Remove the reverse idler gear shaft bolt (A).

7. Expand the snap ring (8) on the countershaft ball bearing, and remove it from the groove using a pair of snap ring pliers. 8. Separate the transmission housing (C) from the clutch housing (D), and wipe it clean of the sealant.

3. Remove the setting screws (8), then remove the washers (C), springs (D), and steel balls (E). 4. Remove the back-up light switch (A).

B~ ~

5. Remove the bolts and transmission hangers (8) in a crisscross pattern in several steps. (cont'd)

BACK

13-23

Manual Transmission Transmission Disassembly (cont'd) 10. Remove the reverse shift fork (A). Be careful not to lose the steel ball (B).

12. Tape the mainshaft splines, then remove the mainshaft assembly (A) and countershaft assembly (B) with the shift forks (e) from the clutch housing (0).

C~---r~1

11. Remove the reverse idler gear shaft (A) and the reverse idler gear (B).

13. Remove the differential assembly.

13-24

BACK

Reverse Shift Fork Clearance Inspection 1. Measure the clearances between the reverse shift fork (A) and 5th/reverse shift piece pin (8).

3. Measure the clearance between the reverse idler gear (A) and reverse shift fork (8). If the clearance is more than the service limit, go to step 4.

• If the clearance are more than the service limit, go to step 2. • If the clearance are within the service limits, go to step 3.

Standard: Service Limit:

0.5-1.1 mm (0.02-0.04 in.) 1.8 mm (0.07 in.)

CD:

Standard:

Service Limit:

0.05 - 0.35 mm (0.002-0.014 in.) 0: 0.4-0.8 mm (0.02-0.03 in.) CD: 0.5 mm (0.02 in.) 0: 1.0 mm (0.04 in.)

4. Measure the width of the reverse shift fork (A) . • If the width is not within the standard, replace the reverse shift fork with a new one . • If the width is within the standard, replace the reverse idler gear with a new one. 2. Measure the widths of the groove in the reverse shift fork (A).

Standard: 13.0-13.3 mm (0.51-0.52 in.)

• Ifthe widths ofthe grooves are not within the standard, replace the reverse shift fork with a new one. • If the widths of the grooves are within the standard, replace the 5th/reverse shift piece with a new one.

Standard:

CD: 7.05-7.25 mm (0.278-0.285 in.) 0: 7.4-7.7 mm (0.29-0.30 in.)

00

CD

00

BACK

13-25

Manual Transmission Mainshaft Assembly Clearance Inspection NOTE: If replacement is required, always replace the synchro sleeve and hub as a set.

4. Measure the clearance between 4th gear (A) and the spacer collar (B) with a dial indicator (C). Ifthe clearance is more than the service limit, go to step

5.

1. Support the bearing inner race with a socket (A), and push down on the mainshaft (B).


0.06-0.21 mm (0.002-0.008 in.' 0.3 mm (0.01 in.'

2. Measure the clearance between 2nd (C) and 3rd (0) gears with a feeler gauge (E). • Ifthe clearance is more than the service limit, go to step 3. • If the clearance is within the service limit, go to step 4.

B

5. Measure distance CD on the spacer collar.


0.06-0.21 mm (0.002-0.008 in.' 0.3 mm (0.01 in.'

• If distance CD is less than the service limit, replace the spacer collar with a new one . • If distance CD is within the service limit, go to step 6.

3. Measure the thickness of 3rd gear (A). • If the thickness of 3rd gear is less than the service limit, replace 3rd gear with a new one. • If the thickness of 3rd gear is within the service limit, replace the 3rd/4th synchro hub with a new one.


Standard:

26.03 - 26.08 mm (1.025-1.027 in.' 26.01 mm (1.024 in.'

Service Limit:

32.42-32.47 mm (1.276-1.278 in.' 32.3 mm (1.27 in.'

I

13-26

BACK

I

8. Measure distance ® on the spacer collar.

6. Measure the thickness of 4th gear.

• If distance ® is less than the service limit, replace the spacer collar with a new one. • If distance ® is within the service limit, go to step 9.

• If the thickness of 4th gear is less than the service limit, replace 4th gear with a new one. • If the thickness of 4th gear is within the service limit, replace the 3rd/4th synchro hub with a new one.

Standard: Standard: Service Limit:

30.92 - 30.97 mm (1.217-1.219 in.) 30.8 mm (1.21 in.)

Service Limit:

L

26.03 - 26.08 mm (1.025-1.027 in.) 26.01 mm (1.024 in.)

J ® --

9. Measure the thickness of 5th gear. 7. Measure the clearance between the spacer collar (A) and 5th gear (8) with a dial indicator (e). Ifthe clearance is more than the service limit, go to step 8.


0.06-0.21 mm (0.002 - 0.008 in.) 0.3 mm (0.01 in.)

• If the thickness of 5th gear is less than the service limit, replace 5th gear with a new one. • If the thickness of 5th gear is within the service limit, replace the 5th synchro hub with a new one.


30.92-30.97 mm (1.217-1.219 in.) 30.8 mm (1.21 in.)

c

\ o

B

BACK

13-27

Manual Transmission Mainshaft Disassembly 1. Remove the angular ball bearing (A) and the tapered cone ring (B) using a commercially available bearing separator (e) and a commercially available bearing puller (0). Be sure the bearing separator is under the tapered cone ring.

3. Support the 3rd gear (A) on steel blocks and press the mainshaft out of the 3rd/4th synchro hub (B). Use of a jaw-type puller can cause damage to the gearteeth.

D

PRESS

2. Support 5th gear (A) on steel blocks and press the mainshaft out of the 5th synchro hub (B). Use of a jaw-type puller can cause damage to the gear teeth. I

PRESS

...

13-28

I

BACK

Mainshaft Inspection 1. Inspect the gear surface and bearing surface for wear and damage. then measure the mainshaft at points A. B. and C. If any part of the mainshaft is less than the service limit. replace it with a new one. Standard: A (Ball bearing surface):

27.987 - 28.000 mm (1.1018-1.1024 in.) B (Needle bearing surface): 37.984-38.000 mm (1.4954-1.4961 in.) C (Ball bearing surface): 27.977 - 27.990 mm (1.1015-1.1020 in.) Service Limit: A: 27.940 mm (1.1000 in.) B: 37.930 mm (1.4933 in.) C: 27.940 mm (1.1000 in.) A

2. Inspectthe runout by supporting both ends ofthe mainshaft. Rotate the mainshaft two complete revolutions when measuring the runout. If the runout is more than the service limit. replace the mainshaft with a new one. Standard: 0.02 mm (0.001 in.) max. Service Limit: 0.05 mm (0.002 in.)

BACK

13-29

Manual Transmission Mainshaft Reassembly Exploded View

S=~~

-----a~D/4TH

SPRING

~

ijS

SVNCHRO SLEEVE

_---.1ID/4TH SVNCHROHUB

~"'SVNCHRO ~~SPR"G

~ ~

hJ

SYNCHRO RING

~ ---SYNCHRO SPRING

.~G~"

~ --SVNCHRORING ~

-----5TH GEAR

NEEDLE BEARING Check for wear and operation.

Q~

~ Q

/

SPACER COLLAR

NEEDLE BEARING Check for wear and operation.

_

9---

nHGEM

13-30

BACK

Special Tools Required • Driver, 40 mm 1.0. 07746-0030100 • Attachment, 35 mm 1.0. 077 46-0030400 • Driver 07749-0010000 • Attachment, 42 x 47 mm 07746-0010300

5. Install the 5th synchro hub (A) using the special tools and a press (B).

•

NOTE: Refer to the Exploded View, as needed during this procedure. 1. Clean all the parts in solevent, dry them, and apply lubricant to all contact surfaces except the 3rd/4th, and 5th synchro hubs. 2. Install 3rd gear, its bearing, and the 3rd gear synchro ring and synchro spring on the shaft. 3. Support 2nd gear (A) on steel blocks, then install the 3rd/4th synchro hub (B) using the special tools and a press (C). Note the direction of installation for the 3rd/4th synchro hub. After installing, check the operation of the 3rd/4th synchro hub set.

c

•

6. Install the spacer and tapered cone ring. 07746-0030100

7. Install the angular ball bearing (A) with the thinedged outer race facing down. Use the special tools and a press (8).

4. Install the 4th gear synchro spring and ring, 4th gear and its bearing, the spacer ring, and 5th gear and its bearing on the shaft.

BACK

13-31

Manual Transmission Countershaft Assembly Clearance Inspection 1. Measure the clearance between the 1st gear (A) and the thrust washer (8) with a feeler gauge (e). If the clearance is more than the service limit, go to step 2.

3. Measure the thickness ofthe 1st gear.

Standard: 0.06-0.23 mm (0.002-0.009 in.) Service Limit: 0.23 mm (0.009 in.)

Standard:

A

2. Measure the thickness of the thrust washer. • If the thickness is less than the standard, replace the thrust washer with a new one . • If the thickness is within the standard, go to step

3. Standard:

13-32

• If the thickness of 1st gear is less than the standard, replace 1st gear with a new one. • If the thickness of 1st gear is within the standard, replace the 1st/2nd synchro hub with a new one.

1.95-1.97 mm (0.077-0.078 in.)

BACK

32.95-33.00 mm (1.297-1.299 in.)

4. Measure the clearance between the 2nd gear (A) and 3rd gear (B) with a feeler gauge (e). If the clearance is more than the service limit, go to step 5.

6. Measure the thickness of the 2nd gear. • If the thickness of 2nd gear is less than the standard, replace 2nd gear with new one. • If the thickness of 1st gear is within the standard, replace the 1st/2nd synchro hub with a new one.

Standard: 0.10-0.15 mm (0.004-0.006 in.) Service Limit: 0.18 mm (0.007 in.) B

Standard:

28.92-28.97 mm (1.139-1.141 in.)

5. Measure the thickness of the spacer . • If the thickness is less than the standard, replace the spacer with a new one . • If the thickness is within the standard, go to step 6.

Standard:

29.07-29.09 mm (1.144-1.145 in.)

BACK

13-33

Manual Transmission Countershaft Disassembly 1. Securely clamp the countershaft assembly in a bench vise with wood blocks. A

4. Support 4th gear (A) on steel blocks (B), then use a press (C) and an attachment (0) to press the countershaft (E) out of the ball bearing (F).

2. Use a chisel (A) to raise the locknut tab (B) from the groove in the countershaft. 3. Remove the locknut (A) and the spring washer (B).

5. Remove the friction damper (A) from the spacer (B) using a press (C) and a socket (0) as shown.

A

13-34

BACK

Countershaft Inspection 1. Inspect the gear surface and bearing surface for wear and damage, then measure the countershaft at points A, 8, and C. If any part of the countershaft is less than the service limit, replace it with a new one.

Standard:

A: B: C:

Service Limit: A: B: C:

38.000-38.015 mm (1.4961-1.4967 in.) 39.984-40.000 mm (1.5742-1.5748 in.) 24.987 - 25.000 mm (0.9837 -0.9843 in.) 37.950 mm (1.4941 in.) 39.930 mm (1.5720 in.) 24.940 mm (0.9819 in.)

2. Inspect the runout by supporting both ends of the countershaft. Rotate the countershaft two complete revolutions when measuring the runout. Ifthe runout exceeds the service limit, replace the countershaft with a new one.

Standard: 0.02 mm (0.001 in.) max. Service Limit: 0.05 mm (0.002 in.)

c

BACK

13-35

Manual Transmission Countershaft Reassembly Exploded View

)

_ _ _ 'STGEAR ~.

NEEDLE BEARING "d op."tloo.

~ Ch""o' ..."

----THRUST WASHER

_ _ _ FRICTION DAMPER Check for wear and damage.

13-36

BACK

3. Install the 1st/2nd synchro hub (A) by aligning the fingers on the friction damper (B) with 1st/2nd synchro hub grooves.

Special Tools Required • Driver 07749-0010000 • Attachment, 42 x 47 mm 07746-0010300 • Seal driver 07947-6890100

A

NOTE: Refer to the Exploded View as needed during this procedure. 1. Clean all the parts in solvent, dry them, and apply lubricant to all contact surfaces. 2. Install the thrust washer (A) and the needle bearing (B) onto the countershaft (C). Assemble the friction damper (D) and 1st gear (E) together and install them on the countershaft, then install the synchro ring (F) and the synchro spring (G). B

4. Install reverse gear, 2nd gear synchro spring, and the double cone synchro assembly. 5. Install the friction damper (A) on the spacer (B) using the special tools and a press. PRESS

077 49-0010000

~ /07746-0010300

(cont'd)

BACK

13-37

Manual Transmission Countershaft Reassembly (cont'd) 6. Install the friction damper and spacer, and the 2nd gear bearing.

10. Install the spring washer (A),and loosely install the new locknut (B). B

7. Install 2nd gear (A) by aligning the synchro cone fingers (B) with 2nd gear grooves (C). A

c

B

11. Securely clamp the countershaft assembly in a bench vise with wood blocks. 8. Install 3rd gear, 4th gear, and 5th gear. 9. Install the needle bearing (A) and the ball bearing (B) using the special tool and a press IC).

12. Torque the new locknut to 127 N·m (13kg·m, 94Ib·ft), then loosen it and torque it again to the same value. Stake the locknut tab into the groove.

c

•

13-38

BACK

Shift Forks Clearance Inspection NOTE: The synchro sleeve and synchro hub should be replaced as a set.

3. Measure the clearance between the shift fork (A) and the shift arm (8). If the clearance exceeds the service limit, go to step 4.

1. Measure the clearance between each shift fork (A) and its matching synchro sleeve (S). Ifthe clearance exceeds the service limit, go to step 2.

Standard: 0.2-0.5 mm (0.008-0.020 in.' Service Limit: 0.6 mm (0.024 in.)

Standard: 0.35-0.65 mm (0.014-0.026 in.' Service Limit: 1.00 mm (0.039 in.'

4. Measure the width ofthe shift arm (A) .

A

2. Measure the thickness of the shift fork (A) fingers. • If the thickness of the shift fork finger is less than the standard, replace the shift fork with a new one . • If the thickness of the shift fork finger is within the standard, replace the synchro sleeve with a new one.

Standard:

• If the width of the shift arm is less than the standard, replace the shift arm with a new one. • If the width of the shift arm is within the standard, replace the shift fork or shift piece with a new one.

Standard:

A

I

6.2 - 6.4 mm (0.24 - 0.25 in.)

/

12.9-13.0 mm (0.508-0.512 in.'

0-=""-:-=:,-,,--=-~----_

-~

A

BACK

13-39

Manual Transmission Shift Forks DisassemblyIReassembly Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts.

•

5TH SHIFT FORK

3RD/4TH SHIFT FORK

/ PIN DRIVER 5.0 mm

r

/

5x22mm SPRING PIN Replace.

5TH/REVERSE SHIFT PIECE

13-40

BACK

\

1ST/2ND SHIFT FORK

Synchro Sleeve and Hub Inspection and Reassembly

Synchro Ring and Gear Inspection 1. Inspect the inside of the synchro ring (A) for wear.

1. Inspect gear teeth on all synchro hubs and synchro sleeves for rounded off corners, which indicate wear. 2. Install each synchro hub (A) in its mating synchro sleeve (B), and check for freedom of movement. Be sure to match the three sets of longer teeth (C) (120 degrees apart) on the synchro sleeve with the three sets of deeper grooves (D) in the synchro hub. Do not install the synchro sleeve with its longer teeth in the 1st/2nd synchro hub slots (E) because it will damage the spring ring. NOTE: If replacement is required, always replace the synchro sleeve and synchro hub as a set. B

B__

2. Inspect the synchro ring teeth (B) for wear (rounded off).

o o GOOIY

WORN

3. Inspect the synchro sleeve teeth (C) and matching teeth on the gear for wear (rounded off).

c

E

c

o o GOOD

WORN

A

(cont'd)

BACK

13-41

Manual Transmission Synchro Ring and Gear Inspection (cont'd) 8. Measure the clearance between the synchro ring (A) and gear (8) all the way around. Hold the synchro ring against the gear evenly while measuring the clearance. If the clearance is less than the service limit, replace the synchro ring and synchro cone.

4. Inspect the gear hub thrust surface (D) for wear.

Synchro Ring-to-Gear Clearance Standard: 0.85-1.10 mm (0.033-0.043 in.) Service Limit: 0.4 mm (0.016 in.)

5. Inspect the cone surface (E) for wear and roughness. 6. Inspect the teeth on all gears (F) for uneven wear, scoring, galling, and cracks. 7. Coat the cone surface of the gear (E) with oil, and place the synchro ring on it. Rotate the synchro ring, making sure that it does not slip.

Double Cone Synchro-to-Gear Clearance Standard: CD:Outer Synchro Ring (A) to Synchro Cone (C) 0.5 -1.0 mm (0.02 - 0.04 in.) ®:Synchro Cone (C) to Gear (B) 0.5 -1.0 mm (0.02 - 0.04 in.) ®:Outer Synchro Ring (A) to Gear (B) 0.95-1.68 mm (0.037 -0.066 in.) Service Limit: CD:0.3 mm (0.01 in.) ®:0.3 mm (0.01 in.) ®:0.6 mm (0.02 in.)

CD

L

C

~ I

I

1"-8 I

13-42

BACK

Countershaft Bearing Replacement Special Tools Required • Adjustable bearing puller, 25-40 mm 07736-A01000B • Driver 07749-0010000 • Attachment, 62 x 68 mm 07746-0010500

3. Position the oil guide plate (A) and new needle bearing (B) in the bore ofthe clutch housing (C). NOTE: Position the needle bearing with the oil holes (D) facing up.

~L~· ~~A

1. Remove the retaining plate (A) from the clutch housing (B).

~ '--.-I-=-; ~-----------4. Install the needle bearing (A) using the special tools. 2. Remove the needle bearing (A) using the special tool, then remove the oil guide plate (B).

/

07749-0010000

3/S" -16 SLIDE HAMMER (Commercially available)

07746-0010500

A

~-I--_-A

B

(cont'd)

BACK

13-43

Manual Transmission Countershaft Bearing Replacement (cont'd) 5. Install the retaining plate (AI with new bolts (BI and stake the bolt heads into the groove in the retaining plate. B 6x1.0mm 12N·m 11.2 kgf·m, S.7 Ibf.ftl

Mainshaft Bearing and Oil Seal Replacement Special Tools Required • Adjustable bearing puller, 25- 40 mm 07736-A01000B • Driver 07749-0010000 • Attachment, 42 x 47 mm 07746-0010300 • Attachment, 62 x 68 mm 07746-0010500 1. Remove the differential assembly. 2. Remove the ball bearing (AI from the clutch housing (BI using the special tool.

3/S -16 SLIDE HAMMER / ' (Commercially available) N

A

3. Remove the oil seal (el from the clutch side.

13-44

BACK

Mainshaft Thrust Clearance Adjustment 4. Drive the new oil seal (A) in from the transmission side using the special tools.

Special Tools Required • Mainshaft base 07GAJ-PG20130 • Mainshaft holder 07GAJ-PG20110 1. Remove the 78 mm shim (A) and oil guide plate (B) from the transmission housing (C).

A---..

5. Drive the new ball bearing (A) in from the transmission side using the special tools. 2. Install the 3rd/4th synchro hub (A), the spacer collar (B), the 5th synchro hub (C), the spacer (D), and ball bearing (E) on the mainshaft (F), then install the assembled mainshaft in the transmission housing (G).

H

CD

3. Install the washer (H) on the mainshaft. 4. Measure distance CD between the end of the transmission housing and washer with a straight edge and vernier caliper. Measure at three locations and average the reading.

(cont'd)

BACK

13-45

Manual Transmission Mainshaft Thrust Clearance Adjustment (cont'd) 5. Measure distance ® between the end of the clutch housing (A) and bearing inner race (B) with a straight edge and depth gauge. Measure at three locations and average the readings.

78mmSHIM

A B C D E

F G H I J K L M N

0 P Q

Shim Selection Formula:

R 6. Select the proper 78 mm shim from the chart. Follow the example below, and use the measurements you made in steps 4 and 5:

S T U

V • Add distance ® (step 5) to distance CD (step 4). • From this number, subtract 0.93 (which is the midpoint of the flex range of the clutch housing bearing spring washer). • Take this number and compare it to the available shim sizes in the chart. • Try the 1.68 mm (0.0661 in) shim.

(For example)

2.61

+®:0.22

-0.93

=

=1.68

13-46

2.61

W X

y Z AA AB AC AD AE AF AG AH AI AJ AK AL AM AN

BACK

Part Number 23941-P16-000 23942-P 16-000 23943-P16-000 23944-P16-000 23945-P16-000 23946-P16-000 23947-P16-000 23948-P16-000 23949-P16-000 23950-P16-000 23951-P16-000 23952-P16-000 23953-P16-000 23954-P16-000 23955-P16-000 23956-P16-000 23957 -P16-000 23958-P16-000 23959-P16-000 23960-P16-000 23961-P16-000 23962-P16-000 23963-P16-000 23964-P16-000 23965-P16-000 23966-P16-000 23967 -P16-000 23968-P16-000 23969-P16-000 23970-P16-000 23971-P16-000 23972-P16-000 23973-P16-000 23974-P16-000 23975-P16-000 23976-P16-000 23977 -P16-000 23978-P16-000 23979-P16-000 23980-P16-000

Thickness 1.20 mm (0.0472 in.) 1.23 mm (0.0484 in.) 1.26 mm (0.0496 in.) 1.29 mm (0.0508 in.) 1.32 mm (0.0520 in.) 1.35 mm (0.0531 in.) 1.38 mm (0.0543 in.) 1.41 mm (0.0555 in.) 1.44 mm (0.0567 in.) 1.47 mm (0.0579 in.) 1.50 mm (0.0591 in.) 1.53 mm (0.0602 in.) 1.56 mm (0.0614 in.) 1.59 mm (0.0626 in.) 1.62 mm (0.0638 in.) 1.65 mm (0.0650 in.) 1.68 mm (0.0661 in.) 1.71 mm (0.0673 in.) 1.74 mm (0.0685 in.) 1.77 mm (0.0697 in.) 1.80 mm (0.0709 in.) 1.83 mm (0.0720 in.) 1.86 mm (0.0732 in.) 1.89 mm (0.0744 in.) 1.92 mm (0.0756 in.) 1.95 mm (0.0768 in.) 1.98 mm (0.0780 in.) 2.01 mm (0.0791 in.) 2.04 mm (0.0803 in.) 2.07 mm (0.0815 in.) 2.10 mm (0.0827 in.) 2.13 mm (0.0839 in.) 2.16 mm (0.0850 in.) 2.19 mm (0.0862 in.) 2.22 mm (0.0874 in.) 2.25 mm (0.0886 in.) 2.28 mm (0.0898 in.) 2.31 mm (0.0909 in.) 2.34 mm (0.0921 in.) 2.37 mm (0.0933 in.)

7. Install the 78 mm shim (A) selected and oil guide plate (B) in the transmission housing (e). A _____

8. Throughly clean the spring washer (A) and washer (B) before installing them on the ball bearing. Note the installation direction of the spring washer.

A

07GAJ·PG20130

14. Attach the special tool to the mainshaft as follows: • Back-out the mainshaft holder bolt (A) and loosen the two hex bolts (B). • Fit the holder over the mainshaft so its lip is towards the transmission. • Align the mainshaft holder's lip around the groove at the inside of the mainshaft splines, then tighten the hex bolts.

[o~t>

9. Install the mainshaft in the clutch housing.

t

10. Place the transmission housing over the mainshaft and onto the clutch housing.

07GAJ·PG20110 07GAJ·PG20130

11. Tighten the clutch and transmission housings with several 8 mm and 10 mm bolts. NOTE: It is not necessary to use sealing agent between the housings. 12. Tap the mainshaft with a plastic hammer.

15. Seat the mainshaft fully by tapping its end with a plastic hammer. 16. Thread the mainshaft holder bolt in until it just contacts the wide surface of the mainshaft base.

(cont'd)

BACK

13-47

Manual Transmission Transmission Reassembly

Mainshaft Thrust Clearance Adjustment (co nt'd)

1. Install the differential assembly in the clutch housing. 17. Zero a dial gauge (A) on the end ofthe mainshaft. A

07GAJ-PG20110

18. Turn the mainshaft holder bolt (B) clockwise; stop turning when the dial gauge (A) has reached its maximum movement. The reading on the dial gauge is the amount of mainshaft end play.

2. Install the spring washer (A) and washer (B) over the ball bearing Ie). Note the installation direction of the spring washer

Do not turn the mainshaft holder bolt more than 60 degrees after the needle ofthe dial gauge stops moving, this may damage the transmission.

(A).

19. If the reading is within the standard, the clearance is correct. If the reading is not within the standard, recheck the shim thickness.

Standard: 0.' 0 -

o. , 6 mm 10.004 -

0.006 in.'

3. Tape the splines of the mainshaft (E) with vinyl tape to protect the seal. Insert the mainshaft and countershaft (F) into the shift forks (D), and install them as an assembly.

13-48

BACK

4. Install the reverse idler gear (AI and reverse idler gear shaft (81 in the clutch housing (CI.

6. Install the oil gutter plate in the transmission housing.

5. Install the reverse shift fork (AI in the clutch housing (81 with the 5th/reverse shift piece pin positioned in the slot of the reverse shift fork. Make sure the steel ball (CI is in the proper position. 6x 1.0mm 15N·m (1.5 kgf·m, 11lbf·ft)

A

7. Select the proper size 78 mm shim (AI according to the measurements made during the Mainshaft Thrust Clearance Adjustment (see page 13-451. Install the oil guide plate (81 and 78 mm shim into the transmission housing (CI. A_ _

c B

(cont'dl

BACK

13-49

Manual Transmission Transmission Reassembly (cont'd) 8. Remove the dirt and oil from the transmission housing sealing surface. Apply liquid gasket (PIN 08718-0001) to the sealing surface. Be sure to seal the entire circumference ofthe bolt holes to prevent oil leakage.

11. Lower the transmission housing the rest of the way as you expand the snap ring (A). Release the snap ring so it seats in the groove of the countershaft bearing.

NOTE: If 20 minutes have passed after applying liquid gasket, reapply it and assemble the housings. Allow it to cure at least 20 minutes after assembly before filling the transmission with oil.

...... : Liquid gasket

12. Check that the snap ring (A) is securely seated in the groove of the countershaft bearing. 9. Install the 14 x 20 mm dowel pins. Dimension CD as installed: 3.6-6.3 mm (0.14-0.25 in.'

10. Set the tapered cone ring (A) as shown. Place the transmission housing over the clutch housing, being careful to line up the shafts.

13. Apply liquid gasket (PIN 08718-0001) to the threads of the 32 mm sealing bolt (B), and install it on the transmission housing.

13-50

BACK

14. Install the front transmission hanger (A) and the rear transmission hanger (B), then tighten the bolts in a crisscross pattern in several steps. 8 x 1.25 mm bolts: 27 N·m (2.8 kgf.m, 20 Ibf·ft) 10 x 1.25 mm bolts: 47 N·m (4.8 kgf·m, 35Ibf·ft)

15. Install the 5/16 in steel balls (A), 26 mm (1.02 in.) length springs (B), washers (e) and setting screws (D).

16. Install the reverse idler gear shaft bolt (E) with a new washer (F). 17. Install the shift arm cover assembly (see page 1318). 18. Shift the transmission through all the gears before installing it.

BACK

13-51

Manual Transmission Gearshift Mechanism Replacement

®Remove the shift cable from the shift lever bracket. (j)Rotate the shift cable toward the opening.

SHIFT CABLE CLIP Replace.

6x1.0mm 9.S N·m (1.0 kgf·m, 7.2Ibf·ftl SHIFT LEVER KNOB S N·m (O.S kgf.m, 5.Slbf·ftl

\,

SHIfTLEVE~~ ~~

COTTER PIN /RePlace.

/~

Sx 1.~,,!,~,,.d_~ 22 N·m (2.2 kgf·m, 16lbf.ftl

(PIN 0879S-90021

,~

~COTTERPIN Replace.

(!!/

WASHER

~ SHIFT CABLE CLIP Replace.

SELECT LINK PIN ~

~

(PIN OS79S-90021

SELF-LOCKING NUT Replace.

6 x 1.0 mm 10 N·m (1.1 kgf.m, Slbf·ftl

SHIFT LEVER BRACKET FLOATING RUBBER DAMPER Inspect for wear and damage.

13-52

/

a\\®

-------, FLOATING COLLAR

:

~~""""-,-

BACK

MIT Differential Component Location Index '?-... _ _- - - - -

CLUTCH HOUSING

75mmSHIM

CARRIER BEARING Replacement, page 13-55

OIL SEAL Replacement, page 13-55

BEARING OUTER RACE

DIFFERENTIAL CARRIER Backlash Inspection, page 13-54 Replacement, page 13-54 Preload Adjustment, page 13-57

FINAL DRIVEN GEAR

THRUST SHIM Adjustment, page 13-57

CARRIER BEARING



/ l l l A N S..SSlON HOUSING

a

OIL SEAL Replacement, page 13-55

BACK

13-53

MIT Differential Backlash Inspection

Final Driven Gear/Carrier Replacement

,. Place the differential assembly on V-blocks (A), and install both axles.

1. Remove the bolts (left-hand threads) in a crisscross pattern in several steps, then remove the final driven gear from the differential carrier.

2. Measure the backlash of both pinion gears (8) with a dial indicator (e). If the backlash is not within the

standard, replace the differential carrier. Standard (New): 0.05-0.15 mm (0.002-0.006 in.)

2. Install the final driven gear with the chamfer on the inside diameter facing the carrier. Tighten the bolts in a crisscross pattern in several steps. 3. Adjust the carrier bearing preload (see page 13-57).

13-54

BACK

Carrier Bearings Replacement

Oil Seal Replacement

Special Tool Required


Bearing attachment 07LAD-PW50601

• Driver 07749-0010000 • Driver attachment 07GAD-PG40100 • Pilot, 28 x 30 mm 07JAD-PH80400 • Driver attachment 07JAD-PH80101

1. Check the carrier bearings for wear and rough rotation. If they rotate smoothly and their rollers show no signs of wear, the beaings are OK.

1. Remove the differential assembly. 2. Remove the cariier bearing (A) with a commercially-available bearing puller (B) and bearing separator (C).

2. Remove the oil seal (A) from the transmission housing (B).

A

B

3. Install the new bearings (A) with the special tool and a press. Press each bearing on until it bottoms. There should be no clearance between the bearings and the carrier.

3. Remove the oil seal (A) from the clutch housing (B). B

A

4. Inspect the bearing preload (see page 13-57).

(cont'd)

BACK

13-55

MIT Differential Oil Seal Replacement (cont'd) 5. Install the new oil seal (A) in the clutch housing (B) with the special tools.

4. Install the new oil seal (A) in the transmission housing (B) with the special tools.

07GAD·PG40100

A 07JAD·PH80400

13-56

BACK

Carrier Bearing Outer Race Replacement and Preload Adjustment 3. If you replaced the carrier bearing on the clutch housing side of the carrier, remove and discard the beaing outer race, Heat up the clutch housing to about 212°F (100°C) with a heat gun (A), then remove the outer race (B) and the 75 mm shim(C). Do not heat the housing in excess of 212°F (100°C).

Special Tools Required • Driver 07749-0010000 • Attachment, 52 x 55 mm 07746-0010400 • Attachment, 62 x 68 mm 07746-0010500 • Attachment, 72 x 75 mm 07746-0010600 If any of the items listed below were replaced, the carrier bearing preload must be adjusted. • • • •

Transmission housing Clutch housing Differential carrier Carrier bearing and outer race 1. Remove the oil seals from the transmission housing and clutch housing (see page 13-55).

Thrust Shim Replacemnet (Transmission Housing) 2. Drive the bearing outer race (A) and thrust shim (B) out of the transmission housing (C). Do not reuse the thrust shim. If you replaced the carrier bearing on the transmission housing side ofthe carrier, discard the outer race. 07749-0010000

B

4. Select a new thrust shim that's the same size as the one you removed, and use the special tools to install it (A) and the bearing outer race (8) in the transmission housing. (Use a new race if you replaced the bearing.) There should be no space between the race, shim, and housing. 07749-0010000

07746·0010400

B 07746·0010500

B

A

A

(cont'd)

BACK

13-57

MIT Differential Carrier Bearing Outer Race Replacement and Preload Adjustment (cont'd) 5. If you removed the bearing outer race from the clutch housing, use the specail tools to install a new one (A) along with the 75 mm shim (B). There should be no space between the race, shim, and housing.

8. At normal room temperature, measure the starting torque of the differential assembly by rotating it in both directions with the special tool and a torque wrench (A). STANDARD: 1.4-2.5 N·m (14-26 kgf·cm, 12-23 Ibf·in.)

07749-0010000

07HAJ-PK40201

B 6. With the mainshaft and countershaft removed, install the differential assembly, bolt the transmission and clutch housing together, and torque the 10 mm bolts to 47 N·m (4.8 kgf·m, 35 Ibf·ft) and the 8 mm bolts to 27 N·m (2.8 kgf·m, 20 Ibf·ft).

9. Ifthe carrier bearing preload is not within the standard, select a thrust shim that will provide the correct preload:

7. Rotate the differential assembly in both directions to seat the tapered roller bearings.

• Compare the bearing preload you got on the first try with the specified preload of 1.4 - 2.5 N·m (14 - 26 kgf·cm, 12 - 23Ibf·in). • If the preload you measure was less than specified, subtract it from the specified preload. • If the preload you measure was more than specified, subtract it from the specified preload. For example, with a 2.17 mm (0.0854 in.) thrust shim:

CD specified - you got less

® you got more - specified

2.5 N·m (26 kgf·cm, 23 Ibf·in.) 0.6 N·m (6 kgf·cm, 5 Ibf·in.) 1.9 N·m (20 kgf·cm, 18Ibf·in.) less 3.3 N·m (34 kgf·cm, 30 Ibf·in.) 2.5 N·m (26 kgf·cm, 23 Ibf·in.) 0.8 N·m (8 kgf·cm, 7 Ibf·in.) more

NOTE: Each shim size up or down from standard makes about 0.3-0.4 N·m (3-4 kgf·cm, 2.6-3.5 Ibf·in.) difference in preload. In example CD, your preload was 1.9 N·m (20 kgf·cm, 18 Ibf·in.) less than standard, so you need a thrust shim five sizes thicker than standard (try the 2.32 mm (0.0913 in.) thrust shim, and recheck).

13-58

BACK

In example ®, your preload was 0.8 N·m (8 kgf·cm, 7 Ibf·in.) more than standard, so you need a thrust shim two sizes thinner (try the 2.11 mm (0.0831 in.) thrust shim, and recheck). THRUST SHIM

Part Number

A B C D E F G H I

J K L

M N

0 P Q R

S T AA

AB AC AD AE AF AG AH

41381-PX5-000 41382-PX5-000 41383-PX5-000 41384-PX5-000 41385-PX5-000 41386-PX5-000 41387 -PX5-000 41388-PX5-000 41389-PX5-000 41390-PX5-000 41391-PX5-000 41392-PX5-000 41393-PX5-000 41394-PX5-000 41395-PX5-000 41396-PX5-000 41397 -PX5-000 41398-PX5-000 41399-PX5-000 41400-PX5-000 41873-P16-000 41874-P16-000 41875-P16-000 41876-P16-000 41877 -P 16-000 41878-P16-000 41879-P16-000 41880-P 16-000

Thickness 1.90 mm (0.0748 in.) 1.93 mm (0.0760 in.) 1.96 mm (0.0772 in.) 1.99 mm (0.0783 in.) 2.02 mm (0.0795 in.) 2.05 mm (0.0807 in.) 2.08 mm (0.0819 in.) 2.11 mm (0.0831 in.) 2.14 mm (0.0843 in.) 2.17 mm (0.0854 in.) 2.20 mm (0.0866 in.) 2.23 mm (0.0878 in.) 2.26 mm (0.0890 in.) 2.29 mm (0.0902 in.) 2.32 mm (0.0913 in.) 2.35 mm (0.0925 in.) 2.38 mm (0.0937 in.) 2.41 mm (0.0949 in.) 2.44 mm (0.0961 in.) 2.47 mm (0.0972 in.) 1.66 mm (0.0654 in.) 1.69 mm (0.0665 in.) 1.72 mm (0.0677 in.) 1.75 mm (0.0689 in.) 1.78 mm (0.0701 in.) 1.81 mm (0.0713 in.) 1.84 mm (0.0724 in.) 1.87 mm (0.0736 in.)

10. Once the carrier bearing preload is correct, install new oil seals in the differential (see page 13-55). 11. Reinstall the transmission.

BACK

13-59

BACK

Automatic Transmission Transmission End Cover

Automatic Transmission Special Tools ................................................... 14-2 General Troubleshooting Information ......... 14-3 DTC Troubleshooting Index ............................ 14-7 Symptom Troubleshooting Index ...............•. 14-8 System Description .......................••............... 14-18 DTC Troubleshooting ..................................... 14-64 ~ Indicator Circuit Troubleshooting ....•................................•... 14-93 Interlock System Troubleshooting Shift Lock System Circuit ..•...........•............ 14-96 Key Interlock System Circuit ...................... 14-99 Road Test ........................................................ 14-101 Stall Speed Test .............................................. 14-103 Pressure Tests ...••................................•.......•.. 14-104 Torque Converter Clutch Solenoid Valve Test ......•••.................•.....•... 14-106 Torque Converter Clutch Solenoid Valve Replacement ..................... 14-106 Shift Solenoid Valves Band C Test ............... 14-107 Shift Solenoid Valves Band C Replacement ............................................... 14-107 AfT Clutch Pressure Control Solenoid Valves A and B Test .................................... 14-108 AfT Clutch Pressure Control Solenoid Valves A and B Replacement ..................... 14-109 Speed Sensor Replacement .......................... 14-109 2nd Clutch Pressure Switch ('98-00 Models) Replacement .................... 14-110 2nd Clutch Pressure Switch ('01-02 Models) Replacement .................... 14-111 3rd Clutch Pressure Switch Replacement .......... ....... .............................. 14-112 ATF Level Check ............................................. 14-113 ATF Replacement ........................................... 14-113 Transmission Removal .................................. 14-114 Transmission Installation .............................. 14-119 ATF Cooler Flushing ....................................... 14-125 ATF Cooler Hoses Replacement ................... 14-126 Shift Lever Removal ....................................... 14-127 Shift Lever Installation ................................... 14-128 Shift Lever Disassembly/Reassembly .......... 14-130 Shift Cable Replacement ............................... 14-131 Shift Cable Adjustment .................................. 14-134

AfT Gear Position Indicator Component Location Index ........................... Circuit Diagram ............................................... Transmission Range Switch Test ................. Transmission Range Switch Replacement ............................................... Indicator Input Test ........................................ Indicator Bulb Replacement ..........................

14-136 14-137 14-138 14-139 14-141 14-142

Transmission Housing Housing and Shaft Assemblies Removal .... . 14-153 Bearing Replacement ..................................... 14-155 Shaft Assemblies and Housing Installation ................................................... 14-192

Valve Body Valve Bodies and ATF Strainer Removal .... . Valve Body Repair .......................................... Valve Body Valve Installation ....................... . Main Valve Body Disassembly, Inspection, and Reassembly ..................... . ATF Pump Inspection ..................................... Regulator Valve Body Disassembly, Inspection, and Reassembly ................... .. Servo Body Disassembly, Inspection, and Reassembly ......................................... Accumulator Body Disassembly, Inspection, and Reassembly ..................... . Valve Bodies and ATF Strainer Installation ...................................................

14-156 14-158 14-159 14-160 14-162 14-163 14-164 14-165 14-189

Torque Converter Housing Mainshaft Bearing/Oil Seal Replacement ............................................... 14-166 Countershaft Bearing Replacement ............. 14-167 14-167 Secondary Shaft Bearing Replacement

Shafts and Clutches Mainshaft Disassembly, Inspection, and Reassembly ......................................... 3rd/4th Clutch Clearance Inspection ............. Mainshaft Sealing Rings Replacement ........ Countershaft Disassembly, Inspection, and Reassembly ...................... Countershaft Reverse Selector Hub, 3rd Gear, and 1st Gear Replacement ........ Countershaft Bearing Hub/Bearing Replacement ............................................... Secondary Shaft Disassembly, Inspection, and Reassembly ......................................... Secondary Shaft Clearance Inspection ........ Secondary Shaft Idler Gear Bearing Replacement ............................................... Clutch Disassembly ........................................ Clutch Inspection ............................................ Clutch Reassembly .........................................

14-168 14-169 14-170 14-171 14-172 14-174 14-175 14-176 14-178 14-179 14-182 14-184

AfT Differential

AfT Interlock System Component Location Index ........................... Circuit Diagram ............................................... Control Unit Input Test ................................... Key Interlock Solenoid/Switch Test .............. Shift Lock Solenoid Test ................................ Shift Lock Solenoid Replacement ................. Park Pin Switch Test .......................................

14-149 End Cover and Idler Gears Removal Park Lever Stop Inspection and Adjustment .................................................. 14-152 End Cover and Idler Gears Installation ....... .. 14-194

14-143 14-144 14-145 14-147 14-147 14-148 14-148

Component Location Index ........................... Backlash Inspection ........................................ Final Driven Gear/Carrier Replacement ............................................... Carrier Bearing Replacement ........................ Oil Seal Replacement ..................................... Carrier Bearing Outer Race Replacement ............................................... Carrier Bearing Preload Inspection ...............

BACK

14-200 14-201 14-201 14-202 14-203 14-204 14-205

Automatic Transmission Special Tools Tool Number Descr~tion 07GAB-PF50101 or 07GAB-PF50100 Mainshaft Holder 07GAD-PG40101 or 07GAD-PG40100 Seal Driver Attachment 07GAD-SD40101 Attachment, 78 x 90 mm ® G) 07GAE-PG40200 or 07GAE-PG4020A Clutch Spring Compressor Bolt Assembly 07HAC-PK40102 Housing Puller *® 07HAD-SF10100 Driver Attachment ® (f) 07HAJ-PK40201 Preload Inspection Tool 07JAD-PH80101 Driver Attachment ® 07 JAD-PH80400 Pilot, 28 x 30 mm ® @) 07LAD-PW50601 Attachment, 40 x 50 mm 07LAE-PX40100 Clutch Spring Compressor Attachment **@ @ 07MAJ-PY4011A AfT Pressure Hose, 2,210 mm @ 07MAJ-PY40120 AfT Pressure Hose Adapter @ 07SAZ-001000A Backprobe Set @ 07ZAE-PRP0100 Clutch Compressor Attachment @ 07406-0020400 AfT Oil Pressure Gauge Set w/Panel 07736-A01000B or 07736-A01000A Adjustable Bearing Puller, 25-40 mm ***® @ 077 46-00 10300 Attachment, 42 x 47 mm @ 077 46-0010500 Attachment, 62 x 68 mm @ 077 46-00 10600 Attachment, 72 x 75 mm 077 46-0030100 Driver 40 mm I.D. ® @ 077 49-0010000 Driver 07947 -6340500 Driver Attachment ®l 07949-3710001 Driver ® * If the top arm IS too short, replace It with 07SAC-POZ01001. ** 07HAE-PL501 01 may be used to substitute one of these tools. *** Must be used with commercially available 3/8"-16 slide hammer. Ref.No.

Qty

CD ®

1 1 1 1 1 1 1 1 1 1 2 4 4 2 1 1 1 1 1 1 1 1 1 1

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BACK

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General Troubleshooting Information How to Check for DTCs with the PGM Tester IScan Tool When the PCM senses an abnormality in the input or output systems, the ~ indicator in the gauge assembly will blink. When the 16P Data Link Connector (DLC) (located next to the driver's side kick panel) is connected to the OBD II Scan Tool or Honda PGM Tester as shown, the scan tool or tester will indicate the Diagnostic Trouble Code (DTC) when the ignition switch is turned ON (II). HONDA PGM TESTER or OBD II SCAN TOOL

/ DATA LINK CONNECTOR (16PI

Ifthe ~ indicator or the MIL has been reported on, or if a driveability problem is suspected, follow this procedure: 1. Connect the OBD II Scan Tool (conforming to SAE J1978) or Honda PGM Tester to the 16P DLC. (See the OBD II Scan Tool or Honda PGM Tester user's manual for specific instructions. If you are using the Honda PGM Tester, make sure it is set to the SAE DTC type.) 2. Turn the ignition switch ON (II), and observe the DTC on the screen. 3. Record all fuel and emission DTCs, AfT DTCs, and freeze data. 4. If there is a fuel and emissions DTC, first check the fuel and emissions system as indicated by the DTC (except for DTC P0700). DTC P0700 means there is one or more AfT DTC, and no problems were detected in the fuel and emissions circuit ofthe PCM. 5. Get the anti-theft code for the radio, then write down the radio station presets. 6. Reset the memory with the PGM Tester or by removing the BACK UP fuse in the passenger's under-dash fuse/ relay box for more than 10 seconds. 7. Drive the vehicle for several minutes under the same conditions as those indicated by the freeze data, and then recheck for DTCs.lfthe AfT DTC returns, go to the DTC Troubleshooting Index on page 14-7. Ifthe DTC does not return, there was an intermittent problem within the circuit. Make sure all pins and terminals in the circuit are tight, and then go to step 8. 8. Enter the anti-theft code for the radio, reset the radio preset stations, and set the clock. (cont'd)

BACK

14-3

Automatic Transmission General Troubleshooting Information (cont'd) How to Check for DTCs When the PCM senses an abnormality in the input or output systems, the ~ indicator in the gauge assembly will usually blink and/or the Malfunction Indicator Lamp (MIL) may come on. When the Data Link Connector (DLC) (located next to the driver's side kick panel) is connected to the Honda PGM Tester, the ~ indicator will blink the Diagnostic Trouble Code (DTC) when the ignition switch is turned ON (II). When the ~ indicator has been reported on, connect the Honda PGM Tester to the DLC. Turn the ignition switch ON (II), select Honda Systems, and then the SCS mode, then observe the ~ indicator.

~INDICATOR

Codes 1 through 9 are indicated by individual short blinks. Codes 10 and above are indicated by a series of long and short blinks. One long blink equals 10 short blinks. Add the long and short blinks together to determine the code. After determining the code, refer to the DTC Troubleshooting Index.

Short blink (oncel

OFF~~·----------------------------~fl~-------------------------seeDTC1 OFF~~------------------------~rtJl~----------------------seeDTC2 Long blink

O~~·

Short blinks (five timesl

lfuiiUiJl'------l

U1J1J1IlJL

See DTC15

If the ~ indicator or the MIL has been reported on, or if a driveability problem, follow this procedure: 1. Record all fuel/emissions DTCs, AfT DTCs, and freeze data. 2. If there is a fuel and emissions DTC, first check the fuel and emissions system as indicated by the DTC (except for DTC P0700), DTC P0700 means there is one or more AfT DTC, and no problems were detected in the fuel and emissions circuit of the PCM. 3. Get the customer's radio anti-theft code, and write down the numbers of the radio station presets. 4. Reset the memory by removing the BACK UP fuse in the passenger's under-dash fuse/relay box for more than 10 seconds. 5. Drive the vehicle for several minutes under the same conditions as those indicated by the freeze data, and then recheck for DTCs. If the DTC returns, refer to the DTC Troubleshooting Index. If the DTC does no return, there was an intermittent problem within the circuit. Make sure all pins and terminals in the circuit are tight, then go to step 6. 6. Enter the radio code, reset the preset stations, and reset the clock.

14-4

BACK

How to Troubleshoot Circuits at the PCM Special Tools Required

Backprobe set 07SAZ-001000A (two required) SRS components are located in this area. Review the SRS components locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-28). 1. Pull back the carpet from the passenger's side of the center console to expose the PCM. 2. Inspect the circuit on the PCM, according to the DTC troubleshooting, with the special tools and a digital multi meter. 3. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a multi meter (C). Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it comes in contact with the terminal end of the wire. C

07SAZ-001000A

(cont'd)

BACK

14-5

Automatic Transmission General Troubleshooting Information (cont'd) How to Reset the PCM 1. Make sure you have the anti-theft code for the radio, then write down the radio station presets. 2. Turn the ignition switch OFF. 3. Use one of these methods to reset the PCM memory: • Use the OBO II Scan Tool or the Honda PGM Tester. • Remove the BACK UP fuse (7.5 A)(A) from the passenger's under-dash fuse/relay box (B) for 10 seconds. A

B

How to End a Troubleshooting Session This procedure must be done after any troubleshooting. 1. Turn the ignition switch OFF. 2. Disconnect the OBO II Scan Tool or Honda PGM Tester from the OLC. 3. Reset the PCM. 4. Turn the ignition switch ON (II). 5. Enter the radio code, reset the preset stations, and set the clock. 6. To verify that the problem is repaired, test-drive the vihicle for several minuites at speeds over 30 mph (48km/h).

14-6

BACK

DTC Troubleshooting Index NOTE: Record all freeze data before you troubleshoot. DTC*

~ Indicator

MIL

Detection Item

Page

~: J P0715 (15)

Blinks

ON

Mainshaft speed sensor

(see page 14-76)

P0720 (9)

Blinks

ON

Countershaft speed sensor

(see page 14-75)

P0730 (41)

OFF

ON

Shift control system

(see page 14-89)

P0740(40)

OFF

ON

Lock-up control system

(see page 14-88)

P0753 (7)

Blinks

ON

Shift solenoid valve A

(see page 14-71)

P0758 (8)

Blinks

ON

Shift solenoid valve B

(see page 14-73)

P0763 (22)

Blinks

ON

Shift solenoid valve C

(see page 14-80)

P0780 (45)

Blinks

ON

Mechanical problem in hydraulic system

(see page 14-90)

P1705 (5)

Blinks

ON

Transmission range switch (short to ground)

(see page 14-66)

P1706 (6)

OFF

ON

Transmission range switch (open)

(see page 14-69)

P1738 (25)

OFF

OFF

2nd clutch pressure switch

(see page 14-84)

P1739 (26)

OFF

OFF

3rd clutch pressure switch

(see page 14-86)

P1750 (46)

Blinks

ON


(see page 14-91)

P1751 (47)

Blinks

ON


(see page 14-92)

P1753 (1)

Blinks

ON

Torque converter clutch solenoid valve

(see page 14-64)

P1768 (16)

Blinks

ON

AfT clutch pressure control solenoid valve A

(see page 14-78)

Pl773 (23)

Blinks

ON

AfT clutch pressure control solenoid valve B

(see page 14-82)

The DTC in the parentheses is the flash code the ~ indicator indicates when the Data Link Connector (DLC) is connected to the Honda PGM Tester. NOTE: Codes P0780 (45), P1750 (46), and P1751 (47) are applied to the '00-02 models.

BACK

14-7

Automatic Transmission Symptom Troubleshooting Index These symptoms DO NOT trigger Diagnostic Trouble Codes (OTCs) or cause the ~ indicator to blink. If the Malfunction Indicator Lamp (MIL) was reported ON or the ~ indicator has been blinking, check for OTCs. But if the vehicle has one of the symptoms in the following chart, check the probable cause(s) for it, in the sequence listed, until you find the problem.

Symptom

Probable cause(s) ~

Notes

indicator

Check the

~ indicator circuit

(see page 14-93).

When you turn the ignition switch ON (II), the ~indicator comes on and stays on or never comes on at all

A problem in the circuit

Shift lever cannot be moved from [f] position while you're pushing on the brake pedal

A problem in shift lock system of interlock system.

Check interlock system -shift lock system circuit (see page 14-96).

Ignition key cannot be moved from ACC (I) position to LOCK (0) position while you're pushing the ignition key with the shift lever in [f] position

A problem in key interlock system of interlock system

Check interlock system - key interlock system circuit (see page 14-99).

14-8

BACK

Probable cause(s)

Symptom Engine runs, but vehicle does not move in any gear

1. 2.

3. 4.

5. 6. 7.

8. 9. 10.

Vehicle moves in III and lID, but not in ~, ~, or ill position

1. 2.

3.

Notes

Low ATF level Shift cable broken or out of adjustment Joint in shift cable and transmission or body worn ATF pump worn or binding Regulator valve stuck or spring worn ATF strainer clogged Mainshaft worn or damaged Final gears worn or damaged Transmission-to-engine assembly error Axle disengaged

• Check ATF level and check ATF cooler lines for leakage and loose connections. If necessary, flush ATF cooler lines. • Check for a loose shift cable at the shift lever and the transmission control shaft. • Improper alignment of ATF pump and torque converter housing may cause ATF pump seizure. The symptoms are mostly an rpm-related ticking noise or a high pitched squeak. • Measure line pressure. • Ifthe strainer is clogged, find the damaged components that caused debris. • Inspect the differential pinion gear for wear. If the differential pinion gears are worn, replace the differential assembly, replace the ATF strainer, thoroughly clean the transmission, and flush the torque converter, cooler, and lines. • Be careful not to damage the torque converter housing when replacing the main ball bearing. You may also damage the ATF pump when you torque down the main valve body. This will result in ATF pump seizure if not detected. Use the proper tools. • Install the main seal flush with the torque converter housing. If you push it into the torque converter housing until it bottoms out, it will block the fluid return passage and result in damage.

1st accumulator defective 1st gears worn or damaged 1st clutch defective

• Inspect 1st clutch pressure. • Inspectthe secondary shaft and 1st/2nd clutch assembly for wear and damage. • Inspect the clutch piston and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

(cont'd)

BACK

14-9

Automatic Transmission Symptom Troubleshooting Index (cont'd) Probable cause(s)

Symptom Vehicle moves in ~, ~, ill, IR), but not in III position

1. 2.

3. 4.

5.

~,~,III,[!],but

1. 2.

not in IR) position

3.

Vehicle moves in

4.

5. 6.

14-10

Notes

Shift solenoid valve A defective Shift valve A defective 2nd accumulator defective 2nd gears worn or damaged 2nd clutch defective

• Check the III indicator indication, and check for loose connectors. Inspect the O-rings, and check the shift solenoid valve for seizure. • Inspectthe secondary shaft and 1st/2nd clutch assembly for wear and damage. • Inspect the clutch piston and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

Shift fork shaft stuck Modulator valve defective Reverse CPC valve defective 4th accumulator defective 4th clutch defective Reverse gears worn or damaged

• Measure line pressure and 4th clutch pressure. • Check for a missing shift fork bolt on the shift fork shaft. • If the ATF strainer is clogged with particles of steel or aluminum, inspectthe ATF pump.lfthe ATF pump is OK, and no cause for the contamination is found, replace the torque converter. • Inspect the reverse selector gear teeth chamfers, and inspect engagement teeth chamfers of the counters haft 4th gear and reverse gear. Replace the reverse gears and the reverse selector if they are worn or damaged. If the transmission makes clicking, grinding, or whirring noises, also replace the mainshaft 4th gear, reverse idler gear, and countershaft 4th gear. • Ifthe 4th clutch feed pipe guide in the end cover is scored by the mainshaft, inspect the ball bearing for excessive movement in the transmission housing. If the ball bearing is OK, replace the end cover as it is dented. The O-ring under the guide is probably worn. • Replace the mainshaft if the bushing for the 3rd and 4th clutch feed pipes are loose or damaged. If the 4th clutch feed pipe is damaged or out of round, replace the end cover. • Inspect the clutch piston, clutch piston check valve, and O-rings. Check the spring retainer for wear and damage. Inspectthe clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clearance with the clutch end plate.

BACK

Probable cause(s)

Symptom

Poor acceleration; flares on starting

1. 2.

offin~and~

positions: Stall speed high in ~, ~, [lJ, and II) positions

3. 4.

5.

6.

Poor acceleration; flares on starting off in ~ and ~ positions: Stall speed high in ~,~,and II) positions

Poor acceleration; flares on starting off in [lJ position: Stall speed high in [lJ position

Poor acceleration; flares on starting off in [RJ position: Stall speed is in specification in ~, ~, [lJ, and II) positions, but high in [RJ position

1. 2.

1. 2.

Notes

Low ATF level Shift cable broken or out of adjustment ATF pump worn or binding Regulator valve stuck or spring worn ATF strainer clogged Torque converter check valve defective

• Check ATF level and check ATF cooler lines for leakage and loose connections. If necessary, flush ATF cooler lines. • Check for a loose shift cable at the shift lever and the transmission control shaft. • Check line pressure. • Improper alignment of ATF pump and torque converter housing may cause ATF pump seizure. The symptoms are mostly an rpm-ticking noise or a high pitched squeak. • Be careful not to damage the torque converter housing when replacing the main ball bearing. You may also damage the ATF pump when you torque down the main valve body. This will result in ATF pump seizure if not detected. Use the proper tools.

Shift cable broken or out of adjustment 1st cI utch defective

• Check for a loose shift cable at the shift lever and the transmission control shaft. • Check 1st clutch pressure. • Inspect the clutch piston and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

Shift cable broken or out of adjustment 2nd clutch defective

• Check for a loose shift cable at the shift lever and the transmission control shaft. • Check 2nd clutch pressure. • Inspect the clutch piston and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. Ifthey are OK, adjust the clutch end plate clearance.

4th clutch defective

• Check 4th clutch pressure. • Inspect the clutch piston, clutch piston check valve, and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

(cont'd)

BACK

14-11

Automatic Transmission Symptom Troubleshooting Index (cont'd) Symptom

Probable cause(s)

Notes

.- Poor acceleration; Stall speed low

1. Torque converter clutch solenoid valve defective 2. Torque converter one-way clutch defective 3. Engine output low 4. Lock-up clutch piston defective 5. Lock-up shift valve defective 6. Restricted cooler

Check ATF cooling system for restriction.

Engine idle vibration

1. Low ATF level 2. Torque converter clutch solenoid valve defective 3. Drive plate defective or transmission misassembled 4. Engine output low 5. Lock-up clutch piston defective 6. ATF pump worn or binding 7. Lock-up shift valve defective 8. Restricted cooler

• Set idle rpm in gear to the specified idle speed. If still no good, adjust the engine mounts as outlined in the engine section ofthis service manual. • Check ATF level and check ATF cooler lines for leakage and loose connections. If necessary, flush ATF cooler lines. • Check ATF cooling system for restriction.

Vehicle moves in IHl position

1. 2.

• Check ATF level and check ATF cooler lines for leakage and loose connections. If necessary, flush ATF cooler lines. • Inspectthe clutch piston, clutch piston check valve, and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-ta-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance. • Check for clutch pressure in neutral.

3. 4.

5. 6.

7. 8. 9.

14-12

Excessive ATF Foreign material in separator plate orifice 1st clutch defective 2nd clutch defective 3rd clutch defective 4th clutch defective Clutch clearance incorrect Needle bearing seized up, worn or damaged Thrust washer seized up, worn, or damaged

BACK

Symptom

Probable cause(s) ._._--_.._------ -_.-1. Shift solenoid valve C defective 2. AfT clutch pressure control solenoid valves A and B defective 3. Shift cable broken or out of adjustment 4. Joint in shift cable and transmission or body worn s. Shift fork shaft stuck 6. CPC valve A stuck 7. Foreign material in separator plate orifice 8. Shift valve C defective 9. Servo control valve defective 10. 1st accumulator defective 11. 1st check ball stuck 12. 1st clutch defective

Notes

-

Late shift from rID position to ~ and ~ positions

• Check the ~ indicator indication, and check for loose connectors. Inspect the O-ring, and check the shift solenoid valve for seizure. • Inspect the AfT clutch pressure control solenoid valve body gasket and ATF feed pipes for wear and damage. If the AfT clutch pressure control solenoid valve is stuck, inspect the CPC valves. • Check for a loose shift cable at the shift lever and the transmission control shaft. • If the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump. If the ATF pump is OK, and no cause for the contamination is found, replace the torque converter. • Check 1st clutch pressure. • Inspect the clutch piston, clutch piston check valve, and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance. -

Late shift from position to [HJ position

rID

1. 2.

3. 4.

s. 6. 7.

8. 9.

Shift solenoid valve C defective AfT clutch pressure control solenoid valves A and B defective Shift cable broken or out of adjustment Joint in shift cable and transmission or body worn Shift fork shaft stuck Foreign material in separator plate orifice Reverse CPC valve defective 4th accumulator defective 4th clutch defective

• Check the ~ indicator indication, and check for loose connectors. Inspect the O-ring, and check the shift solenoid valve for seizure. • Inspect the AfT clutch pressure control solenoid valve body gasket and ATF feed pipes for wear and damage. If the AfT clutch pressure control solenoid valve is stuck, inspect the CPC valves. • Check for a loose shift cable at the shift lever and the transmission control shaft. • If the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump. If the ATF pump is OK, and no cause for the contamination is found, replace the torque converter. • Check 4th clutch pressure. • Inspect the clutch piston, clutch piston check valve, and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn and damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

(cont'd)

BACK

14-13


Probable cause(s)

Notes ---

No shift Erratic shifting gears: Fails to shift in ~ position; does not upshift to 4th

Modulator valve defective 1. 2. 3. 4.

5. Erratic shifting gears: Fails to shift in ~ and IR!I positions; does not upshift to 3rd and 4th Erratic shifting gears: Fails to shift in ~, ~ and [j] positions; starts off in3rd Excessive shock, or flares on all upshifts and downshifts

Excessive shock or flares on 1-2 upshift or 2-1 downshift

14-14

Measure line pressure.

Shift solenoid valve A defective Mainshaft speed sensor defective Countershaft speed sensor defective Shift valve A defective Shift valve 0 defective

--• Inspect the O-ring, and check the shift solenoid valve for seizure. • Check the ~ indicator indication, and check for loose connectors. Inspect the transmission range switch. If the transmission range switch is faulty, replace it. If the transmission range switch is out of adjustment, adjust it and the shift cable.

Shift solenoid valve B defective Shift fork shaft stuck Shift valve B defective Servo control valve defective

• Check the ~ indicator indication, and check for loose connectors. Inspect the O-ring, and check the shift solenoid valve for seizure. • Check for a missing shift fork bolt on the shift fork shaft.

Shift solenoid valve B defective Shift valve B defective Shift valve E defective

Check the ~ indicator indication, and check for loose connectors. Inspect the O-ring, and check the shift solenoid valve for seizure.

1. AfT clutch pressure control solenoid valves A and B defective 2. CPC valve A defective 3. CPC valve B defective 4. Foreign material in separator plate orifice

• Check the ~ indicator indication, and check for loose connectors. Inspect the AfT clutch pressure control solenoid valve body gasket and ATF feed pipes for wear and damage. If the AfT clutch pressure control solenoid valve is stuck, inspect the CPC valves. • If the ATF strainer is clogged with particles of steel or aluminum, inspectthe ATF pump. Ifthe ATF pump is OK, and no cause for the contamination is found, replace the torque converter.

1. 2. 3. 4.

1. 2. 3.

1. Shift solenoid valve C defective 2. 2nd clutch pressure switch defective 3. Foreign material in separator plate orifice 4. Shift valve C defective 5. 1st accumulator defective 6. 2nd accumulator defective 7. 1st check ball stuck 8. 2nd check ball stuck 9. 1st clutch defective 10. 2nd clutch defective

• Check the ~ indicator indication, and check for loose connectors. Inspect the O-rings, and check the shift solenoid valve for seizure. Check that the outlet is not clogged inside of the 2nd clutch pressure switch connector. • Check 1st and 2nd clutch pressures. • Inspect the clutch piston and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. Ifthe clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

BACK

Probable cause(s)

Symptom Excessive shock, or flares on 2-3 upshift or 3-2 downshift

1. 2. 3. 4. 5.

6.

7. 8. 9.

Excessive shock, or flares on 3-4 upshift or 4-3 downshift

1. 2. 3. 4. 5.

6.

7.

Noise from transmission in all shift lever positions

Vehicle does not accelerate more than 31 mph (50 km/h)

1. 2.

Notes

Shift solenoid valve C defective 3rd clutch pressure switch defective Foreign material in separator plate orifice Shift valve C defective 2nd accumulator defective 3rd accumulator defective 2nd check ball stuck 2nd clutch defective 3rd clutch defective

• Check the ~ indicator indication, and check for loose connectors. Inspect the O-rings, and check the shift solenoid valve for seizure. Check that the outlet is not clogged inside of the 3rd clutch pressure switch connector. • Check 2nd and 3rd clutch pressures. • Inspect the clutch piston, clutch piston check valve, and O-rings. Check the spring retainer for wear and damage. Inspectthe clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

Shift solenoid valve C defective Foreign material in separator plate orifice Shift valve C defective 3rd accumulator defective 4th accumulator defective 3rd clutch defective 4th clutch defective

• Check the ~ indicator indication, and check for loose connectors. Inspect the O-rings, and check the shift solenoid valve for seizure. • Check 3rd and 4th clutch pressures. • If the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump. Ifthe ATF pump is OK, and no cause for the contamination is found, replace the torque converter, and check the stall speed. • Inspect the clutch piston, clutch piston check valve, and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

ATF pump worn or binding Torque converter housing or transmission housing bearing worn or damaged

• Improper alignment of ATF pump and torque converter housing may cause ATF pump seizure. The symptoms are mostly an rpm-ticking noise or a high pitched squeak. • Inspect the contact of the countershaft and secondary shaft with the bearings. Check the ATF guide plates for damage and wear. Inspect the 1st clutch feed pipe for damage and out of round. Ifthe 1st clutch feed pipe is damaged or out of round, replace it. Replace the seconda ry shaft if the bushi ng for the 1st cI utch feed pipe is damaged or out of round.

Torque converter one-way clutch defective

Replace torque converter.

(cont'd)

BACK

14-15


Symptom Vibration in all shift lever positions

Shift lever does not operate smoothly

Transmission does not shift into ~ position

Lock-up clutch does not disengage

Drive plate defective or transmission misassembled

• Set idle rpm in gear to the specified idle speed. If still no good, adjust the engine mounts as outlined in the engine section of the service manual. • Check the stall speed.

1. AfT gear position switch defective or out of adjustment 2. Shift cable broken or out of adjustment 3. Joint in shift cable and transmission or body worn

1. Shift cable broken or out of adjustment 2. Joint in shift cable and transmission or body worn 3. Park mechanism defective

1. Torque converter clutch 2.

3. 4.

5. 6.

7.

14-16

Notes

solenoid valve defective AfT clutch pressure control solenoid valves A and B defective Lock-up clutch piston defective Lock-up shift valve defective Lock-up control valve defective Lock-up timing valve defective Restricted cooler

• Check the ~ indicator indication, and check for loose connectors. Inspect the transmission range switch. If the transmission range switch is faulty, replace it. Ifthe transmission range switch is out of adjustment, adjust it and the shift cable. • Check for a loose shift cable at the shift lever and the transmission control shaft. • Check for a loose shift cable at the shift lever and the transmission control shaft. • Check the park pawl spring installation and the park lever spring installation. If installation is incorrect, install the spring correctly. Make sure that the park lever stop is not installed upside down. Check the distance between the park pawl and the park lever roller pin. If the distance is out of tolerance, adjust the distance with the park lever stop. • Check the ~ indicator indication, and check for loose connectors. Inspect the AfT clutch pressure control solenoid valve body gasket and ATF feed pipes for wear and damage. If the AfT clutch pressure control solenoid valve is stuck, inspect the CPC valves. • Check ATF cooling system for restriction.

BACK

Lock-up clutch does not operate smoothly

1. Torque converter clutch 2. 3. 4.

5. 6.

7. Lock-up clutch does not engage

3. 4.

5. 6.

7. 8.

indicator does not indicate shift lever positions

solenoid valve defective AfT clutch pressure control solenoid valves A and B defective Mainshaft speed sensor defective Countershatft speed sensor defective Lock-up clutch piston defective Torque converter check valve defective Lock-up shift valve defective Lock-up control valve defective

1. Transmission range switch 2. 3.

Speedometer does not operate

solenoid valve defective AfT clutch pressure control solenoid valves A and B defective Lock-up clutch piston defective Torque converter check valve defective Lock-up shift valve defective Lock-up control valve defective Lock-up timing valve defective

1. Torque converter clutch 2.

AfT gear position

Notes

Probable cause(s)

Symptom

defective or out of adjustment Shift cable broken or out of adjustment Joint in shift cable and transmission or body worn

Countershaft speed sensor defective

• Check the ~ indicator indication, and check for loose connectors. Inspect the AfT clutch pressure control solenoid valve body gasket and ATF feed pipes for wear and damage. If the AfT clutch pressure control solenoid valve is stuck, inspect the CPC valves. • Center all engine mounts.

Check the ~ indicator indication, and check for loose connectors. Inspect the AfT clutch pressure control solenoid valve body gasket and ATF feed pipes for wear and damage. Ifthe AfT clutch pressure control solenoid valve is stuck, inspect the CPC valves.

• Check the ~ indicator indication, and check for loose connectors. Inspect the transmission range switch. If the transmission range switch is faulty, replace it. Ifthe transmission range switch is out of adjustment, adjust it and the shift cable. • Check for a loose shift cable at the shift lever and the transmission control shaft. Check the ~ indicator indication, and check for loose connectors.

BACK

14-17

Automatic Transmission System Description General Operation The automatic transmission is a combination of a 3-element torque converter and triple-shaft electronically controlled automatic transmission which provides 4 speeds forward and 1 reverse. The entire unit is positioned in line with the engine. Torque Converter, Gears, and Clutches The torque converter consists of a pump, turbine, and stator assembly in a single unit. They are connected to the engine crankshaft so they turn together as a unit as the engine turns. Around the outside of the torque converter is a ring gear which meshes with the starter pinion when the engine is being started. The entire torque converter assembly serves as a flywheel while transmitting power to the transmission mainshaft. The transmission has three parallel shafts: the mainshaft, the countershaft, and the secondary shaft. The mainshaft is in line with the engine crankshaft. The mainshaft includes the 3rd and 4th clutches, and gears for 3rd, 4th, reverse, and idler (reverse gear is integral with 4th the gear). The countershaft includes the final drive, 1st, 3rd, 4th, reverse, 2nd, park, and idler gears (the final drive gear is integral with the countershaft). The secondary shaft includes the 1st and 2nd clutches, and gears for 1st, 2nd, and idler. The countershaft 4th gear and the countershaft reverse gear can be locked to the countershaft at its center, providing 4th gear or reverse, depending on which way the selector moved. The gears on the mainshaft and the secondary shaft are in constant mesh with those on the countershaft. When certain combinations of gears in the transmission are engaged by the clutches, power is transmitted from the mainshaft and the secondary shaft to the and [BJ positions. countershaft to provide ~, ~, /II,

rn

Electronic Control The electronic control system consists of the Powertrain Control Module (PCM), sensors, and six solenoid valves. Shifting and lock-up are electronically controlled for comfortable driving under all conditions. The PCM is located below the dashboard, under the front lower panel behind the center console. Hydraulic Control The valve bodies include the main valve body, the regulator valve body, the servo body, and the accumulator body. They are bolted to the torque converter housing. The main valve body contains the manual valve, the modulator valve, the shift valve C, the shift valve 0, the shift valve E, the servo control valve, the torque converter check valve, the reverse CPC valve, the lock-up shift valve, the lock-up control valve, the cooler check valve, and the ATF pump gears. The regulator valve body contains the regulator valve, the lock-up timing valve, and the relief valve. The servo body contains the servo valve, the shift valve A, the shift valve B, the CPC valves A and B, and the 3rd and 4th accumulators. The accumulator body contains the 1st and 2nd accumulators, and the lubrication check valve. Fluid from the regulator passes through the manual valve to the various control valves. The 1st, 3rd, and 4th clutches receive fluid from their respective feed pipes, and the 2nd clutch receives fluid from the internal hydraulic circuit. Shift Control Mechanism The PCM controls shift solenoid valves A, B, and C, and AfT clutch pressure control solenoid valves A and B, while receiving input signal from various sensors located throughout the vehicle. The shift solenoid valves shift the positions of the shift valves to switch the port leading hydraulic pressure to the clutch. The AfT clutch pressure control solenoid valves A and B control the CPC valves A and B, to shift smoothly between lower gear and higher gear. This pressurizes a line to one of the clutches, engaging the clutch and its corresponding gear. Lock-up Mechanism In ~ position (3rd and 4th), and ~ position (3rd), pressurized fluid is drained from the back of the torque converter through a fluid passage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the mainshaft rotates at the same speed as the engine crankshaft. Together with hydraulic control, the PCM optimizes the timing of the lock-up mechanism. When the torque converter clutch solenoid valve activates, modulator pressure changes to switch lock-up on and off. The lock-up control valve and the lock-up timing valve control the range of lock-up according to AfT clutch pressure control solenoid valves A and B. The torque converter clutch solenoid valve is mounted on the torque converter housing, and AfT clutch pressure control solenoid valves A and B are mounted on the transmission housing. They are all controlled by the PCM.

14-18

BACK

Gear Selection The shift lever has seven positions: (f] PARK, 1RI REVERSE, [ftI NEUTRAL, ~ 1stthrough 4th gear ranges, ~ 1stthrough 1st gear. 3rd gear ranges, 00 2nd gear, and

rn

Description

Position

(f] PARK

Front wheels locked; park pawl engaged with the park gear on the countershaft. All clutches released.

1RI REVERSE

Reverse; reverse selector engaged with countershaft reverse gear and 4th clutch engaged.

[ftI NEUTRAL

All clutches released.

~DRIVE

General driving; starts off in 1st, shifts automatically to 2nd, 3rd, then 4th, depending on vehicle speed and throttle position. Downshift through 3rd, 2nd, and 1st on deceleration to stop. The lock-up mechanism operates in 3rd and 4th gears.

(1st through 4th)

~DRIVE

(1st through 3rd)

00 SECOND

rn FIRST

For rapid acceleration at highway speeds and general driving; up-hill and down-hill driving; starts off in 1st, shifts automatically to 2nd, then 3rd, depending on vehicle speed and throttle position. Downshifts through 2nd to 1st on deceleration to stop. The lock-up mechanism operates in 3rd gear. Driving in 2nd gear; stays in 2nd gear, does not shift up and down. For engine braking or better traction starting off on loose or slippery surface. Driving in 1st gear, stays in 1st gear, does not shift up. For engine braking.

Starting is possible only in (f] and [ftI positions through the use of a slide-type, neutral-safety switch. Automatic Transaxle (A/T) Gear Position Indicator The A/T gear position indicator in the instrument panel shows what gear has been selected without looking down at the console.

(cont'd)

BACK

14-19

Automatic Transmission System Description (cont'd) Clutches The four-speed automatic transmission uses hydraulically-actuated cluches to engage or disengage the transmission gears. When hydraulic pressure is introduced into the clutch drum, the clutch piston moves. This presses the friction discs and steel plates together, locking them so they don't slip. Power is then transmitted through the engaged clutch pack to its hub-mounted gear. Likewise, when the hydraulic pressure is bled from the clutch pack, the piston releases the friction discs and the steel plates, and they are free to slide past each other. This allows the gear to spin independently on its shaft, transmitting no power.

1st Clutch The 1st clutch engages/disengages 1st gear, and is located at the middle of the secondary shaft. The 1st clutch is joined back-to-back to the 2nd clutch. The 1st clutch is supplied hydraulic pressure by its ATF feed pipe within the secondary shaft.

2nd Clutch The 2nd clutch engages/disengages 2nd gear, and is located at the middle of the secondary shaft. The 2nd clutch is joined back-to-back to the 1st clutch. The 2nd clutch is supplied hydraulic pressure through the secondary shaft by a circuit connected to the internal hydraulic circuit. 3rdClutch The 3rd clutch engages/disengages 3rd gear, and is located at the middle of the mainshaft. The 3rd clutch is joined back-to~back to the 4th clutch. The 3rd clutch is supplied hydraulic pressure by its ATF feed pipe within the mainshaft.

4th Clutch The 4th clutch engages/disengages 4th gear, as well as reverse gear, and is located at the middle of the mainshaft. The 4th clutch is joined back-to-back to the 3rd clutch. The 4th clutch is supplied hydraulic pressure by its ATF feed pipe within the mainshaft.

14-20

BACK

Transmission Cutaway View ATFPUMP DRIVEN GEAR MAINSHAFT 4TH GEAR

LOCK-UP CLUTCH PISTON

4TH CLUTCH

PITOTPIPE ('00-02 models)

DRIVE PLATE

FINAL DRIVE GEAR

COUNTERSHAFT 3RDGEAR

1ST CLUTCH

FINAL DRIVEN GEAR

(cont'd)

BACK

14-21

Automatic Transmission System Description (cont'd) Power Flow POSITION

~

!Rl IHI ~

1ST 2ND 3RD 4TH 1ST 2ND 3RD

~

[!)

III

TORQUE 'CONVERTER

1ST GEAR 1ST CLUTCH

2ND GEAR 2ND CLUTCH

0 0 0 0 0 0 0 0 0 0 0 0

x x x 0 x x x 0 x x x 0

x x x x 0 x x

PART 3RDGEAR 3RD CLUTCH

x

0 x 0 x

GEAR

4TH CLUTCH

x

x x

x

x

0

x x 0 x x

x

x x

x

x

0 x

x

x

x x 0 x x

x

x x

x x

0

x

x x x x

REVERSE GEAR

PARK GEAR

x 0 x x x x

0 x

x x x x x x

x

x x x x x x x x

x

0: Operates

x: Doesn't operate Gear Operation Gears on the mainshaft: • The 3rd gear is engaged/disengaged with the mainshaft by the 3rd clutch. • The 4th gear is engaged/disengaged with the mainshaft by the 4th clutch. • The reverse gear is engaged/disengaged with the mainshaft by the 4th clutch. • The idler gear is splined with the mainshaft and rotates with the mainshaft. Gears on the countershaft: • The final drive gear is integral with the countershaft. • The 1st gear, 3rdgear, 2nd gear, and park gear are splined with the countershaft and rotate with the countershaft. • The 4th gear and reverse gear rotate freely from the countershaft. The reverse selector engages the 4th gear or the reverse gear with the reverse selector hub. The reverse selector hub is splined with the countershaft so that the 4th gear or reverse gear engage with the countershaft. • The idler gear rotates freely from the countershaft. Gears on the secondary shaft: • The 1st gear is engaged/disengaged with the secondary shaft by the 1st clutch. • The 2nd gear is engaged/disengaged with the secondary shaft by the 2nd clutch. • 'The idler gear is splined with the secondary shaft and rotates with the secondary shaft.

14-22

BACK

~Position

Hydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft. The countershaft is locked by the park pawl interlocking the park gear.

[H] Position Engine power transmitted from the torque converter drives the mainshaft idler gear, the countershaft idler gear, and the secondary shaft idler gear, but hydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft. The countershaft 4th gear is engaged with the reverse selector hub and the countershaft by the reverse selector, when the shift lever is shifted in [H] position from ~ position. The countershaft reverse gear is engaged when shifted from!Rl position.

TORQUE CONVERTER

~

MAINSHAFT IDLER GEAR

/

MAINSHAFT

"J~COUNlERSHAFT

DLFi":-:r=rr=:;F~-"C)"(t/

IDLER GEAR

.---__~~ ==----'=:::L..!:=u~~/ SECONDARY SHAFT ,

/

/SECONDARY SHAFT

IDLER GEAR

(cont'd)

BACK

14-23

Automatic Transmission System Description (cont'd) Power Flow (cont'd) In ~ or IP! position, the optimum gear is automatically selected from the 1st, 2nd, 3rd, and 4th gears, according to conditions such as the balance between the throttle opening (engine loading) and vehicle speed. ~ or ~ Position in 1st gear and

rn Position

Hydraulic pressure is applied to the 1st clutch, then the 1st clutch engages the secondary shaft 1st gear with the secondary shaft. o The mainshaft idler gear drives the secondary shaft via the countershaft idler gear and secondary shaft idler gear. o The secondary shaft 1st gear drives the countershaft 1st gear and the countershaft . • Power is transmitted to the final drive gear, which in turn drives the final driven gear.

o

TORQUE CONVERTER


'"

MAINSHAFT

COUNTERSHAFT

IDLER GEAR

FINAL DRIVE GEAR

1ST CLUTCH

_ _ _ _ FINAL DRIVEN GEAR

14-24

BACK

~ or ~ Position in 2nd gear and ~ Position o

o

o o

Hydraulic pressure is applied to the 2nd clutch, then the 2nd clutch engages the secondary shaft 2nd gear with the secondary shaft. The mainshaft idler gear drives the secondary shaft via the countershaft idler gear and secondary shaft idler gear. The secondary shaft 2nd gear drives the countershaft 2nd gear and the countershaft. Power is transmitted to the final drive gear, which in turn drives the final driven gear. TORQUE CONVERTER

'"


..... _ - - - - - COUNTERSHAFT

FINAL DRIVE GEAR

- - - - - - - - SECONDARY SHAFT

~SECONDARY

SHAFT

2ND GEAR

2ND CLUTCH

__- - - - - - - F I N A L DRIVEN GEAR

(cont'd)

BACK

14-25

Automatic Transmission System Description (co nt'd) Power Flow (cont'd) ~ or ~ Position in 3rd gear

• Hydraulic pressure is applied to the 3rd clutch, then the 3rd clutch engages the mainshaft 3rd gear with the mainshaft. • The mainshaft 3rd gear drives the countershaft 3rd gear and the countershaft. • Power is transmitted to the final drive gear, which in turn drives the final driven gear. TORQUE CONVERTER

MAINSHAFT 3RDGEAR

""

3RDCLUTCH

L---=----1---"lJ..::b. /

COUNTERSHAFT 3RDGEAR

-

14-26

~FINALDRIVENGEAR

BACK

MAINSHAFT

~ Position in 4th gear

• Hydraulic pressure is applied to the servo valve to engage the reverse selector with the countershaft 4th gear while the shift lever is in the forward range (~, ~, 00 and [I] position). • Hydraulic pressure is also applied to the 4th clutch, then the 4th clutch engages the mainshaft 4th gear with the mainshaft. • The mainshaft 4th gear drives the countershaft 4th gear, which drives the reverse selector hub and the countershaft. • Power is transmitted to the final drive gear, which in turn drives the final driven gear. TORQUE CONVERTER

'"

4TH CLUTCH


l. .- ~'- -'_/u.:~ J.,~

MAINSHAfT

~ COUNTERSHAFT IDLER GEAR

~

____- - - - - - SECONDARY SHAFT FINAL DRIVE GEAR

REVERSE SELECTOR HUB

COUNTERSHAFT 4TH GEAR

(cont'd)

BACK

14-27

Automatic Transmission System Description (cont'd) Power Flow (cont'd) 1ft) Position • Hydraulic pressure is applied to the servo valve to engage the reverse selector with the countershaft reverse gear while the shift lever is in the 1ft) position. • Hydraulic pressure is also applied to the 4th clutch, then the 4th clutch engages the mainshaft reverse gear with the mainshaft. • The mainshaft reverse gear drives the countershaft reverse gear via the reverse idler gear. • The rotation direction ofthe countershaft reverse gear is changed via the reverse idler gear. • The countershaft reverse gear drives the countershaft via the reverse selector, which drives the reverse selector hub. • Power is transmitted to the final drive gear, which in turn drives the final driven gear.

TORQUE CONVERTER

MAINSHAFT REVERSE GEAR

\

~_---REVERSE

IDLER GEAR

REVERSE SELECTOR HUB /

FINAL DRIVEN GEAR

\

COUNTERSHAFT REVERSE GEAR SHIFT FORK

14-28

BACK

Electronic Control System Functional Diagram The electronic control system consists of the Powertrain Control Module (PCM), sensors, and six solenoid valves. Shifting and lock-up are electronically controlled for comfortable driving under all conditions. The PCM is located below the dashboard, under the front lower panel behind the center console. PCM

H-----l[

11-----+1

Throttle Position Sensor Signal

1

Data Link Connector

I

PGM-FI Control System Engine Coolant Temperature Lt----H Sensor Signal 1

AfT Control System

1+1t----;1

'--

MULTIPLEX CONTROL UNIT IDRIVER'SI

-EJ l P

1+1----1:

1---.....f-----1H

H-II------l~ Shift Control

I

Shift Solenoid Valve B

Shift Solenoid Valve C

1

Automatic Transaxle Clutch Pressure Control Solenoid Valve A

1

Automatic Transaxle Clutch

1+11---......-;1

D4

Shift Solenoid Valve A

H-I1--......--1--l Pressure Control Solenoid 1 ValveB

I I

J

D3

H-I1----t--1--l1

2nd Clutch Pressure Switch

I

1+11---+---7-;1 3rd Clutch Pressure ~ 1 Switch

I

L

2

-1

Lock-up Control 1+1----11 1

~ Indicator

I

'-----------'

~

Self-Diagnosis Signal

Torque Converter Clutch Solenoid Valve

,.-------,

Lt----1t+1

I 1 L -_ _ _ _ _ _ _ _- '

SeH-Diagnosis Function

' - -_ _ _ _ _....1

1-1-_ _-11

L

Mainshaft Speed Sensor Signal

I

I

L--_ _ _ _ _ _ _ _ _- - '

1-1-_ _-11 Countershaft Speed 1

Sensor Signal

(cont'd)

BACK

14-29

Automatic Transmission System Description (cont'd) Electronic Control System (cont'd) Electronic Controls Location KEY INTERLOCK SOLENOID

COUNTERSHAFT SPEED SENSOR

2ND CLUTCH PRESSURE SWITCH

TRANSMISSION RANGE SWITCH AfT CLUTCH PRESSURE CONTROL SOLENOID VALVES A and B

~) MAINS HAFT SPEED SENSOR 3RD CLUTCH PRESSURE SWITCH SHIFT SOLENOID VALVE C

14-30

BACK

SHIFT SOLENOID VALVE B

Shift Control Shifting is related to engine torque through the AfT clutch pressure control solenoids, which are controlled by the PCM. The PCM instantly determines which gear should be selected by various signals sent from sensors, and actuates the shift solenoid valves A, B, and C to control shifting. Also, a Grade Logic Control System has been adopted to control shifting in ~ and ~ positions while the vehicle is ascending or descending a slope, or reducing speed. The combination of driving signals to shift solenoid valves A, B, and C are shown in the table below.

Position

Gear position

Shifting from !HI position Stays in 1st Shifting gears between 1st and 2nd Stays in 2nd Shifting gears between 2nd and 3rd Stays in 3rd Shifting gears between 3rd and 4th ~ Stays in 4th 2nd 00 1st III Shiftil}g from ~ and [HI position 1ft! Stays in reverse Reverse inhibit Park ~ [HI Neutral . . NOTE: For a deSCription of the reverse inhibit mode, refer to page 14-56. ~,~

A ON OFF ON ON ON ON OFF OFF ON OFF OFF OFF OFF OFF OFF

Shift solenoid valves B ON ON ON ON OFF OFF OFF OFF ON ON ON ON ON ON ON

C ON ON ON OFF OFF ON ON OFF OFF ON ON OFF ON OFF OFF

Lock-up Control The torque converter clutch solenoid valve controls modulator pressure to switch the lock-up shift valve and lock-up ON and OFF. The PCM controls the torque converter clutch solenoid valve and the AfT clutch pressure control solenoid valves A and B. When the torque converter clutch solenoid valve is turned ON, the condition of lock-up starts. The AfT clutch pressure control solenoid valves A and B regulate AfT clutch pressure control solenoid pressure, and apply pressure to the lock-up control valve and the lock-up timing valve. The lock-up control mechanism operates in 3rd, and 4th gear in ~ and in 3rd gear in ~ positions.

(cont'd)

BACK

14-31

Automatic Transmission System Description (cont'd) Electronic Control System (cont'd) Grade Logic Control System How it works: The PCM compares actual driving conditions with memorized driving conditions, based on the input from the countershaft speed sensor, the throttle position sensor, the engine coolant temperature sensor, the brake pedal position switch signal, and the shift lever position signal, to control shifting while the vehicle is ascending or descending a slope, or reducing speed.

.------

Y H

Countershaft Speed Sensor

1/1

c

0

Throttle Position Sensor

E

PCM

SIGNALS DETECTED

SENSORS/SWITCHES

}Judgement of Controlling Area

-f-

~

Driving Resistance

r-

rr-

I

I

"0

c

Calculation of actual acceleration

0

(,)

aI

c

:~ Q

'-----

r-IEngine Coolant Temperature Sensor

Coolant Temperature

r - I Transmission Range Switch

~ or ~ Position

t-~

I

Detection of standard acceleration (in Memory)

Calculation of deceleration

I

Calculation of gradient

I I

I I

Selection of Shifting Mode ·Normal Mode (Flat road mode) ·Ascending Mode ·Fuzzy Logic ·Descending Mode ·Gradual Descending Mode ·Steep Descending Mode ·Deceleration Mode

I

I Automatic 4 Speeds

14-32

BACK

I

Ascending Control

When the PCM determines that the vehicle is climbing a hill in ~ and ~ positions, the system extends the engagement area of 2nd gear and 3rd gear to prevent the transmission from 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 schedules stored in the PCM between 2nd and 3rd gears, and between 3rd and 4th gears, enable the PCM's fuzzy logic to automatically select the most suitable gear according to the magnitude of a gradient. • Fuzzy logic is a form of artificial intelligence that lets computers respond to changing conditions much like a human mind would. 4TH

ASCENDING MODE: Upshift Schedule

- - - : FLAT ROAD MODE • - - - - - _. : GRADUAL ASCENDING MODE _ •• _ .• _ .. : STEEP ASCENDING MODE ~ ~

: 2ND·3RD SHIFTING CHARACTERISTICS CONTROL AREA _ : 3RD-4TH SHIFTING CHARACTERISTICS - - CONTROL AREA

o '---'-........II.... Descending Control

When the PCM determines that the vehicle is going down a hill in ~ and ~ positions, the shift-up speed from 3rd to 4th gear and from 2nd to 3rd (when the throttle is closed) becomes faster than the set speed for flat road driving to widen the 3rd gear and 2nd gear driving areas. This, in combination with engine braking from the deceleration lock-up, achieves smooth driving when the vehicle is descending. There are two descending modes with different 3rd gear driving areas and 2nd gear driving areas according to the magnitude of a gradient stored in the PCM. When the vehicle is in 4th gear, and you are decelerating when you are applying the brakes on a steep hill, the transmission will downshift to 3rd gear. When you accelerate, the transmission will then return to higher gear. 100%

DESCENDING MODE: Downshift Schedule

50 - - - : FLAT ROAD MODE • - - - - - - : GRADUAL DESCENDING MODE - " - " - : STEEP DESCENDING MODE

o 62 mph (100 km/hl

Vehicle speed

Deceleration Control

When the vehicle goes around a corner and needs to decelerate first and then accelerate, the PCM sets the data for deceleration control to reduce the number of times the transmission shifts. When the vehicle is decelerating from speeds above 27 mph (43 km/h), the PCM shifts the transmission from 4th to 2nd earlier than normal to cope with upcoming acceleration.

(cont'd)

BACK

14-33

Automatic Transmission System Description (cont'd) Electronic Control System (cont'd) PCM Electrical Connections PGM·FI MAIN RELAY

IGNITION SWITCH ATTERY

+

-<:T"..P

~

~'~

PCM

r-

B2

F.U 81

-
B21

I

C2B C27 CIS


I

ENGINE COOLANT TEMPERATURE SENSOR

I ,8

.

DATA LINK CONNECTOR

1-l-

C26

AIO

LSA,

A32

LSA LS B,

IGPI

1

Jr

822

LSB·

VBU

? ?

VCC2 TPS SG2

ECT

AUTOMATIC TRANSAXLE CONTROL SYSTEM

b I I I I I I I I I I I I I I

LGI LG2 05 A9

SH 8

07

I

02

~

SHIFT SOLENOID *VALVE8

SHC

03

~

LC

01

VB SOL

TIT

011

7!T

EJ EJ

VSSOUT

'"'"'

NMSG NC

000 @00

NCSG ILU

012 010

R

06


016

II MULTIPLEX CONTROL UNIT (DRIVER'S)

A2B

I


ATP R

N

OP2SW

D'

D9

OJ

DB

2

014 0'5

D. INDICATOR

I

@I

0'3 A'4

BI4

ATPD.

ATP2 ATP'

OP3SW

B2.

ATPNP

D41ND

~

3RD CLUTCH PRESSURE SWITCH

ATPDJ

CRS

~ r UNIT CRUISE CONTROL

AS

1

PCM Connedor TerminallocattOns

14-34

MAiNSHAFT SPEED SENSOR

P

,

A (32P)

SHIFT SOLENOID VALVE C

~ TOROL'E CONVERTER CLUTCH SOLENOID VAlVE

~T GEAR POSITION INDICATOR

~~.

BIB

SHIFT SOLENOID VALVE A

I I I

PGMFI CONTROL SYSTEM

BKSW

IGNITION SWITCH

SHA

NM

TRANSMISSION RANGE

/>JT CLUTCH PRESSURE CONTROL SOLENOID VALVE B

I

SCS

IGI

GAUGE ASSEM8L Y

BB B25

IGP2

BRAKE LIGHT 820

/>JT CLUTCH PRESSURE CONTROL SOUENOID VALVE A

PG2

BRAKE PEDAL POSITION SWITCH

0

BI7

PGI

B(25P)

C (3IP)

BACK

o (16P)

I

PCM Inputs and Outputs The PCM terminal voltage and measuring conditions are shown for the connector terminals related to the AfT control system. The other PCM terminal voltage and measuring conditions are described in section 11.

PCM Connector Terminal Locations

,,:..

VI

/

-

/

23V

1sT

1 2 345 5 6 7 5 6/ 8 9 10 1 8 9 10 7 8111 2 3 1/12 3 4 23 241 9 10 11 12 1314 1617 13 1415 16 17 18 19 20 21/ 6 7 8 9 10 111121 112 113 14 15 16 17 18 1920 32 19 20 13 14 15 16 2122 23 24 25 25 26 27 28 29 30 25 26 27 28 2930

21V /

V

'--

A (32P)

'---

181V / /V

/

C (31P)

B(25P)

'--

D(16P)

PCM CONNECTOR A (32P) Terminal Number A5

Wire

Signal

Description

BLU/GRN

CRS

A9

BLU/WHT

VSSOUT

A10

BRN

SCS

Downshift signal input from cruise control unit Vehicle speed signal detected from countershaft speed sensor Timing and adjustment service check signal

A14

GRN/BLK

D41ND

A28

WHT/RED

ILU

A32

WHT/BLK

BKSW

D4 indicator control

Interlock control

Brake pedal position switch signal output

Measuring Conditions/Terminal Voltage When cruise control is used: Pulsing signal Depending on vehicle speed: Pulsing signal

With ignition switch ON (II) and data link connector open: 5 V With ignition switch ON (II) and data link connector connected with Honda PGM tester: OV When ignition switch is first turned ON (II): Battery voltage for two seconds In ~. position: Battery voltage When ignition switch ON (II), brake pedal pressed, and accelerator pedal released: Battery voltage Brake pedal pressed: Battery voltage Brake pedal released: 0 V

(cont'd)

BACK

14-35

Automatic Transmission System Description (cont'd) Electronic Control System (cont'd) PCM Inputs and Outputs


/

/

VI

r--r--

/

/

r-

r5l

5 6 345 567 8 9 10 1 8 9 10 1 2 7 8111 2 3 2 3/ Vl2 3 4 9 23 241 10 1112 1314 1617 181V 13 1415 16 17 1819 20 6 7 8 9 10 111121 112j13 14 1516 17 18 1920 32 19 20 29 30 2122 23 2425 25 26 27 2B 1314 15 16 2B 29 30 25 26 27

21V

/

V

'--

A (32P)

'--'--

-'--

V V/

21V V

C(31P)

B(25P)

'--

D(16P)

PCM CONNECTOR B (25P) Terminal Number B1

Wire

Signal

VEL/BlK

IGP1

B2 B8

BlK WHT

PG1 lSA-

B9

VEL/BlK

IGP2

B10 B14

BlK BlU/BlK

PG2 OP2SW

B17

RED

lSA+

B18

GRN

lSB-

B20 B21

BRN/BlK WHT/YEl

lG1 VBU

B22 B24

BRN/BlK BlU/WHT

lG2 OP3SW

B25

ORN

lSB+

14-36

Description Power supply circuit from main relay_ Ground (G101) AfT clutch pressure control solenoid valve A power supply negative electrode Power supply circuit from main relay Ground (G101) AfT 2nd clutch pressure switch signal input AfT clutch pressure control solenoid valve A power supply positive electrode AfT clutch pressure control solenoid valve B power sUlmly negative electrode Ground (G101) Back-up power supply (Fuse No. 13 in passenger's under-dash fuse/relay box) Ground (G101) AfT 3rd clutch pressure switch signal input AfT clutch pressure control solenoid valve B power supply positive electrode

BACK

Measuring Conditions/Terminal Voltage With ignition switch ON (II): Battery voltage With ignition switch OFF: 0 V

With ignition switch ON (II): Battery voltage With ignition switch OFF: 0 V With ignition switch ON (II): Battery voltage (No 2nd clutch pressure) With ignition switch ON (II): Pulsing signal

Always battery voltage

With ignition switch ON (II): Battery voltage (No 3rd clutch pressure) With ignition switch ON (II): Pulsing signal

PCM CONNECTOR D (16P) Terminal Number D1

Wire

Signal

Description

VEL

lC

D2

GRN/WHT

SHB

Torque converter clutch solenoid valve control Shift solenoid valve B control

D3

GRN

SHC

Shift solenoid valve C control

D4 D5

--

--

BlK/YEl

VBSOl

D6

WHT

ATPR

D7

BLU/YEl

SHA

Not used Power supply for solenoid valves (Fuse No.6 in driver's under-dash fuse/relaj' box) Transmission range switch 00 position input Shift solenoid valve A control

Measuring Conditions/Terminal Voltage

During lock-up condition: Battery voltage During no lock-up condition: 0 V Battery voltage in following positions: • [1] and 00 positions. • ~, and ~ positions in 1st and 2nd gear • [fl, IBJ, and IN] positions o V in following positions: • ~, and ~ positions in 3rd gear • ~ position in 4th gear Battery voltage in following positions: • [1] position • ~, and ~ positions in 1st and 3rd gear o V in following positions: • 00 position • ~, and ~ positions in 2nd gear • ~ position in 4th gear • [fl, 00, and IN] positions With ignition switch ON (II): Battery voltage With ignition switch OFF: 0 V In 00 position: 0 V In other than 00 position: Battery voltage Battery voltage in following positions: • 00 position • ~, and ~ positions in 2nd and 3rd gear oV in following positions: • [1] position • ~, and ~ positions in 1st gear • ~ position in 4th gear • [fl, IBJ, and IN] positions

(cont'd)

BACK

14-37



/ r--r--r5 6 345 5 6 7 8 9 10 1 8 9 10 1 2 23/ 1/12 3 4 7 8111 2 3 16 9 1819 14 1516 17 18 19 20 23 1112 1314 1617 13 14 15 17 20 6 7 8 9 10 111121 21 10 241 18 1 112 113 32 19 20 25 26 27 28 29 30 13 14 15 16 28 29 30 2122 23 24 25 25 26 27

VI

V

V

/

/

/

'--

A (32P)

'--'--

'-- '--

/

V/

/V

C (31P)

B(25P)

Isl

21V

V

-

D(16P)


Wire

Signal

Description

PNK

ATPD3

D9

VEL

ATPD4

D10

BLU

NC

D11

RED

NM

Transmission range switch ~ position input Transmission range switch ~ position input Countershaft speed sensor input Mainshaft speed sensor input

D12

WHT

NMSG

D13

BLU/WHT

ATPNP

D14

BLU

ATP2

D15

BRN

ATP 1

D16

GRN

NCSG

14-38

Mainshaft speed sensor ground Transmission range switch ~ and IHI positions input Transmission range switch [!] position input Transmission range switch ill position input Countershaft speed sensor ground

BACK

Measuring Conditions/Terminal Voltage In ~ position: 0 V In other than ~ position: Battery voltage In ~ position: 0 V In other than ~ position: Battery voltage Depending on vehicle speed: Pulsing signal When vehicle is stopped: Approx. 0 V Depending on vehicle speed: Pulsing signal When engine is stopped: Approx. 0 V

In ~ and IHI positions: 0 V In other than ~ and IHI positions: Battery voltage In [!] position: 0 V In other than [!] position: Battery voltage In ill position: 0 V In other than ill position: Battery voltage

Hydraulic Controls The valve body includes the main valve body, the regulator valve body, the servo body, and the accumulator body. The ATF pump is driven by splines on the right end ofthe torque converter which is attached to the engine. Fluid flows through the regulator valve to maintain specified pressure, through the main valve body, to the manual valve, directing pressure to each of the clutches. The shift solenoid valves Band C are mounted on the outside of the torque converter housing. The shift solenoid valve A and the torque converter clutch solenoid valve are mounted on the torque converter housing as an assembly. The AfT clutch pressure control solenoid valves A and B are mounted on the transmission housing. 3RDCLUTCH

/

AfT CLUTCH PRESSURE CONTROL SOLENOID VALVES A and B

~

PRESSURE SWITCH

~ /SERVOBOOY

REGULATOR VALVE BODY

TORQUE CONVERTER CLUTCH SOLENOID VALVE/SHIFT SOLENOID VALVE A

'------------2ND CLUTCH

PRESSURE SWITCH

(cont'd)

BACK

14-39

Automatic Transmission System Description (co nt'd) Hydraulic Controls (cont'd) Main Valve Body The main valve body contains the manual valve, the modulator valve, the shift valve C, the shift valve D, the shift valve E, the servo control valve, the torque converter check valve, the reverse CPC valve, the lock-up shift valve, the lock-up control valve, the cooler check valve, and the ATF pump gears. The primary function of the main valve body is to switch fluid pressure on and off and to control hydraulic pressure going to the hydraulic control system. TORQUE CONVERTER CHECK VALVE

SH FT VALVE D

MODULATOR VALVE

SHIFT VALVE C

REVERSE CPC VALVE

SERVO CONTROL VALVE

Regulator Valve Body The regulator valve body is located on the main valve body. The regulator valve body contains the regulator valve, the lock-up timing valve, and the relief valve. REGULATOR VALVE

~


LOCK-UP TIMING VALVE

14-40

BACK

Regulator Valve The regulator valve maintains a constant hydraulic pressure from the ATF pump to the hydraulic control system, while also furnishing fluid to the lubricating system and torque converter. The fluid from the ATF pump flows through Sand S'. Fluid entering from S flows through the valve orifice to the A cavity. This pressure of the A cavity pushes the regulator valve to the right side, and this movement of the regulator valve uncovers the fluid port to the torque converter and the relief valve. The fluid flows out to the torque converter and the relief valve, and the regulator valve moves to the left side. According to the level of the hydraulic pressure through S, the position of the regulator valve changes, and the amount of fluid from S' through torque converter also changes. This operation is continued, maintaining the line pressure. NOTE: When used, "Ieft" or "right" indicates direction on the illustration below.

1T

From ATF PUMP To TORQUE CONVERTEr

LUBRICATION

VALVE ORIFICE

~~r

Increases in hydraulic pressure according to torque are performed by the regulator valve using stator torque reaction. The stator shaft is splined with the stator in the torque converter, and its arm end contacts the regulator spring cap. When the vehicle is accelerating or climbing (Torque Converter Range), stator torque reaction acts on the stator shaft, and the stator arm pushes the regulator spring cap in the direction of the arrow in proportion to the reaction. The stator reaction spring compresses, and the regulator valve moves to increase the line pressure which is regulated by the regulator valve. The line pressure reaches its maximum when the stator torque reaction reaches its maximum.

TORQUE CONVERTER

STATOR

~ VALVE

SPRING CAP

(cont'd)

BACK

14-41

Automatic Transmission System Description (cont'd) Hydraulic Controls (cont'd) Servo Body The servo body is on the main valve body. It contains the servo valve, the shift valve A, the shift valve 8, the CPC valves A and 8, and the 3rd and 4th accumulators. Accumulator Body The accumulator body is on the torque converter housing, next to the main valve body. It contains the 1st and 2nd accumulators and the lubrication check valve.

CPCVALVEB

SERVO BODY

~ SERVO VALVE 4TH ACCUMULATOR PISTON

-------SERVO BODY 2ND ACCUMULATOR PISTON

LUBRICATION CHECK VALVE

14-42

BACK

Hydraulic Flow As the engine turns, the ATF pump starts to operate. Automatic transmission fluid (ATF) is drawn through the ATF strainer (filter) and discharged into the hydraulic circuit. Then, ATF flowing from the ATF pump becomes line pressure that's regulated by the regulator valve. Torque converter pressure from the regulator valve enters the torque converter through the lock-up shift valve, and it is discharged from the torque converter. The torque converter check valve prevents torque converter pressure from rising. The PCM controls the shift solenoid valves ON and OFF, and the shift solenoid valves apply shift solenoid pressure to the shift valves. Applying shift solenoid pressure to the shift valves moves the position of the shift valve, and switches the port of hydraulic pressure. The PCM also controls AfT clutch pressure control solenoid valves A and B. The AfT clutch pressure control solenoid valves regulate AfT clutch pressure control solenoid pressure and apply AfT clutch pressure control solenoid pressure to CPC valves A and B. When shifting between upper gear and lower gear, the clutch is engaged by pressure from the CPC pressure mode. The PCM controls one of the shift solenoid valves to move the position of the shift valve. This movement switches the port of the CPC and line pressure. Line pressure is then applied to the clutch, and CPC pressure is intercepted. Engaging the clutch with line pressure happens when shifting is completed. Hydraulic pressure at the ports is as follows: PORT NO. 1

3 3'

3" 4 4' 4" 4A 4B 5A 5D 5B 5E 5F 5F' 5C 5G

DESCRIPTION OF PRESSURE LINE LINE LINE LINE LINE LINE LINE CPCA CPC B CPCA CPCB CPCAor LINE CPC A or LINE CPCAor LINE CPCAor LINE CPC B or LINE CPC B or LINE

PORT NO. 5H 5J 5K 5K' 6 SA SB SC LA 9 10 20 25 30 40 41 56

DESCRIPTION OF PRESSURE CPC B or LINE CPC B or LINE CPC B or LINE CPC B or LINE MODULATE SHA SH B SHC LC LINE 1ST CLUTCH 2ND CLUTCH LINE 3RDCLUTCH 4TH CLUTCH 4TH CLUTCH LSA

PORT NO. 57 58 90 90' 91 91' 92 93 94 95 95' 96 97 99 X HX

AX

DESCRIPTION OF PRESSURE LS B LS Aor LS B TORQUE CONVERTER TORQUE CONVERTER TORQUE CONVERTER TORQUE CONVERTER TORQUE CONVERTER ATFCOOLER TORQUE CONVERTER LUBRICATION LUBRICATION TORQUE CONVERTER TORQUE CONVERTER SUCTION DRAIN HIGH POSITION DRAIN AIR DRAIN

NOTE: • CPC: Clutch Pressure Control pressure • SH: Shift Control Solenoid pressure • LS: AfT Clutch Pressure Control Solenoid pressure • LC: Torque Converter Clutch Solenoid pressure

(cont'd)

BACK

14-43

Automatic Transmission System Description (cont'd) Hydraulic Flow (cont'd)

!Hl Position The PCM controls the shift solenoid valves. The conditions of the shift solenoid valve and positions of the shift valve are as follows: • Shift solenoid valve A is turned OFF, and the shift valve A is moved to the left side. • Shift solenoid valve 8 is turned ON, and the shift valve 8 remains in the right side. • Shift solenoid valve C is turned OFF, and the shift valve C remains in the left side. Line pressure (1) passes through the manual valve and stops at the shift valve D. Line pressure (1) also flows to the modulator valve, and becomes modulator pressure (6). Modulator pressure (6) flows to the shift solenoid valves and the AfT clutch pressure control solenoid valves. Under this condition, hydraulic pressure is not applied to the clutches. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

14-44

BACK

IQ1I Position: 1st gear shifting from [NJ position The peM turns shift solenoid valves A and e ON when shifting to IQ1I position from [NJ. Shift solenoid valve B remains ON. Shift solenoid valve e is turned ON, and SH e pressure (Se) in the right Side of shift valve e is released, then shift valve e is moved to the right side. Shift solenoid valve A is turned ON, and SH A pressure (SA) in the left side of shift valve A is released, then shift valve A is moved to the right side. The NT clutch pressure control solenoid valve A regulates LS A pressure (56), and applies it to the epe valve A. Line pressure (1) becomes line pressure (4) at the manual valve, and flows to the shift valve e and the epe valve A. Line pressure (4A) becomes epe A pressure (4A) and passes through the shift valve e, A and B, then epe A pressure (4A) becomes 1st clutch pressure (10) at shift valve B. 1st clutch pressure (10) is applied to the 1st clutch, then the 1st clutch is engaged with pressure ofthe epe pressure mode. Line pressure (4) passes through shift valve A and B, and stops at shift valve B. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit . • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

(cont'd)

BACK

14-45

Automatic Transmission System Description (cont'd) Hydraulic Flow (cont'd) ~

Position: Driving in 1st gear

The PCM turns shift solenoid valve A OFF, but shift solenoid valves Band C remain ON. SH A pressure (SA) is applied to the left side of shift valve A, then shift valve A is moved to the left side. This movement switches the port of line pressure and CPC pressure on shift valve A. The 1st clutch pressure is changed to line pressure mode, and the 1st clutch is engaged securely. The CPC A pressure (5E) stops at shift valve B. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar. 11f ACC\NUUlOll

TCfWl£ CD'lVERrE.R

~~H SOlENOID

r--\..

I I

I

I

14-46

BACK

~ Position: Shifting between 1st gear and 2nd gear

As the speed of the vehicle reaches the prescribed value, the PCM turns shift solenoid valve A OFF. Shift solenoid valves Band C remain ON. Then shift solenoid valve A is turned ON, and SH A pressure (SA) in the left side of the shift valve A is released. Shift valve A is moved to the right side to switch the port of line pressure and CPC pressure. The PCM also controls the AfT clutch pressure control solenoid valves. The AfT clutch pressure control solenoid valves A and B apply their pressure to the CPC valves A and B. line pressure (4) becomes CPC B pressure (4B) at the CPC valve B, and CPC B pressure passes through shift valves C, B, and A, to become 2nd clutch pressure. The 1st and 2nd clutches are engaged with the CPC pressure mode. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

.... .~... -li-::::~_v...wc

(cont'd)

BACK

14-47


Position: Driving in 2nd gear

The PCM turns shift solenoid valve C OFF, and controls AfT clutch pressure control solenoid valve A to release LS A pressure (56). The shift solenoid valves A and B remain ON. Releasing LS A pressure in the CPC valve A releases CPC A pressure in the 1st clutch pressure circuit. Shift solenoid valve C is turned OFF, and SH C pressure (SC) is applied to the right side of it. Then shift valve C is moved to the left side to switch the port of line pressure and CPC pressure. The 2nd clutch pressure is changed to line pressure mode, and the 2nd clutch is engaged securely. The CPC B pressure (50) stops at shift valve B. NOTE: • When used, "Ieft" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar. ,IT ACCUMULATOII

.~iif ==-

n

RJI........

ti

~ v~ ) ~ f\

....:;:..;.:.;

J~~'~

-. -Ilrl

,iIi':

TO ROUE CQNVEATt" Cl U1'CH SDC.ENDlD

r--,. ..

v"-

I~

r:. J

Iv.....-

· ' . .r·r

_....... -;b

~

-.

1-

.':="(

14-48

J

....l

I

.,......... c

~-

~-~ -"r-I_

~

I

,

..

lll"'~

-,

,

."

-

I

~.

.,,---vu,,_...

• 'I-1:C-II' L

1

--

.l..JA =-

___......... --==_v. . . f( !

....b.

\\.. I ~ -F"

........

,,K... ..

_ 11 If

JI.

J

I

~_

n .4 ~~~,

~

.

•.uu.

...., J

AfJ

....... P"'"' ." .......

BACK

'r'

1

]

10 10

It-t!.~ ....

~

•

VMWI

[--

'I~

...

'~

_v......

'Ill

'~~I~ n. I:

...

;Ir"~

Jo.l

-,

"~---

W!1 j I

';"

--Ii

-ttfi}u _ . IT

~

r=

I': 0011

~ .:1l=o:......

~~,

m

~

@'~ 1Ir_I-_r_

;II ~

I

E"i t -

:F-. II '. ~ ~~ l J J

rV

..... --

..J!I. I ~

"~

'-tf

li

I

I

VMVlA

I I

~

Position: Shifting between 2nd gear and 3rd gear

As the speed of the vehicle reaches the prescribed value, the PCM turns shift solenoid valve 8 OFF. The PCM also controls AfT clutch pressure control solenoid valve A to apply LS A pressure (56) to the CPC valve A. Shift solenoid valve A remains ON, and C remains OFF. Shift soleniod valve 8 is turned OFF, and SH 8 pressure (58) is applied to the right side of shift valve 8. Then shift valve 8 is moved to the left side to switch the port of line pressure and CPC pressure. Line pressure (4) becomes CPC A pressure (4A) at the CPC valve A. The CPC A pressure (4A) becomes 3rd clutch pressure (30) at shift valve 8, and flows to the 3rd clutch. The 2nd clutch pressure is changed to CPC pressure mode by switching the position of shift valve B. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit . • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

(cont'd)

BACK

14-49


Position: Driving in 3rd gear

The PCM turns shift solenoid valve C ON, and controls AfT clutch pressure control solenoid valve B to release lS B pressure (57). Shift solenoid valve A remains ON, and B remains OFF. Releasing lS B pressure in the CPC valve B releases CPC B pressure in the 2nd clutch pressure circuit. Shift solenoid valve C is turned ON, and SH C pressure (SC) in the right side of shift valve C is released. Then shift valve C is moved to the right side to switch the port of line pressure and CPC pressure. 3rd clutch pressure is changed to line pressure mode, and the 3rd clutch is engaged securely. The CPC A pressure (4A) stops at shift valve E. NOTE: • When used, "Ieft" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

14-50

BACK

~ Position: Shifting between 3rd gear and 4th gear

As the speed of the vehicle reaches the prescribed value, the PCM turns shift solenoid valve A OFF. The PCM also controls AfT clutch pressure control solenoid valve 8 to apply LS 8 pressure (57) to CPC valve 8. Shift solenoid valve 8 remains OFF, and C remains ON. Shift solenoid valve A is turned OFF, and SH A pressure (SA) is applied to the left side of shift valve A. Then shift valve A is moved to the left side to switch the port of line pressure and CPC pressure. Line pressure (4) becomes CPC 8 pressure (48) at CPC valve 8. The CPC 8 pressure (48) becomes 4th clutch pressure (41) at shift valve D, and flows to the 4th clutch via the manual valve. The 3rd clutch pressure is changed to CPC pressure mode by switching the position of shift valve A. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

--......-

".WI • -

A/fcunae"",

.... _

........ v....

~~mffi=fP

(cont'd)

BACK

14-51


Position: Driving in 4th gear

The PCM turns shift solenoid valve C OFF, and controls AfT clutch pressure control solenoid valve A to release LS A pressure (56). Shift solenoid valves A and B remain OFF. Releasing LS A pressure (56) releases CPC A pressure in the 3rd clutch pressure circuit. Shift solenoid valve C is turned OFF, and SH C pressure (SC) is applied to the right side of shift valve C. Then shift valve C is moved to the left side to switch the port of line pressure and CPC pressure. The CPC B pressure (5B) changes to line pressure (5B) at shift valve C, and flows to the 4th clutch via shift valve C, shift valve B, shift valve 0, and the manual valve. The 4th clutch pressure is changed to line pressure mode by switching the position of shift valve A, and shift valve C. The 4th clutch is engaged securely. The CPC B pressure (50) stops at shift valve A.

NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

I I

la.

14-52

BACK

00 Position The PCM controls the shift solenoid valves and the AIT clutch pressure control solenoid valves. The conditions of the shift solenoid valves and the positions of the shift valves are as follows: • Shift solenoid valve A is turned ON, and shift valve A is in the right side. • Shift solenoid valve B is turned ON, and shift valve B is in the right side. • Shift solenoid valve C is turned OFF, and shift valve C is moved to the left side. The PCM also controls AIT clutch pressure control solenoid valve B to apply LS B pressure (57) to CPC valve B. Line pressure (4) from the manual valve becomes line pressure (5C) at shift valve C. Line pressure (5C) flows to shift valve A via shift valve B, and becomes 2nd clutch pressure (20). The 2nd clutch pressure is applied to the 2nd clutch, and 2nd clutch is engaged securely. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

(cont'd)

BACK

14-53


ill Position The PCM controls the shift solenoid valves and the AfT clutch pressure control solenoid valves. The conditions of the shift solenoid valves and the positions of the shift valves are as follows: • Shift solenoid valve A is turned OFF, and shift valve A is moved to the left side. • Shift solenoid valve 8 is turned ON, and shift valve 8 is in the right side. • Shift solenoid valve C is turned ON, and shift valve C is in the right side. Line pressure (4) becomes line pressure (58) at shift valve C. Line pressure (5C) flows to shift valve 8 via shift valve A, and becomes 1st clutch pressure (10). 1st clutch pressure (10) is applied to the 1st clutch, and 1st clutch is engaged securely. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

"m'" ,. B~, ~ ct.u","

k: 1 .~

...

"" I)

i)

~l)S f\

~

r=-I t

H

•

~

rE!flb ..,. ,r

.---~

-,I;,

OROUE CONVERTER LuTCH SOLENOID "'-YE

~;!.

J

r·",;i-

~

·,VYI

I~

I

nl,

II'=iI

r

.=.

14-54

-rf- -. ~---

1~ct..,....

j=""

~ 2nw

, J i ~ ~~ I lID

W

II-il

.CfC'

[v..... IHI'TVALYEC

-;D

An cum:tI .....UM

10-

'II

I....., .......

AI

I!I'

-

'.

_1111

r

UK

IT

I

r.. ·

..U.

H.

[ · _ v....

I

f!I

,t

I

flu

n

~--

=--- ~~ ~JA ~

·1

.1

is_

1"- 11.:

~

I#~="

'(f

I~

~

~

~"PUW

BACK

.l.

~.

~

~,

~ :-.;~

-v....

lm :~[ ~....

'=tf

• MII

IU'

........

-

I I

." I.~YALVEA

·UW'-

"I' ~..

J

•

•

.lIi'I."

II.

-VAl.VEa

I'

uH

......

~

,Jl'

II~·-

11'".

..

~:

I"~

U

t i ~J

~

~UWT

• .c=-J ...

~,!H

-

--

';'

r'-v;~

11-1'

.11"1

I

.Ibl'·_

!~

i-:' ~==. . JI. .:r::u

l_

'Y

," .~

...

,r.

I'~

....

_a.UTCM

11 •

1

I I

[RJ Position: Shifting to [RJ position from [t] or [HI position. Line pressure (1) becomes line pressure (3) at the manual valve, and flows to the reverse CPC valve. Line pressure (3) is regulated by the reverse CPC valve and becomes line pressure (3'). Line pressure (3') pushes the servo valve to the reverse position, passes through the servo valve, and flows to the manual valve. Line pressure (3') becomes 4th clutch pressure (40). The 4th clutch pressure (40) is applied to the 4th clutch, and 4th clutch is engaged with the reverse CPC pressure mode. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

(cont'd)

BACK

14-55

Automatic Transmission System Description (cont'd) Hydraulic Flow (cont'd) [RJ Position: Driving in reverse gear The PCM turns shift solenoid valve C OFF. Shift solenoid valve A remains OFF, and B remains ON. Shift solenoid valve C is turned OFF, and SH C pressure (SC) is applied to the right side of the reverse CPC valve. Then the reverse CPC valve moves to the left side, creating full line pressure. Line pressure to the 4th clutch is the same as in [RJ position, and 4th clutch pressure increases. The 4th clutch is engaged with line pressure mode. Reverse Inhibitor Control

When the [RJ position is selected while the vehicle is moving forward at speed over 6 mph (10 km/h), the PCM outputs the 1st speed signal to turn the shift solenoid valve C ON; shift solenoid valve A remains OFF, and shift solenoid valve B remains ON. The reverse CPC valve is moved to right side and cover the port so stop the line pressure (3') to the servo valve. The line pressure (3') is not applied to the servo valve, and the 4th clutch pressure (40) is not applied to the 4th clutch, as result, power is not transmitted to the reverse position. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

+ £2:t

14-56

J

BACK

[f] Position Shift solenoid valve C is turned OFF by the PCM, and SH C pressure (SC) is applied to the right side of the reverse CPC valve. Then the reverse CPC valve is moved to the left side to uncover the port leading line pressure (3) to the servo valve. Line pressure (3') passes through the servo valve and flows to the manual valve. Line pressure (3') is intercepted at the manual valve, and is not applied to the clutches. NOTE:

• When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar. 1ST ACCUMULATOIII

2NDACCUMUUTOII

JllDACCUMUUTOll

(cont'd)

BACK

14-57

Automatic Transmission System Description (cont'd) Lock-up System In ~ position (3rd and 4th), and ~ position (3rd), pressurized fluid is drained from the back of the torque converter through a fluid passage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the mainshaft rotates at the same speed as the engine crankshaft. Together with hydraulic control, the PCM optimizes the timing of the lock-up mechanism. When the torque converter clutch solenoid valve (lock-up control solenoid valve) activates, modulator pressure changes to switch lock-up ON and OFF. The lock-up control valve and the lock-up timing valve control the range of lock-up according to AfT clutch pressure control solenoid valves A and B. The torque converter clutch solenoid valve is mounted on the torque converter housing, and AfT clutch pressure control solenoid valves A and B are mounted on the transmission housing. They are controlled by the PCM. General Operation

1. Operation (clutch on) With the lock-up clutch on, fluid in the chamber between the torque converter cover and the lock-up piston is drained off, and the converter fluid exerts pressure through the piston against the torque converter cover. As a result, the converter turbine is locked to the converter cover. The effect is to bypass the converter, placing the vehicle in direct drive. !powerflow

I

LOCK·UP PISTON

DAMPER SPRING

The power flows by way of: E~gina

TURBINE

~Ivep_

T~rque converter cover

'1Ck.UP piston

/

TORQUE CONVERTER COVER To ATF coolar

DTmper spring Turbina

I

Mainshaft

MAINSHAFT

2. Operation (clutch off) With the lock-up clutch off, fluid flows in the reverse of CLUTCH ON. As a result, the lock-up piston moves away from the converter cover, and torque converter lock-up is released. IPower flow

I

TURBINE

E~gina

PUMP

DrvePlate T'jrque converter cover Pimp Turbine

I

Mainshaft

To ATF cooler INlET

ttl I

MAiNSHAFT

14-58

BACK

No Lock-up The torque converter clutch solenoid valve is turned OFF by the PCM. The lock-up shift valve receives LC pressure (LA) on the left side, and modulator pressure (6) on the right side. The lock-up shift valve is in the right side to uncover the port leading torque converter pressure (92) to the left side of the torque converter. Torque converter pressure (92) becomes torque converter pressure (94), and enters into the left side of the torque converter (to disengage the lock-up clutch). The lock-up clutch is OFF. NOTE: • When used, "Ieft" or "right" indicates direction on the hydraulic circuit . • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

VALVE

REGULATOR VALVE

ATFCOCIWI ' - -_ _ _J

(cont'd)

BACK

14-59

Automatic Transmission System Description (cont'd) Lock-up System (cont'd) Partial lock-up As the speed of the vehicle reaches the prescribed value, the torque converter clutch solenoid valve is turned ON by the PCM to release LC pressure (LA) in the left side of the lock-up shift valve. The lock-up shift valve is moved to the left side to switch the port leading torque converter pressure to the left side and right side of the torque converter. Torque converter pressure (92) flows to the right side of the torque converter to engage the lock-up clutch. The PCM also controls AfT clutch pressure control solenoid valves A and B, and LS A or LS B pressure is applied to the lock-up control valve and the lock-up timing valve. The position of the lock-up control valve depends on torque converter pressure and LS A or LS B pressure. When LS A or LS B pressure (58) is lower, torque converter pressure (91) from the lock-up timing valve is lower. The lock-up clutch is engaged partially. LS A or LS B (58) increases, and the lock-up timing valve is moved to the left side to uncover the port leading torque converter pressure to high. The lock-up clutch is then engaged securely. Under this condition, the lock-up clutch is engaged by pressure from the right side of the torque converter; this condition is partial lock-up. NOTE: • When used, "Ieft" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

TCNIOUECONVEATER

I~~=LI'.:"'

14-60

BACK

Full Lock-up

When the vehicle speed further increases, the PCM controls AfT clutch pressure control solenoid valves A and B to increase LS A or LS B pressure (58). The LS A or LS B pressure (58) is applied to the lock-up control valve and the lock-up timing valve, and moves them to the left side. Under this condition, torque converter back pressure is released fully, causing the lock-up clutch to be fully engaged. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

[JJE§jJ~::::A"::LS:':..:'= ........... VALVE

COD.... _CII VALVE

REUEFVALVE

ATFCOOU. ' - -_ _ _- J

(cont'd)

BACK

14-61

Automatic Transmission System Description (cont'd) Circuit Diagram UNDER·HOOD FUSEIRELAY BOX BATTERY

N047(2OA)

;-t-lr-<~~--------~r-~::::----;:::::::::~~----------------------WHTNEL-----------------------------No.41 (lODA)

No 42 (SOA)

No 6 (ISA)

IGI BAT ST IGNITION SWITCH

No.5-C (4DA)

No.9 (7.SA)

No I(ISA)


DRIVERS UNDER·DASH FUSEIRELAY BOX

No.46 (ISA)

SHIFT lOCK SOLENOID SHIFT LOCK SOLENOID

PGM·FI MAIN

B22

RELAY

BlKNEL

PASSENGER·S UNDER· DASH FUSEIRELAY BOX

GRN TRANSMISSION RANGE SWITCH YEUBlK

YEUBlK

B21

BI

B9

VBU

IGPI

IGP2

WHTNEl

ToSV

BLK

os

GIOI

BIO

B2 PGI

VB SOL

ILU

PG2

Tol2V

TOl2V 5V

REGULATOR

POWERTRAIN CONTROL MODULE (PCM)

OUT

VSP

04 IND

AS

AI4

BlUlWHT

GAWIIU<

DRIVERS UNDER-DASH FUSEIRElAY BOX No9 (7.SA)

Y YEl

NP

DRIVER'S UNDER.DASH FUSEIRELAY BOX

}-------H e15 co

BlKIBlU

WHT---;

el. REDlBlK

."

1l-1!"

--I •

BLKlBlU

I

MULTIPLEX CONTROL UNIT, DRIVER'S

-ip:

BLKlBLU

BlUIWHT

BLU

YEL PNK

~

el2

!

I

BAN

I

I

l

i STARTER CUT RELAY

WHT---4 REDlBLK -;

.!...

REDlBU<

r- LTBLU

co e7

PNK---; 9

1-___------'

PNK---4

BlU---;

BLU ---4

BRN---; •

BRN---4

e. II.

WHT

p

GAUGE ASSEMBLY

••

ATP

L

--t:>

pNK

~BLU

L!!-. BRN J Bn

BLK

1

I.

,

a

T

Gsal

6

7

RED

D.

TRANSMISSION RANGE SWITCH

14-62

BACK

I

BlU

GAY

31

2

1111111 YEL

N

• •

D,

ST

REDlWHT

A

E

G~I

CRUISE CONTROL UNIT

IW

GRN

REDlWHT

010

016

C26

C2I

C27

CII

NC

NCSG

ECT

VCC2

TPS

SG2

.,.,-

.,-

?

.,LSA·

LSA+

LSI·

B8

117

II'

WIlT

RED

GRN

.,- .,-

LSI. 1125

ORN

.,-

LC

SHA

SHI

SHC

01

07

02

D3

VEL

GRNlWHT

ILUIYEL

.,-

.,- .,-

POWERrRAIN CONTROL MODULE [PCM)

GRN

II.

B24

lLUllLK

ILUNlHT

.,-

LGI

~G2

B20

B22

Ll

T T

VEL

GRN.9LK

ILK

ILK 2ND CLUTCH

3RDCWTCH

PRESSURE SWITCH

PRESSURE SWITCH

TORQUE SHIFT CONVERTER SOLENOID

CLUTCH SOLENOID

VALVE A

VAlVE

GIOI

Gl0l

GIOI

PeM Co_ Terminal Locahans

A (32P)

I (2SP)

C(31P)

BACK

o (16P)

14-63

Automatic Transmission DTC Troubleshooting DTC P1753: Problem in Torque Converter Clutch Solenoid Valve Circuit


NOTE: Record all freeze data before you troubleshoot.

6. Measure the resistance between the D1 and 820 or 822 terminals. PCM CONNECTORS


lC (YEll

2. Disconnect PCM connector 8 (25P) and D (16P). 3. Turn the ignition switch ON (II). 4. Measure the voltage between the D1 and 820 or 822 terminals. PCM CONNECTORS lG1 (BRN/BlK)

lC(YEl) B(25P) 1

'-------{QI----------'


2

Is the resistance 12- 25

9

~2

?

YES-Go to step 11. '------{':i,}---------'

NO-Go to step 7.

lG1 (BRN/BlK)

7. Check for continuity between the 820 and 822 terminals and body ground.


PCM CONNECTOR B (25P)

Is there voltage? YES- Repair short to power in the wire between the D1 terminal and the torque converter clutch solenoid valve .•

2 9

7 8

10

19 20

NO- Go to step 5.

3 4 5

21 22

232425

lG2 (BRN/BlK)


Is there continuity? YES- Go to step 8. NO- Repair open in the wires between the 820 and 822 terminals and ground (G101) .•

14-64

BACK

8. Disconnect the torque converter clutch solenoid valve/shift solenoid valve A 2P connector.

11. Turn the ignition switch ON (II). 12. Measure the voltage between the D5 and 820 or 822 terminals.

9. Check for continuity between the Dl and 820 or 822 terminals.

PCM CONNECTORS

PCM CONNECTORS LC (YEll )-----...,

r-----------~~~------~~

B(25P) 1

2

9

10

19 20 '---------;~I-------'

lG1 (BRN/BlK)

LG1 (BRN/BLK)

Wire side of female terminals Wire side of female terminals

Is there battery voltage? Is there continuity? YES-Repair short to ground in the wire between the Dl terminal and the torque converter clutch solenoid valve .• NO-Go to step 10. 10. Measure the resistance between the No.1 terminal of the torque converter clutch solenoid valve/shift solenoid valve A connector and body ground.

YES- Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck.• NO-Check for blown No.6 (15A) fuse in the driver's under-dash fuse/relay box. Ifthe fuse is OK, repair open in the wire between the D5 terminal and the driver's under-dash fuse/relay box .•

TORQUE CONVERTER CLUTCH SOLENOID VALVE SHIFT SOLENOID VALVE A CONNECTOR (2P)


Is the resistance 12- 25 Q ? YES-Check for open in the wire between the Dl terminal and the torque converter clutch solenoid valve .• NO- Replace the torque converter clutch solenoid valve/shift solenoid valve A..

BACK

14-65

Automatic Transmission DTC Troubleshooting (cont'd) DTC P1705: Short in Transmission Range Switch Circuit


NOTE: Record all freeze data before you troubleshoot. NO-Check for short in the wire between the D6 terminal and the transmission range switch or AfT gear position indicator, and check for an open in the wires between the 820 and 822 terminals and body ground (G101). If wires are OK, check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .•

1. Turn the ignition switch ON (II). 2. Observe the AfT gear position indicator, and shift each position separately.

Do any indicators stay on when the shift lever is not in that position? YES-Go to step 3.

8. Shift to all positions other than ~ or IHJ.

NO- The system is OK at this time. Check the wire harness for damage.•

9. Measure the voltage between the D13 and 820 or 822 terminals. PCM CONNECTORS

3. Disconnect the transmission range switch connector.

1

2

9

10

Do all gear position indicators go out? YES - Replace the transmission range switch ••

19 20

4. Turn the ignition switch OFF, and connect the transmission range switch connector.

6. Shift to all positions other than

IRJ.

°(16P)

B(25P)

10 11 12 13 14

19 20

/

V7

16 17 18

2122

23 24 25

l~2T

'Y.

(BRN/BlK)

lG1 BRN / BlK

r-

8

1

2 3

V

r--

5

6 7 8 9 10 11 12

11

I

16 14 15 '-ATPR(WHT)

'Y. Wire side of female terminals

14-66

~

/

r--

5

6 7 8 9 10 11 12

I

16

--

ATP NP (BlU/WHT

'::i

Is there about 5 V?

PCM CONNECTORS

9

21 22

1314 15

23 24 25

2 3


7. Measure the voltage between the D6 and 820 or 822 terminals.

345

V7 8 11 12 13 14 V 1617 18 345

lG1 (BRN/BLK)


2

(16P)

r-

1

l;2T (BRN/BlK)

NO-Goto step 4.

1

°

B(25P)

BACK

YES-Go to step 10. NO-Check for short in the wire between the D13 terminal and the transmission range switch, and in the ~ and IHJ position signal wires between the AfT gear position indicator and the transmission range switch. If wires are OK, check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck.•

10. Shift to all positions other than~.

12. Shift to all positions other than~.

11. Measure the voltage between the 09 and 820 or 822 terminals.

13. Measure the voltage between the 08 and 820 or 822 terminals. PCM CONNECTORS

PCM CONNECTORS

1

2

9

10 11

19

20

V 7 81 12 13 14 V 16 17 181 345

21 22

1

lG1 (BRN/BlK)

6

7

2

3V J5l

1

2

8

9 10 111121

9

10

11 12 13 14

19

20

21 22

13 14 1511 16 '--

23 24 25

l';2 (BRN/BlK)

-1

D (16P)

B (25P)

D (16P)

B(25P)

Y.

ATP D4 (V EL)

Y.

r81

1

V 16 17 181

6

23 24 25

13 1411

y.

l;2T (BRN/BlK) lG1 (BRN/BlK)


V7

345

2 3 7

8

V

-

5

9 10 11 12 16 '--

J ATPD3 (PNK

Y. Wire side of female terminals

Is there about 5 V? Is there battery voltage? YES-Goto step 12. YES-Go to step 14.

NO - Check for short in the wi re between the 09 terminal and the transmission range switch. If wire is OK, check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .•

NO- Check for short in the wire between the 08 terminal and the transmission range switch or AfT gear position indicator. If wires are OK, check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .•

(cont'd)

BACK

14-67

Automatic Transmission OTe Troubleshooting (cont'd) 14. Shift to all positions other than 00.

16. Shift to all positions other than III.



PCM CONNECTORS

PCM CONNECTORS

D (16P)

B(25P)

1

2

9

10 11 12 13 14

19 20

v

V

2

V 1617 18

6 7 8 9 10 11 12

9

10 11 12 13 14

23 2425

13 14 15

L";2l" (BRN/BLK) LG1 (BRN/BLK)

2 3

1

7 8

':L

1

D (16P)

B (25P)

.-5

345 21 22

.--

16

19 20

'--

1 ATP2 (BLU)

II

345 2122

L~2T

I

,.........

7 8

1617 18

':L

LG1 (BRN/BLK)

2 3

V

.5

6 7 8 9 10 11 12 13 14 15

23 24 25

16 '--

':L

(BRN/BLK)

1

I ATP1 (BRN)

':L Wire side of female terminals




YES- Go to step 16.

YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck.•

NO-Check for short in the wire between the 014 terminal and the transmission range switch or AfT gear position indicator. If wires are OK, check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .•

14-68

BACK

NO-Check for short in the wire between the 015 terminal and the transmission range switch or AfT gear position indicator. If wires are OK, check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck.•

DTC P1706: Open in Transmission Range Switch Circuit (no gear position inputs)

4. Turn the ignition switch ON (II). 5. Shift to ~ position.

NOTE: Record all freeze data before you troubleshoot. 1. Test the transmission range switch (see page 14138). Is the switch OK?

6. Measure the voltage between the 09 and 820 or 822 terminals. PCM CONNECTORS B(25P) 1

2

9

10 11 12 1314

YES-Go to step 2. NO- Replace the transmission range switch .•

D(16P)

19

20

21 22


9

10

11 12 13 14

19

20

21 22

2 3

6 7 8

16 17 18

131415

23 24 25

'Y.

lG1 BRNI BlK


345

V

-1

7 8

l-;2T (BRN/BlK)


2

v

345

V

r-5

9 10 11 12

~

16 '--

ATPD4(YELI


Is there voltage?

7 8

YES- Repair open in the wire between the 09 terminal and the transmission range switch .•

23 24 25

lG1 (BRN/BlK)

NO-Goto step 7. 7. Shift to [RI position. 8. Measure the voltage between the 06 and 820 or 822 terminals.


PCM CONNECTORS


D(16P)

B(25P)

YES-Goto step 4. 1

NO- Repair open in the wires between the 820 and 822 terminals and ground (G 101), or repair poor ground (G101) .•

2

V7

345

9

10 11 12 13 14

V 16

19

20

23 24 25

21 22

T

l-;2 (BRN/BlK) lG1 BRN I BlK

-

8

17 18

'Y.

1

2 3

-5

/

6 7 8 9 10 11 12

j: I

14 15

16

-

ATPR(WHT)


Is there voltage? YES-Repair open in the wire between the 06 terminal and the transmission range switch .• NO-Gotostep9.

(cont'd)

BACK

14-69

Automatic Transmission DTC Troubleshooting (cont'd) 9. Shift to (f] or [ID position.

00 position.

13. Shift to



PCM CONNECTORS

PCM CONNECTORS

1

2

345

9

10

11 12 13 14

20

19

/

-

/

16 17 18

6 7 8

V

r5

1

2

9 10 11 12

9

10 11 12 1314

1314 15

23 24 25

21 22

2 3

1

7 8

D (16P)

B (25P)

D (16P)

B(25P)

16

19

/

345

20

21 22

/

6

16 17 18

23 24 25

lG1 (BRN/BlK)

V

r5

9 10 11 12 16 '--

I ATP NP (BLU/WHT

':i

(BRN/BlK)

7 8

13 14 15

'--

l~2T

2 3

1

7 8

;2T (BRN/BlK) lG1 BRN BlK

':i

I ATP2(BLU)

':i ':i



Is there voltage? Is there voltage? YES - Repa i r open in the wi re between the D 14 terminal and the transmission range switch .•

YES-Repair open in the wire between the D13 terminal and the transmission range switch .•

NO-Gotostep 15. NO-Go to step 11. 15. Shift to 11. Shiftto~ position. 12. Measure the voltage between the D8 and 820 or 822 terminals.

rn position.


PCM CONNECTORS

PCM CONNECTORS B(25P)

D (16P)

D (16P)

B{25P) 1

2

345

9

10

11 12 13 14

19

20

21 22

~2T

/

/

7 8

1617 18

2 3

678 13 141!

23 24 25

/

5

9 10 11 12

':i

1

2

345

9

10

11 12 1314

19

20

21 22

/

/

7 8

16 17 18

23 2425

1

2 3/

678 13 14 15

f5l

9 10 111121 16 '--

16 '--

(BRN/BlK) lG1 BRN / BlK

1

r--

I ATPD3{PNK

';2T (BRN/BlK)

I ATP 1 (BRN)

':i

lG1 (BRN/BlK)

':i

':i


Is there voltage? Is there voltage? YES-Repair open in the wire between the 015 terminal and the transmission range switch .•

YES-Repair open in the wire between the D8 terminal and the transmission range switch .•

NO-Check for loose terminal fit in the PCM connectors. If necessary, subsitute a known-good PCM and recheck .•

NO-Goto step 13.

14-70

BACK

DTC P0753: Problem in Shift Solenoid Valve A Circuit NOTE: Record all freeze data before you troubleshoot.

5. Turn the ignition switch OFF. 6. Measure the resistance between the D7 and 820 or 822 terminals. PCM CONNECTORS

1. Turn the ignition switch OFF. 2. Disconnect PCM connectors 8 (25P) and D (16P).

B(25P)

-1 -2


9


0

V7

345

10 1112 1314

19 20

SH A (BlU/YEl)

Q

2122

/

81

1617 18J

23 24 25

1

2

9

10 11 12 1314

19 20

0

345

2122

23/

lsi J

6 7 8 9 10 11112 131 415

16

-

Q

SH A (BlU/YEl)

y.

-;-

D(16P)

'- TlG2 (BRN/BlK)

lG1 (BRN/BlK)

B(25P)

-1

D (16P)

V V 1617 181

r-1

23 24 25

131 415

7 81


23V lsi

Is the resistance 12- 25 Q ?

6 7 8 9 10 111121 16

VES-Gotostep 11.

'-

'-TlG2 (BRN/BlK)

lG1 (BRN/BlK)

Y.


NO- Go to step 7. 7. Check for continuity between the 820 and 822 terminals and body ground. PCM CONNECTOR B (25P)

Is there voltage? VES- Repair short to power in the wire between the D7 terminal and the shift solenoid valve A .•

345

2

NO-Goto step 5.

9

10

11 12 13 14

19

20

21 22

7 8

23 24 25


Is there continuity? YES - Go to step 8. NO- Repair open in the wires between the 820 and 822 terminals and ground (G101) .•

(cont'd)

BACK

14-71

Automatic Transmission DTC Troubleshooting (cont'd) 11. Turn the ignition switch ON (II).

8. Disconnect the torque converter clutch solenoid valve/shift solenoid valve A 2P connector.


9. Check for continuity between the 07 and 820 or 822 terminals.

PCM CONNECTORS VB SOL (BLK/YEL)

PCM CONNECTORS SH A (BLU/YEL)

':i

B (25P)

)--------,

D(16P)

r--r--

1

2

9

10 1112 1314

19 20

345

-=r '-T 2122

V 7 eJ

V

1617 1aJ 23 24 25

"-"&PI 1 2 6 7

?h 5

e 9 10 1~12J

1314 15

LG2 (BRN/BLK)

LG1 (BRN/BLK)

3/

-

16

':i

LG1 (BRN/BLK)


/s there battery voltage? /s there continuity? YES- Repair short to ground in the wire between the 07 terminal and shift solenoid valve A.• NO- Go to step 10. 10. Measure the resistance between the No.2 terminal of the torque converter clutch solenoid valve/shift solenoid valve A connector and body ground. TORQUE CONVERTER CLUTCH SOLENOID VALVEI SHIFT SOLENOID VALVE A CONNECTOR (2P)


/s the resistance 12- 25 Q ? YES-Check for open in the wire between the 07 terminal and shift solenoid valve A.. NO- Replace the torque converter clutch solenoid valve/shift solenoid valve A .•

14-72

BACK

YES - Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck.• NO-Check for blown No.6 (15A) fuse in the driver's under-dash fuse/relay box. If the fuse is OK, repair open in the wire between the 05 terminal and the driver's under-dash fuse/relay box.•

DTC P0758: Problem in Shift Solenoid Valve B Circuit NOTE: Record all freeze data before you troubleshoot.

5. Turn the ignition switch OFF. 6. Measure the resistance between the 02 and 820 or 822 terminals. PCM CONNECTORS

1. Turn the ignition switch OFF. 2. Disconnect PCM connectors 8 (25P) and 0 (16P).

B(25P) -r--

3. Turn the ignition switch ON (II). 4. Measure the voltage between the 02 and 820 or 822 terminals. PCM CONNECTORS

':i.

B(25P) -r---

1

2

9

10 1112 1314

19 20

0

SH B (GRN/WHT)

345

2122

/

V7

1

81

1617 18 1

23 24 25

2 3

1314 15

lG1 (BRN/BlK)

10

IO(16P) r-

V 7 81 1112 1314 V 1617 181 345

1

23 24 25

2122

2 3/

r5J

6 7 8 9 10111121 1314 15

16 '-

- TlG2 (BRN/BlK)

Q

lG1 (BRN/BlK)


V r5J


16

-

YES - Go to step 11 .

':i.


9

0

6 7 8 9 10111121

...... TlG2 (BRN/BlK)

2

19 20

IIO(16P) r-

1

SH B (GRN/WHT)

.Q

NO - Go to step 7. 7. Check for continuity between the 820 and 822 terminals and body ground.

Is there voltage?


YES - Repair short to power in the wire between the 02 terminal and the shift solenoid valve 8 .•

2

NO - Go to step 5.

9

10

19

20

7 8

345 11 21 22

23 24 25

lG2 (BRN/BlK)


Is there continuity? YES-Go to step 8. NO- Repair open in the wires between the 820 and 822 terminals and ground (G101 ).•

(cont'd)

BACK

14-73

Automatic Transmission DTC Troubleshooting (cont'd) 8. Disconnect the shift solenoid valve B 2P connector.


9. Check for continuity between the D2 and B20 or B22 terminals.

12. Measure the voltage between the D5 and B20 terminals.

PCM CONNECTORS

PCM CONNECTORS VB SOL }-_ _ _ _ _ _ _....:.IB:...:l::.:.:;K/yELI

SH B IGRN/WHTI l--------.

DI16PI

BI25PI 2 9

10 11 12 13 14

19 20

21 22

232425

lG2IBRN/BlK) '------I

lG1 IBRN/BlK)

Qr------.......J

lG1IBRN/BlKI


' - - - - - - 1 'Y.}-------l




YES- Repair short to ground in the wire between the D2 terminal and the shift solenoid valve B.•

YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .•

NO- Go to step 10. 10. Measure shift control solenoid valve B resistance at the solenoid valve connector. SHIFT SOLENOID VALVE B CONNECTOR


Is the resistance 12- 25 Q ? YES - Check for open in the wi res between the D2 terminal and the shift solenoid valve Band between the No.1 terminal of the shift solenoid valve B connector and ground (G101) .• NO- Replace the shift solenoid valve B.•

14-74

BACK

NO-Check for blown No.6 (15A) fuse in the driver's under-dash fuse/relay box. If the fuse is OK, repair open in the wire between the D5 terminal and the driver's under-dash fuse/relay box .•

DTC P0720: Problem in Countershaft Speed Sensor Circuit NOTE: Record all freeze data before you troubleshoot.

4. Disconnect PCM connector D (16P). 5. Check for continuity between body ground and the D10 terminal and D16 terminal individually. PCM CONNECTOR D (16PI

1. Check the countershaft speed sensor installation.

NC(BLUI

Is the countershaft speed sensor installed properly?

~:::;:t::J 2 3

6 7 8 9

YES-Go to step 2.

5

12

13 14 15 NO- Reinstall and recheck .• 2. Disconnect the countershaft speed sensor 2P connector.

=

= 3. Measure countershaft speed sensor resistance at the sensor connector.



COUNTERSHAFT SPEED SENSOR CONNECTOR

YES- Repair short in the wires between the D10 and D16 terminals and the countershaft speed sensor.• NO-Go to step 6. 6. Connect the countershaft speed sensor connector. 7. Measure the resistance between the D10 and D16 terminals. PCM CONNECTOR D (16PI



NC (BLUI

.---

1

YES - Go to step 4.

2 3 II

II

....--

5

6 7 8 9 10 11 12

NO- Replace the countershaft speed sensor..

13 14 15

Q

16

NCSG(GRNT


Is the resistance 400- 600 Q ? YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .• NO- Repair loose terminal or open in the wires between the D10 and D16 terminals and the countershaft speed sensor.•

BACK

14-75

Automatic Transmission DTC Troubleshooting (cont'd) DTC P0715: Problem in Mainshaft Speed Sensor Circuit

4. Disconnect PCM connector D (16P).

NOTE: • Record all freeze data before you troubleshoot. • Code P0715 (15) on the PCM doesn't always mean there's an electrical problem in the mainshaft or countershaft speed sensor circuit; code P0715 (15) may also indicate a mechanical problem in the transmission. Any problem causing irregular countershaft to mainshaft speed difference can cause this code.

5. Check for continuity between body ground and the D11 terminal and D12 terminal individually. PCM CONNECTOR D (16P)

2 3

5

6 7 8 9 10 11 12 13 14 15

16

NM(REO)

1. Check the mainshaft and countershaft speed sensor installation. Are the mainshaft and countershaft speed sensors installed properly?


YES-Go to step 2.


NO- Reinstall and recheck .•

YES- Repair short in the wires between the D11 and 012 terminals and the mainshaft speed sensor.•

2. Disconnect the mainshaft speed sensor 2P connector.

NO - Go to step 6. 3. Measure mainshaft speed sensor resistance at the sensor connector. MAINS HAFT SPEED SENSOR CONNECTOR

6. Connect the mainshaft speed sensor connector. 7. Measure the resistance between the 011 and 012 terminals. PCM CONNECTOR 0 (16P)

2 3

5

6 7 8 9 10 11 12 13141516 NM (RED)


Is the resistance 400- 600 Q ? Wire side of female terminals

YES- Go to step 4. Is the resistance 400- 600 Q ? NO - Replace the mainshaft speed sensor.. YES-Run the Electrical Troubleshooting Flowchart for code P0720 (code 9). Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .• NO-Go to step 8.

14-76

BACK

8. Disconnect the mainshaft speed sensor 2P connector. 9. Check for continuity between the D11 terminal and the No.1 terminal of the mainshaft speed sensor connector. PCM CONNECTOR D (16P)

2 3

5

678

12

13 14 15

MAINSHAFT SPEED SENSOR CONNECTOR Wire side of female terminals

Is there continuity? YES- Go to step 10. NO-Repair open in the wire between the D11 terminal and the mainshaft speed sensor.. 10. Check for continuity between the D12 terminal and the No.2 terminal of the mainshaft speed sensor connector. PCM CONNECTOR D (16P) 2 3

5

6 7 8 9 10 11 12 131415

MAINSHAFT SPEED SENSOR CONNECTOR

L..---'---'


Is there continuity? YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .• NO- Repair open in the wire between the D12 terminal and the mainshaft speed sensor..

BACK

14-77

Automatic Transmission DTC Troubleshooting (cont'd) DTC P1768: Problem in AfT Clutch Pressure Control Solenoid Valve A Circuit NOTE: Record all freeze data before you troubleshoot. 1. Disconnect the NT clutch pressure control solenoid valve A 2P connector. 2. Measure NT clutch pressure control solenoid resistance at the solenoid valve connector.

Is there continuity? YES- Repair short to ground in the wires between the 88 and 817 terminals and NT clutch pressure control solenoid valve A .• NO-Go to step 5. 5. Connect the NT clutch pressure control solenoid valve A connector.

AfT CLUTCH PRESSURE CONTROL SOLENOID VALVE A CONNECTOR

6. Measure the resistance between the 88 and 817 terminals. PCM CONNECTOR B (25P) LSA-IWHT)

1


2

345

9

10 11 12 13 14

19

20

2122

V

V

I 7 8

16 17 18

23 24

-LSA+(RED)

~

Is the resistance about 5 Q ? Wire side of female terminals

YES - Go to step 3.

Is the resistance about 5 Q ? NO - Replace the NT clutch pressure control solenoid valve A.•

YES-Go to step 7.

3. Disconnect the 8 (25P) connector from the PCM. 4. Check for continuity between body ground and the 88 terminal and the 817 terminal individually. PCM CONNECTOR B (25P) LSA-(WHT)

2

9

10

19

20

3 4 5

21 22

LSA+(RED)

Q

Q =


14-78

BACK

NO- Repair loose terminal or open in the wires between the 88 and 817 terminals and NT clutch pressure control solenoid valve A.•


7. Disconnect PCM connector 0 (16P). 8. Turn the ignition switch ON (II).

PCM CONNECTOR B 125P)


2

PCM CONNECTORS

'Y.

BI25PI

-..--

345

1

2

9

10 1112 1314

-T 19 20

VB SOL IBLK/YEL

2122

V7

o n6P)

81

V

1617 18 1 23 2425

1

2

3/

9

10

19

20

21 22

23 24 25

M

6 7 8 9 10 111121 1314 15

-TLG2IBRN/BLK)

16

-


'Y.

LG1 IBRN/BLK)

Is there continuity? Wire side of female terminals


Is there battery voltage? YES-Go to step 10. NO-Check for blown No.6 (15A) fuse in the driver's under-dash fuse/relay box. Ifthe fuse is OK, repair open in the wire between the 05 terminal and the driver's under-dash fuse/relay box.•

NO- Repair open in the wire between the 82, 810, 820 and 822 terminals and ground (G101). Repair poor ground (G101) .•


BACK

14-79

Automatic Transmission DTC Troubleshooting (cont'd) DTC P0763: Problem in Shift Solenoid Valve C Circuit NOTE: Record all freeze data before you troubleshoot.



SHC(GRN)

Q

2. Disconnect PCM connectors 8 (25P) and D (16P). ,--,--


345

1

2

9

10 1112 1314

19 20

~T

2122

D (16P)

II V 1617 18 1 7 81

23 2425

r1

II

2 3

1314 15

lG1 (BRN/BlK)

10 1112 1314 2122 L-

T

I

1

1617 18 1

2 3

I f5l

6 7 8 9 10 111121 1314 15

2324 25

16 '-

lG2 (BRN/BlK)

Q


I f5l

6 7 8 9 10 111121

L-TlG2 (BRN/BlK)

9

,..-

7 81

lG1 (BRN/BlK)

SHC(GRN)

':i.

B(25P)

2

-=r

II

3 4 5

1

19 20

II

D (16P)

B(25P)


16

-

Is the resistance 12- 25 Q ? YES- Go to step 11.

':i.

NO-Go to step 7. 7. Check for continuity between the 820 and 822 terminals and body ground.



Is there voltage? YES- Repair short to power in the wire between the D3 terminal and the shift solenoid valve C.•

2 9

78

10

19 20

NO - Go to step 5.

345 21 22

23 24 25

LG2 (BRN/BlK)


Is there continuity? YES - Go to step 8. NO- Repair open in the wires between the 820 and 822 terminals and ground (G101) .•

14-80

BACK

8. Disconnect the shift solenoid valve C 2P connector.


9. Check for continuity between the D3 and 820 or 822 terminals.


PCM CONNECTORS SHC(GRNI

)--------. r-----,

B(25PI 2 9

.----------~'Y.l------------=-=, B(25PI

345

10

19 20

2122

232425

1

2

9

10

19 20

21 22

LG1 (BRN/BLKI

232425

LG2 (BRN/BLKI

LG2 (BRN/BLKI

~------~~r---------~

LG1 (BRN/BLKI


L--------I'Y.l-------'




YES-Repair short to ground in the wire between the D3 terminal and the shift solenoid valve C.•

YES - Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .•

NO- Go to step 10. NO-Check for blown No.6 (15A) fuse in the driver's under-dash fuse/relay box. (f the fuse is OK, repair open in the wire between the D5 terminal and the driver's under-dash fuse/relay box .•

10. Measure shift solenoid valve C resistance at the solenoid valve connector. SHIFT SOLENOID VALVE C CONNECTOR


Is the resistance 12- 25 Q ? YES-Check for open in the wires between the D3 terminal and the shift solenoid valve C and between the No.1 terminal of the shift solenoid valve C connector and ground (G101) .• NO- Replace shift solenoid valve C.•

BACK

14-81

Automatic Transmission DTC Troubleshooting (cont'd) DTC P1773: Problem in AfT Clutch Pressure Control Solenoid Valve B Circuit

4. Check for continuity between body ground and the 818 terminal and the 825 terminal individually. PCM CONNECTOR B (25P)

NOTE: Record a" freeze data before you troubleshoot. 1. Disconnect the AfT clutch pressure control solenoid valve 8 2P connector.

2

2. Measure AfT clutch pressure control solenoid resistance at the solenoid valve connector.

9

10 11

19

20

AfT CLUTCH PRESSURE CONTROL SOLENOID VALVE B CONNECTOR


Is there continuity? YES- Repair short to ground in the wires between the 818 and 825 terminals and AfT clutch pressure control solenoid valve 8 .• Terminal side of male terminals

Is the resistance about 5 Q ?

NO - Go to step 5. 5. Connect the AfT clutch pressure control solenoid valve 8 2P connector.

YES- Go to step 3. NO- Replace the AfT clutch pressure control solenoid valve 8 .•

6. Measure the resistance between the 818 and 825 terminals. PCM CONNECTOR B (25P)

3. Disconnect the PCM connector 8 (25P).

1

2

9

10

19

20

V7 8 11 12 13 14 V 16 17 18 3 4 5

21 22

23 24 25

LSB-(GRN)

'--'--

LSB+(ORNI

.Q


Is the resistance about 5 Q ? YES-Go to step 7. NO- Repair loose terminal or open in the wires between the 818 and 825 terminals and AfT clutch pressure control solenoid valve 8 .•

14-82

BACK

7. Disconnect PCM connector D (16PI.


8. Turn the ignition switch ON (III.




PCM CONNECTORS

':L

B(25P) 2 9

3 4 5

D(16P)

7 8

345

2 9

10

11 12 13

19

20

21 22

23 24 25

2 3

6 7 8

10

19 20

VB SOL (BLK/YEL)

2122

23 24 25

1314 15

16

LG2 (BRN/BLK)

L....------{':L 1 - - - - - - - - ' LG1 (BRN/BLK)

= Wire side offemale terminals




YES - Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .•

YES - Go to step 10. NO-Check for blown No.6 (15AI fuse in the driver's under-dash fuse/relay box. If the fuse is OK, repair open in the wire between the D5 terminal and the driver'S under-dash fuse/relay box.•

BACK

NO - Repair open in the wire between the 82, 810, 820 and 822 terminals and ground (G1011. Repair poor ground (G1011 .•

14-83

Automatic Transmission DTC Troubleshooting (cont'd) DTC P1738: Problem in 2nd Clutch Pressure Switch Circuit

3. Turn the ignition switch OFF. 4. Disconnect PCM connector B (25P).

NOTE: Record all freeze data before you troubleshoot. 1. Turn the ignition switch ON (II).

5. Disconnect the 2nd clutch pressure switch connector.

2. Measure the voltage between the B14 and B20 or B22 terminals.

6. Check for continuity between the B14 terminal and body ground.



2 9

1

10 11

19 20

2

3 4 5

9 10 11 12 13 21 22

23 24 25

19 20

21 22

1-.1.-

14V 16 17 18 23 24 25 OP2SWIBlU /BlK)

OP2SW IBlU/BlK)

lG1 IBRN/BlK)

:1 7 8

lG2 IBRN/BlK)



Is there about battery voltage?


YES-Goto step 7.

VES- Repair short to ground in the wire between the B14 terminal and the 2nd clutch pressure switch .•

NO- Go to step 3.

NO-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .•

14-84

BACK

7. Raise the front of the vehicle, and make sure it is securely supported.

13. Turn the ignition switch ON (II). 14. Measure the voltage between the 2nd clutch pressure switch connector terminal and body ground.

8. Set the parking brake, and block rear wheels securely.

2ND CLUTCH PRESSURE SWITCH CONNECTOR

9. Start the engine, then shift to 00 position and drive for more than five seconds. 10. Measure the voltage between the 814 and 820 or 822 terminals. PCM CONNECTOR B (25P)

2 9

10 11

19

20

21 22

23 24 25

Wire side of female terminal

OP2SW (BlU/BlK)

lG1 (BRN/BlK)


lG2 (BRN/BlK)

YES - Go to step 15. Wire side of female terminals

NO- Repair open in the wire between the 2nd clutch pressure switch and the PCM.•

Is there aboutO V? YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .•

15. Measure the resistance between the 2nd clutch pressure switch connector terminal and body ground.

NO-Goto step 11.


11. Turn the ignition switch OFF. 12. Disconnectthe 2nd clutch pressure switch connector.

Terminal side of male terminal

Is the resistance 10 MQ or more? YES- Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .• NO - Replace the 2nd clutch pressure switch .•

BACK

14-85

Automatic Transmission DTC Troubleshooting (cont'd) DTC P1739: Problem in 3rd Clutch Pressure Switch Circuit

3. Turn the ignition switch OFF. 4. Disconnect PCM connector 8 (25P).

NOTE: Record all freeze data before you troubleshoot. ,. Turn the ignition switch ON (II).

5. Disconnect the 3rd clutch pressure switch connector.


6. Check for continuity between the 824 terminal and body ground. PCM CONNECTOR B (25P)


2 9

7 8

10

1

2

9

10 11 12 13 14

19 20

19 20

3 4

2122 '--'--

5

V7

8

[7 1617 18

1

2324 25

W(BLU/WHT)

OP3SW (BLU/WHT)

LG1 (BRN/BLK)

P3

•

LG2 (BRN/BLK)





YES-Go to step 7.

VES- Repair short to ground in the wire between the 824 terminal and the 3rd clutch pressure switch .•

NO - Go to step 3.

NO- Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .•

14-86

BACK


13. Turn the ignition switch ON (II). 14. Measure the voltage between the 3rd clutch pressure switch connector terminal and body ground.

8. Setthe parking brake, and block rear wheels securely.

3RD CLUTCH PRESSURE SWITCH CONNECTOR

9. Start the engine, then shift to ~ position and drive in 3rd gear for more than five seconds. 10. Measure the voltage between the 824 and 820 or 822 terminals. PCM CONNECTOR B (25P)

1

2

9

10

7 8

=

19 20 LG1

Wire side of female terminal OP3SW (BLU/WHT)

(BRN/BLK)


LG2 (BRN/BLK)

YES-Go to step 15. Wire side of female terminals

NO- Repair open in the wire between the 3rd clutch pressure switch and the PCM .•

Is there about 0 V? YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .•

15. Measure the resistance between the 3rd clutch pressure switch connector terminal and body ground.

NO-Goto step 11.


11. Turn the ignition switch OFF. 12. Disconnect the 3rd clutch pressure switch connector.


Is the resistance 10 MQ or more? YES - Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .• NO- Replace the 3rd clutch pressure switch .•

BACK

14-87

Automatic Transmission DTC Troubleshooting (cont'd) DTC P0740: Problem in Lock-up Control System

8. Recheck for code P0740.

Does the OBO /I scan too/ indicate code P0740? NOTE: • Record all freeze data before you troubleshoot. • Keep replacement solenoid valves on hand: - Torque converter clutch solenoid valve/shift solenoid valve A - AIT clutch pressure control solenoid valves A and B 1. Check whether the OBD II scan tool indicates another code.

Does the OBO /I scan too/ indicate another code? YES - Perform the Troubleshooting Flowchart for the indicated Code(s). Recheck for code P0740 after troubleshooting .•

NO- Go to step 2. NOTE: Do not continue with this troubleshooting until the causes of any other DTCs have been corrected. 2. Measure the line pressure. /s the line pressure within the service limit?

YES - Go to step 3.

NO- Repair the hydraulic system as necessary (see page 14-104).• 3. Replace the torque converter clutch solenoid valve/ shift solenoid valve A (see page 14-106). 4. Replace the AIT clutch pressure control solenoid valves A and B (see page 14-109). 5. Turn the ignition switch OFF and reset the PCM memory by removing the BACK UP fuse in the passenger's under-dash fuse/relay box for more than 10 seconds. 6. Using the scan tool, check to be sure that the engine coolant temperature is in 176°F (80°C) and above. 7. Drive the vehicle at 55 mph (88 km/h) constantly for more than one minute.

14-88

BACK

YES - Replace the transmission and torque converter.•

NO - The system is OK at this ti me.•

DTC P0730: Problem in Shift Control System


NOTE: • Record all freeze data before you troubleshoot . • Keep replacement solenoid valves on hand: - Torque converter clutch solenoid valve/shift solenoid valve A - Shift solenoid valves Band C - AfT clutch pressure control solenoid valves A and B

Does the aBO II scan too/ indicate code P0730? YES - Replace the transmission .•

NO - The system is OK atthis time .•

1. Check whether the OBD II scan tool indicates another code.

Does the aBO II scan tool indicate another code? YES- Perform the Troubleshooting Flowchart for the indicated Code(s). Recheck for code P0730 after troubleshooting .•

NO - Go to step 2. NOTE: Do not continue with the troubleshooting until the causes of any other DTCs have been corrected. 2. Measure the 1st, 2nd, 3rd, and 4th clutch pressure (see page 14-104).

Is each clutch pressure within the service limit? YES - Go to step 3.

NO- Repair the hydraulic system as necessary .• 3. Replace the torque converter clutch solenoid valve/ shift solenoid valve A (see page 14-106). 4. Replace the shift solenoid valve B and shift solenoid valve C (see page 14-107). 5. Replace the AfT clutch pressure control solenoid valves A and B (see page 14-109). 6. Turn the ignition switch OFF and reset the PCM memory by removing the BACK UP fuse in the passenger's under-dash fuse/relay box for more than 10 seconds. 7. Drive the vehicle at a speed over 12 mph (20 km/h) in 1st, 2nd, 3rd, 4th gear in ~ position for more than 30 seconds.

BACK

14-89

Automatic Transmission OTe Troubleshooting (cont'd) DTC P0780: Mechanical Problem in Hydraulic

Control System for Shift Solenoid Valve A and AfT Clutch Pressure Control Solenoid Valves A and B, or Problem in Hydraulic Control System NOTE: • Record all freeze data before you troubleshoot . • Keep replacement solenoid valves on hand: - Torque converter clutch solenoid valve/shift solenoid valve A - AfT clutch pressure control solenoid valves A and B 1. Check whether the OBD II scan tool indicates another code. Does the

aao /I scan tool indicate another code?

YES - Perform the Troubleshooting Flowchart for the indicated Code(s). Recheck for code P0780 after troubleshooting .•

NO- Go to step 2. 2. Turn the ignition switch OFF. 3. Replace the torque converter clutch solenoid valve/ shift solenoid valve A (see page 14-106), and the AfT clutch pressure control solenoid valves A and B (see page 14-109). 4. Reset the PCM memory by removing the BACK UP fuse in the passenger's under-dash fuse relay box for more than 10 seconds. 5. Drive the vehicle for several minutes in 1st, 2nd, 3rd, and 4th gears in ~ position. 6. Recheck for code P0780. Does the

aao /I scan tool indicate code P0780?

YES- Replace the transmission assembly.• NO- The problem has been corrected.•

14-90

BACK

DTC P1750: Mechanical Problem in Hydraulic Control System for AfT Clutch Pressure Control Solenoid Valves A and S, or Problem in Hydraulic Control System NOTE: Record all freeze data before you troubleshoot. 1. Check whether the OBD II scan tool indicates another code.

Does the OBO /I scan tool indicate another code? YES - Perform the Troubleshooting Flowchart for the indicated Code(s). Recheck for code P1750 after troubleshooting .• NO-Go to step 2. 2. Turn the ignition switch OFF. 3. Replace the AfT clutch pressure control solenoid valves A and B (see page 14-109). 4. Reset the PCM memory by removing the BACK UP fuse in the passenger's under-dash fuse relay box for more than 10 seconds. 5. Drive the vehicle for several minutes in 1st, 2nd, 3rd, and 4th gears in ~ position. 6. Recheck for code P1750.

Does the OBO /I scan tool indicate code P1750? YES - Replace the transmission .• NO- The problem has been corrected .•

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14-91

Automatic Transmission OTe Troubleshooting (cont'd) DTC P1751: Mechanical Problem in Hydraulic Control System for Shift Solenoid Valve B and AfT Clutch Pressure Control Solenoid Valves A and B, or Problem in Hydraulic Control System NOTE: • Record all freeze data before you troubleshoot . • Keep replacement solenoid valves on hand: - Shift solenoid valve B - AfT clutch pressure control solenoid valves A and B 1. Check whether the OBD " scan tool indicates another code. Does the aBO 1/ scan too/ indicate another code? YES - Perform the Troubleshooting Flowchart for the indicated Code(s). Recheck for code P1751 after troubleshooting .• NO- Go to step 2. 2. Turn the ignition switch OFF. 3. Replace the shift solenoid valve B (see page 14107), and the AfT clutch pressure control solenoid valves A and 8 (see page 14-109). 4. Drive the vehicle for several minutes in 1st, 2nd, 3rd, and 4th gears in ~ position. 5. Recheck for code P1751. Does the aBO 1/ scan too/ indicate code P1751? YES - Replace the transmission .• NO-The problem has been corrected .•

14-92

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~ Indicator Circuit Troubleshooting 1. Turn the ignition switch ON (II), and watch the ~ indicator light.

6. Turn the ignition switch OFF. 7. Reconnect PCM connector A (32P).

Does the ~ indicator come on and stay on? 8. Turn the ignition switch ON (II). YES-Go to step 2. 9. Shift to any positions other than ~. NO-If the light comes on for about two seconds and then goes off. It's OK, if it doesn't come on at all, go to step 11.

10. Measure the voltage between the 09 terminal and body ground. PCM CONNECTOR D (16P)

2. Turn the ignition switch OFF. 3. Disconnect PCM connector A (32P). 4. Turn the ignition switch ON (II).

2 3

5

6 7 8 9

12

131415 5. Measure the voltage between the A14 terminal and body ground.

ATPD4(VEL)

PCM CONNECTOR A (32P)

V2

3 4

V

/

5 6 8 9 10 12 131 415 16 17 18 19 20 21 23 24 26 27

28 29 30

V V 32


Is there about 5 V?

'--

D41ND (GRN/BLK)

YES-Faulty the PCM orthe gauge assembly.•

':i.

NO- Check for short to ground in the wire between the 09 terminal and the transmission range switch. If wire is OK, check the transmission range switch .•

-= Wire side offemale terminals

Is there voltage? YES- Repair short to power in the wire between the A14 terminal and the gauge assembly .•

11. Make sure the Honda PGM Tester is not connected to the DlC. 12. Shift to ~ position.

Does the ~ indicator come on?

NO- Go to step 6.

YES-Check for loose terminal fit in the PCM connectors and recheck the ~ indicator several times. If the problem is intermittent, substitute a knowngood PCM and recheck. If the light then works OK every time, replace the original PCM . • NO-Gotostep 13.

(cont'd)

BACK

14-93

Automatic Transmission ~ Indicator Light Circuit Troubleshooting (cont'd) 13. Turn the ignition switch OFF.


14. Disconnect PCM connector 8 (25P).

19. Reconnect PCM connector 8 (25P).

15. Check for continuity between body ground and 820 and 822 terminals.

20. Connect the digital multimeter between the A 14 and 820 or 822 terminals.


PCM CONNECTORS

7 8

345

2


9 10

A (32P)

1920

B(25P)

2122 LG2 (BRN/BLK)


D41ND (GRN/BLK)

LG2 (BRN/BLK)


Is there continuity between ground and each terminal?

Is there voltage for at least 2 seconds? YES - Go to step 16. NO- Repair open in the wire(s) between the 820 or 822 terminal and ground (G101) .•

YES-Check for open in the wire between the A14 terminal and the gauge assembly. If wire is OK, check for a faulty ~ indicator bulb or a faulty printed circuit board in the gauge assembly. •

16. Turn the ignition switch ON (II). NO-Go to step 22. 17. Measure the voltage between terminals 81 and 8 22, and between terminals 89 and 820. PCM CONNECTOR B (25P)

IGP1 (VEL/BLK)

I 1

f':

IGP2(VE

~

2 10 20

I

1/ 7 8 11 12 13 14V 1617 18 3 4 5

2122

~1

LG1 (BRN/BLK)

23 24 25

LG2 (BRN/BLK)


Is there battery voltage? YES-Go to step 18. NO-Repair open or short in the wire between the 81 or 89 terminal and the PGM-FI main relay and from fuse No. 46 in the under-hood fuse/relay box to the PGM-FI main relay.•

14-94

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22. Turn the ignition switch OFF. 23. Disconnect PCM connector A (32P). 24. Check for continuity between the A 14 terminal and No.12 terminal of the gauge assembly C (16P) connector. PCM CONNECTOR A (32P)

D41ND (GRN/BLK)

Q

GAUGE ASSEMBLV C (16P) CONNECTOR



VES- Check for loose terminal fit in the PCM connectors. Check the transmission range switch. If necessary, substitute a known-good PCM and recheck .• NO- Repair open in the wire between the A 14 terminal and the gauge assembly .•

BACK

14-95

Automatic Transmission Interlock System - Shift Lock System Circuit Troubleshooting 1. Press the brake pedal.

5. Measure the voltage between the 812 terminal of the multiplex control unit, driver's 8 (22P) connector and body ground with the throttle released and the brake pedal pressed.

Are the brake lights ON? YES- Go to step 2. NO- Repair faulty brake light circuit (see page 2291) .•

MULTIPLEX CONTROL UNIT, DRIVER'S B (22P) CONNECTOR

2. Turn the ignition switch ON (II), and shift to [f] position. 3. Press the brake pedal, and release the accelerator pedal. 4. Measure the voltage between the A28 terminal and body ground.




V2

3 4

5 6

V

8 9 10

12 13 14 15 16 17 18 19 20 21 25 26 27

28 29 30

V

/

V

YES-Go to step 6.

23 24 NO-Repair open in the wire between the A28 terminal ofthe PCM and 812 terminal ofthe driver's multiplex control unit.•

~

~u (WKT/RED)

6. Measure the voltage between the 822 terminal of the multiplex control unit, driver's 8 (22P) connector and body ground. Wire side of female terminals MULTIPLEX CONTROL UNIT, DRIVER'S B (22P) CONNECTOR

Is there battery voltage? YES- Go to step 5. NO-Go to step 8.


Is there battery voltage? YES-Go to step 7. NO-Repair open in the wire between the 822 terminal ofthe driver's multiplex control unit and the driver's under-dash fuse No.9 (via the shift lock solenoid) .•

14-96

BACK

7. Turn the ignition switch ON (II), and move the shift lever to [f] position.

8. Turn the ignition switch OFF. 9. Disconnect PCM connectors A (32P) and 8 (25P).

Dose the [f] indicator in the gauge assembly illuminate?

10. Measure the voltage between the A32 and 820 or 822 terminals while pressing the brake pedal.

YES-Check for loose terminal fitto the driver's multiplex control unit 812 and 822 terminal wires. If necessary, substitute a known-good driver's multiplex control unit.•


A (32P)

NO- Repair open in the [f] position switch circuit from the driver's under-dash fuse/relay box K10 (8LK/8LU) wire to ground (G 101) .•

lG2

(BRN/BlK)


Is there battery voltage? YES-Go to step 11.

NO- Repair open in the wire between the A32 terminal and the brake pedal position switch .•

(cont'd)

BACK

14-97

Automatic Transmission Interlock System - Shift Lock System Circuit Troubleshooting (cont'd) 11. Reconnect PCM connectors A (32P) and 8 (25P).

17. Check for continuity between the C18 and 820 or 822 terminals.


PCM CONNECTORS

13. Measure the voltage between the C27 and 820 or 822 terminals.

1

PCM CONNECTORS

2

19 20

B(25P) 1

B(25P)

2 LG1~~

19 20

_ _ _-{

(BRN/BLK)

Wire side of female terminals LG1 L -____- - - { (BRN/BLK)

':i. }-------' Is there continuity?


YES- Repair open in the wire between the C18 terminal and the throttle position sensor.•

Is there about 0.5 V (throttle fully closed)? YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .• NO-Go to step 14. 14. Turn the ignition switch OFF. 15. Disconnect the throttle position sensor connector. 16. Check for continuity between the No.1 terminal of the throttle position sensor and the 820 or 822 terminal of the PCM. PCM CONNECTOR B (25P)

2 9

3 4 5

10 11121314

19 20 LG1 (BRN/BLK)

21 22

23 24 25 LG2 (BRN/BLK)


Is there continuity? YES-Repair throttle position sensor installation .• NO-Go to step 17.

14-98

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Interlock System - Key Interlock System Circuit Troubleshooting 1. Check the AfT shift cable adjustment (see page 14134).

6. Measure the voltage between the No.7 terminal and body ground.

2. Disconnect the key switch 7P connector from the steering lock assembly.

KEY SWITCH CONNECTOR (7P)

3. Connect the No.7 terminal of the key switch connector to the battery positive terminal, and connect the No.5 terminal to the battery negative terminal. KEY SWITCH CONNECTOR (7PI


Is there battery voltage? YES- Go to step 7.

NO - Check for blown No. 47 (20 A) fuse in the under-hood fuse/relay box. If the fuse is OK, repair open or short in the wire between the No.7 terminal ofthe key switch connector and underhood fuse/relay box.•


4. Turn the ignition switch to ACC (I), then push the ignition key.

7. Disconnect the park pin switch 4P connector on the front side ofthe shift lever.

5. Check the key interlock solenoid operation. A clicking sound should be heard while pushing the ignition key, and no sound should be heard when r eleasing the key.

8. With the shift lever in Park, check for continuity between the No.3 and No.4 terminals of the park pin switch 4P connector. PARK PIN SWITCH 4P CONNECTOR

Does the key interlock solenoid operate properly? YES-Go to step 6. NO- Faulty key interlock solenoid/switch. Replace the ignition key cylinder/steering lock assembly.• NOTE: Do not re-key the new ignition switch. Re-key the other lock cylinders to match the new switch.


Is there continuity? YES- Go to step 9. NO- Repair open in the wires between the park pin switch and the 4P connector. If wires are OK, replace the park pin switch .• (cont'd)

BACK

14-99

Automatic Transmission Interlock System - Key Interlock System Circuit Troubleshooting (co nt'd) 9. Check for continuity between the No.4 terminal of the park pin switch 4P connector and the No.5 terminal ofthe key switch connector.

10. Check for continuity between the No.3 terminal of the 4P connector and body ground.

KEY SWITCH CONNECTOR (7PI

PARK PIN SWITCH 4P CONNECTOR

WHT/RED


Is there continuity? Is there continuity? YES-Check for loose key switch connector and park pin switch connector. If necessary, substitute a known-good steering lock assembly.•

YES - Go to step 10. NO- Repair open in the wire between No.4 terminal of the park pin switch 4P connector and the No.5 terminal of the key switch connector.•

14-100

BACK

NO- Repair open in the wire between No.3 terminal ofthe 4P connector and ground (G101) .•

Road Test Special Tools Required Backprobe set 07SAZ-001 OOOA (Two required) 1. Warm up the engine to normal operating temperature (the radiator fan comes on). 2. Apply the parking brake, and block rear wheels. Start the engine, then shift to ~ position while pressing the brake pedal. While fully pressing the brake pedal press the accelerator pedal, and release it suddenly. The engine should not stall. 3. Repeat the same test in ~ position.

4. Connect the Honda PGM Tester (A), and go to the PGM-FI Data List; then go to step 7. If you don't have a PGM Tester, go to step 5.

5. Pull back the carpet from the passenger's side of the center console to expose the PCM (A). 6. Connect the digital multimeter (B) and the special tools (C) to check voltage between the C27( +) terminal and B20 (-) or B22( - )terminal of the PCM. A

~

_ _-B

C 07SAZ-001000A A (32P)

VI2

3 4

B (25P)

5 6

V

8 9 10

VI

112113 1415 1617 18 1920 2122 23 241 2829 30 2526 27 32

/

-

PCM CONNECTORS C (31 P)

-;---

6 7

alll 2 / I 5 6 7 V V / I V 1617 1819 20 21/ V / 25 26 2728 29 30 /

1

2

9

10 1112 1314 15/ 17 181 2324 25 21122 20

L

3 4 5

-r

Y.

lG2 (BRN/BlK) lG1 (BRN/BlK)

D(16P)

r8 9 10 1

I

6 7

2

3V J5l

a 9 10 "1121

1314 15

16 "---

TPS (RED/BlK)

Y.


(cont'd)

BACK

14-101

Automatic Transmission Road Test (cont'd) 7. Test-drive the vehicle on a flat road in the ~ position. Check for abnormal noise and clutch slippage. While driving, check that the shift points occur at the proper speeds by monitoring the throttle position sensor voltage and comparing your shift point speeds and voltage to those in the table. (The throttle position sensor voltage represents the throttle opening.) Upshift-~position

Throttle Opening Throttle position sensor voltage: 0.8 V Throttle position sensor voltage: 2.25 V FUlly-opened throttle, Throttle position sensor voltage: 4.5 V

Unit of Speed mph km/h mph km/h mph km/h

1st-2nd 9-11 15-17 21-23 33-37 34-38 55-61

2nd-3rd 21-23 33-37 39-43 63-69 62-65 99-105

3rd- 4th 26-30 42-48 58-62 94-100 96-100 155-161

Lock-upON 47-49 75-79 68-72 110-116 97-101 156-162

Unit of Speed mph km/h

Lock-up OFF 45-48 73-77 58-62 94-100 91-94 146-152

4th- 3rd 19-21 30-34

3rd-2nd

---

-----

2nd-1st 5-7 (3rd - 1st) 8-12 (3rd - 1st)

85-89 137-143

54-58 87-93

Downshift-~ position

Throttle Opening Throttle position sensor voltage: 0.8 V Throttle position sensor voltage: 2.25 V Fully-opened throttle, Throttle position sensor voltage: 4.5 V

m~h

km/h O!ph km/h

---

26-30 42-48

8. Accelerate to about 35 mph (57 km/h) so the transmission is in 4th, then shift from ~ position to 00 position. The vehicle should immediately begin slowing down from engine braking. 9. Check for abnormal noise and clutch slippage in the following positions.

ill (1st Gear) Position Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage. Upshifts should not occur with the shift lever in this position.

00 (2nd Gear) Position Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage. Upshifts and downshifts should not occur with the shift lever in this position.

lID (Reverse) Position Accelerate from a stop at full throttle, and check that there is no abnormal noise or clutch slippage. 10. Test in [f] (Park) Position. Park the vehicle on a slope (approx. 16°), apply the parking brake, and shift into [f] position. Release the brake; the vehicle should not move.

14-102

BACK

Stall Speed Test 1. Set the parking brake. and block the front wheels. 2. Connect a tachometer to the engine. and start the engine. 3. Make sure the AlC switch is OFF. 4. After the engine has warmed up to normal operating temperature (the radiator fan comes on). shift to 00 position. 5. Fully press the brake pedal and accelerator for 6 to 8 seconds. and note engine speed. Do not move the shift lever while raising engine speed. 6. Allow two minutes for cooling. then repeat the test in ~.11J. and !Rl positions. NOTE: • Do not test stall speed for more than 10 seconds at a time. • Stall speed tests should be used for diagnostic purposes only. • Stall speed should be the same in ~. 00. and !Rl positions. • Do not test stall speed with the AfT pressure gauges installed.

rn.

Stall Speed rpm: F23A1 and F23A4 Engines: Specification: 2,550 rpm Service Limit: 2,400-2,700 rpm F23A5 Engine: Specification: 2,500 rpm Service Limit: 2,350-2,650 rpm TROUBLE Stall rpm high in ~, 00. and !Rl positions

rn.

Stall Stall Stall Stall

rpm rpm rpm rpm

rn

high in position high in 00 position high in !Rl_position low in~. 00. and!Rl positions

rn

PROBABLE CAUSE • Low fluid level or ATF pump output • Clogged ATF strainer • Pressure regulator valve stuck closed • Slipping clutch Slippage of 1st clutch Slippage of 2nd clutch Slippage of 4th clutch • Engine output low • Torque converter one-way clutch slipping_

BACK

14-103

Automatic Transmission Pressure Tests Special Tools Required

• AfT oil pressure gauge set 07406-0020400 • AfT pressure hose, 2210 mm 07MAJ-PY4011A • AfT pressure hose adapter 07MAJ-PY40120 1. Before testing, be sure the transmission fluid is filled to the proper level. 2. Raise the front of the vehicle, and make sure it is securely supported. 3. Set the parking brake, and block rear wheels securely. 4. Allow the front wheels to rotate freely. 5. Warm up the engine (the radiator fan comes on), then stop it and connect the tachometer. 6. Connect the oil pressure gauges to each inspection hole securely, and do not allow dust or other foreign particles to enter the holes. TORQUE: 18 N·m 11.8 kgf·m, 13Ibf·ft) AfT OIL PRESSURE GAUGE SETWfPANEL 07406-0020400

AfT PRESSURE HOSE, 2210 mm 07MAJ-PY4011A

AfT PRESSURE HOSE ADAPTER 07MAJ-PY40120

(4 Required)

(4 Required)

3RD CLUTCH PRESSURE INSPECTION HOLE

END COVER

14-104

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7. Start the engine, and run it at 1,500 rpm. 8. Shift to [HJ or [fJ position, and measure line pressure at the line pressure inspection hole (A). NOTE: Higher pressure may be indicated if measurements are made in shift lever positions other than [HJ or [fJ. 9. Shift to II] position, and measure 1st clutch pressure at the 1st clutch pressure inspection hole (8). 10. Shift to

00 position, and measure 2nd clutch pressure at the 2nd clutch pressure inspection hole (C).

11. Shift to [fJ position, then press the brake pedal and hold it. 12. Shift to ~ position, and release the brake pedal (the transmission is in 1st gear). 13. Accelerate the engine to 2,500 rpm (the transmission will shift to 2nd gear). 14. Release the accelerator for more than 5 seconds after the transmission is shifted to 2nd gear; the engine speed will decrease to about 1,000 rpm. 15. Press the accelerator slowly (so it takes at least 5 seconds to raise the engine speed to 2,000 rpm), then hold the engine speed at 2,000 rpm. 16. Measure 3rd and 4th clutch pressure at the 3rd clutch pressure inspection hole (D), and the 4th clutch pressure inspection hole (E), as the transmission shifts from 2nd gear to 3rd gear, then to 4th gear. PRESSURE ---

Line (A)

SHIFT LEVER POSITION [HJ or [E

1st clutch (8)

II]

2nd clutch (C)

00

3rd clutch (D)

~

4th clutch (E)

[RJ

SYMPTOM

PROBABLE CAUSE

No (or 10w)line pressure

Torque converter, ATF pump, pressure regulator valve, torque converter check valve 1st clutch

No or low 1st pressure No or low 2nd pressure No or low 3rd pressure No or low 4th pressure

2nd clutch

FLUID PRESSURE Standard Service Limit

850-910 kPa (8.7-9.3 kgf/cm2, 120-130 psi)

800 kPa (8.2 kgf/cm2, 120 psi)

840-920 kPa (8.6-9.4 kgf/cm2, 120-130 psi)

790 kPa (8.1 kgf/cm2, 120 psi)

3rd clutch 4th clutch Servo valve or 4th clutch

17. Install the sealing bolt with a new sealing washers, and tighten the bolts to the specified torque. TORQUE: 18 N·m (1.8 kgf·m, 13Ibf·ft)

NOTE: Do not reuse old sealing washers.

BACK

14-105

Automatic Transmission Torque Converter Clutch Solenoid Valve - Shift Solenoid Valve A Test 1. Disconnect the torque converter clutch solenoid valve/shift solenoid valve A 2P connector.

Torque Converter Clutch Solenoid Valve - Shift Solenoid Valve A Replacement NOTE: Torque converter clutch solenoid valve-shift solenoid valve A must be removed/replaced as an assembly. 1. Remove the mounting bolts and torque converter clutch solenoid valve-shift solenoid valve A.

2. Measure the resistance of the torque converter clutch solenoid valve between the No.1 terminal of the 2P connector and body ground. STANDARD: 12-25 Q

3. Measure the resistance of the shift solenoid valve A between the No.2 terminal of the 2P connector and body ground. STANDARD: 12-25 Q

B

2. Clean the mounting surface and fluid passage of the torque converter clutch solenoid valve-shift solenoid valve A, and install a new torque converter clutch solenoid valve-shift solenoid valve A with a new filter/gasket (8). 3. Install the bolts with the connector bracket (C) and the harness clamp bracket (D), and tighten the bolts.

4. Replace the torque converter clutch solenoid valve/ shift solenoid valve A if either resistance is out of specification. 5. If the resistance is within the standard, connect the No.1 terminal of the 2P connector to the battery positive terminal. A clicking sound should be heard. Connect the No.2 terminal to the battery positive terminal. A clicking sound should be heard. Replace the torque converter clutch solenoid valve/ shift solenoid valve A if no sound is heard when connecting either terminal to the battery positive terminal.

14-106

\

BACK

4. Check the connector for rust, dirt, or oil, then reconnect the connector securely.

Shift Solenoid Valves Band C Test

Shift Solenoid Valves Band C Replacement

1. Disconnect the shift solenoid valve 8 or C 2P connector. NOTE: If the shift solenoid valves 8 and C are replaced or removed at the same time, be sure to reinstall them correctly. The connector color of shift solenoid valve 8 is black, and the connector color of shift solenoid valve C is brown.

B

1. Remove the mounting bolt and the shift solenoid valve 8.

A

2. Measure the resistance between the No.1 and No.2 terminals of the shift solenoid valve 8 or C.

STANDARD: 12-25 Q 3. Replace the shift solenoid valve 8 or C if the resistance is out of standard. 4. If the resistance is within the standard, connect the No.2 terminal of the shift solenoid valve 8 or C connector to the battery positive terminal, and connect the No.1 terminal to the battery negative terminal. A clicking sound should be heard. Replace the shift solenoid valve 8 or C if no clicking sound is heard.

11.2 kgf.m, 8.7Ibf·ftl

2. Remove the mounting bolt and the shift solenoid valveC. 3. Install a new shift solenoid valve 8 or C with new 0rings (A). While installing the valves, do not allow dust or other foreign particles to enter the transmission. 4. Check the connector for rust, dirt, or oil, then reconnect the connector securely.

BACK

14-107

Automatic Transmission AIT Clutch Pressure Control Solenoid Valves A and B Test 1. Disconnect the AfT clutch pressure control solenoid valves A and B 2P connectors. B

7. Connect the No.1 terminal of the AfT clutch pressure control solenoid valves A and B to the battery positive terminal, and connect the No.2 terminal to the battery negative terminal. Make sure the A/T clutch pressure control solenoid valves A (A) and B (B) move.

A

2. Measure the resistance of the A/T clutch pressure control solenoid valves A and B between the No. 1 and No.2 terminals of each connector.

B

A

8. Disconnect one of the battery terminals and check valve movement.

STANDARD: About 5.0 Q

NOTE: You can see the valve movement through the fluid passage in the mounting surface of the AfT clutch pressure control solenoid valves A and B body (C).

3. If the resistance of either AfT clutch pressure control solenoid is out of standard, replace the AfT clutch pressure control solenoid valves A and B. 4. Connect the No.1 terminal of the AfT clutch pressure control solenoid valve A (and B) to the battery positive terminal, and connect the No.2 terminal to the battery negative terminal. A clicking sound should be heard.

9. If either valve binds, or moves sluggishly, or ifthe AfT clutch pressure control solenoid does not operate, replace the AfT clutch pressure control solenoid valves A and B.

5. If not, remove the A/T clutch pressure control solenoid valves A and B. 6. Check the fluid passage of the A/T clutch pressure control solenoid valves for dust and dirt.

14-108

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AfT Clutch Pressure Control Solenoid Valves A and B Replacement

Speed Sensor Replacement 1. Disconnect the connectors from the mainshaft and countershaft speed sensors.

1. Remove the mounting bolts and the AfT clutch pressure control solenoid valves A and 8 (A).

2. Remove the bolt securing the mainshaft speed sensor, then remove the mainshaft speed sensor (A) from the end cover.

e

6x1.0mm 12 N·m 11.2 kgf·m, 8.7Ibf·ftl

\

B

~

6x 1.0 mm 12 N·m 11.2 kgf·m, 8.7Ibf·ftl

6x1.0mm 12 N·m 11.2 kgf.m, 8.7Ibf·ftl

2. Clean the mounting surface and fluid passage of the AfT clutch pressure control solenoid valves A and 8 and the transmission housing. 3. Install a new AfT clutch pressure control solenoid valves A and 8 with a new gasket (8), new O-rings (C), ATF feed pipes (D), and harness clamp bracket (E).

3. Remove the bolt securing the countershaft speed sensor, then remove the countershaft speed sensor (8) from the transmission housing. 4. Replace the O-rings (C) with new ones before installing the sensors. 5. Install the mainshaft and countershaft speed sensors, then connect the connectors.

NOTE: Install the filter side of the ATF feed pipes in the transmission housing. 4. Check the AfT clutch pressure control solenoid valve connectors for rust, dirt, or oil, then connect them securely.

BACK

14-109

Automatic Transmission 2nd Clutch Pressure Switch ('98-00 Models) Replacement 4. Reconnect the connector (A), making sure there is no water, oil, dust, or other foreign particles inside it.

1. Remove the rear stiffener (A).

10x 1.25 mm 38 N·m 13.9 kgf·m, 28 Ibf·ftl

.~

B

2. Disconnect the 2nd clutch pressure switch connector (B).

5. Install the rear stiffener (B).

3. Replace the 2nd clutch pressure switch, then install a new one with a new sealing washer. Tighten the switch on the metal part, not the plastic part.

14-110

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2nd Clutch Pressure Switch ('01-02 Models) Replacement 1. Support the transmission with a transmission jack.

4. Remove the rear stiffener (A).

2. Remove the rear mount bracket bolts.

5. Disconnect the 2nd clutch pressure switch connector. 3. Remove the rear mount nut (A), then remove the rear mount bracket (8). A

€I ________ 12 x 1.25 mm

54N·m (5.5 kgf·m, 40 Ibf·ft)

6. Replace the 2nd clutch pressure switch (A), then install a new one with a new sealing washer (8). Tighten the switch on the metal part, not the plastic part.

(cont'd)

BACK

14-111

Automatic Transmission 2nd Clutch Pressure Switch ('01-02 Models) Replacement (cont'd)

3rd Clutch Pressure Switch Replacement 1. Disconnect the connector from the 3rd clutch pressure switch.

20 N·m (2.0 kgf·m, 14Ibf·ft)

2. Replace the 3rd clutch pressure switch, then install a new one with a new sealing washer. Tighten the switch on the metal part, not the plastic part. 3. Reconnect the connector, making sure there is no water, oil, dust, or other foreign particles inside it.

8. Secure the nut (e) by your hand until it contacts the stiffener, then tighten it to the specified torque. If you can not tighten the nut to the stiffener surface by hand, replace the nut and the special bolt (D). 9. Reconnect the connector, making sure there is no water, oil, dust, or other foreign particles inside it. 10. Install the rear mount bracket, and loosely tighten the rear mount nut. 11. Install the rear mount bracket bolts. 12. Tighten the rear mount nut to the specified torque.

14-112

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ATF Level Check

ATF Replacement

NOTE: Keep all foreign particles out of the transmission.

NOTE: Keep all foreign particles out of the transmission.

1. Warm up the engine to normal operating temperature (the radiator fan comes on).

1. Bring the transmission up to operating temperature (the radiator fan comes on) by driving the vehicle.

2. Park the vehicle on the level ground. Turn off the engine.

2. Park the vehicle on level ground, and turn the engine off.

3. Remove the dipstick (yellow loop) (A) from the transmission, and wipe it with a clean cloth. A

3. Remove the drain plug, and drain the automatic transmission fluid (ATF). NOTE: If a cooler flusher is to be used, refer to ATF Cooler Flushing (see page 14-125).

) / 4. Insert the dipstick into the transmission. 5. Remove the dipstick and check the fluid level. It should be between the upper mark (B) and lower mark (C).

18x 1.5 mm 49 N·m (5.0 kgf.m, 36 Ibf.ft)

4. Reinstall the drain plug with a new sealing washer, then refill the transmission with the recommended fluid into the filler hole to the upper mark on the dipstick. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality. Automatic Transmission Fluid Capacity: 2.5 a(2.6 us qt, 2.2 Imp qt) at changing 6.1 a (6.4 US qt, 5.4 Imp qt) at overhaul

-8

-c 6. If the level is below the lower mark, pour the recommended fluid into the filler hole to bring it to the upper mark. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality. 7. Insert the dipstick back into the transmission.

BACK

14-113

Automatic Transmission Transmission Removal 1. Before disconnecting power, make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset stations.

8. Remove the starter cables (A) and harness clamps (B), and remove the breather tube (C) and radiator hose (D) from the clamps (E). E

2. Disconnect the battery negative terminal, then remove the positive terminal. 3. Remove the battery hold-down bracket, then remove the battery and battery tray. 4. Remove the battery cable clamps from the battery base.

D

5. Remove the battery base.

'6. Remove the intake air duct and air cleaner housing assembly. 7. Raise the vehicle, and make sure it is sacurely supported. Remove the drain plug, and drain the automatic transmission fluid (ATF). Reinstall the drain plug with a new sealing washer. 9. Remove the transmission ground cable (A), and disconnect the connectors from the Aff clutch pressure control solenoid valves A and B (B), mainshaft speed sensor (C) and 3rd clutch pressure switch (D), then remove the harness clamps (E) from the clamp brackets. Do not allow water, fluid, oil, dust, or other foreign particles to get inside the 3rd clutch pressure switch connector.

14-114

BACK

10. Disconnect the torque converter clutch solenoid valve/shift solenoid valve A connector (A).

15. Disconnectthe 2nd clutch pressure switch connector (A), then remove the rear stiffener (8) ('98-00 models). Do not allow water, fluid, oil, dust, or other foreign particles to get inside the connector. B

\ 11. Remove the ATF cooler hoses (8) from the ATF cooler lines (C). Turn the ends ofthe ATF cooler hoses up to prevent ATF from flowing out, then plug the ATF cooler hoses and lines.

A

16. Remove the transmission housing bolts. NOTE: Check for any signs of leakage at the hose joints. 12. Disconnect the shift solenoid valve 8 connector (D), and C connector (E), then remove the harness clamp (F) from the clamp bracket (G). 13. Disconnect the countershaft speed sensor connector (A), and remove the harness clamp (8) from the connector/clamp bracket (C). B

14. Remove the transmission range switch connector (D) from the connector/clamp bracket, then disconnect it.

(cont'd)

BACK

14-115

Automatic Transmission Transmission Removal (cont'd) 17. Remove the front mount bracket bolts.

19. Remove the cotter pins (A) and castle nuts (B), and remove the damper forks (C), then separate the ball joints from the lower arms (0) (see page 18-17).

/c

E

18. Remove the splash shield.

20. Remove the bolts securing the radius rods (E), then separate the radius rods from the lower arms (0).

21. Pry the driveshaft out of the differential (see step 10 on page 16-4).

22. Make a reference mark (A) across the front beam (both side) (B) and the rear beam (C).

14-116

BACK

26. Remove the engine stiffener (A).

23. Remove the front beam.

E

24. Pull on the inboard joints to remove the drives hafts (A) from the differential. 27. Remove the bolts securing the shift cable holder (B), then remove the shift cable cover (C). NOTE: To prevent damage to the control lever joint, remove the bolts securing the shift cable holder before removing the bolts securing the shift cable cover. 28. Remove the lock bolt (D) securing the control lever (E), then remove the shift cable (F) with the control lever. Do not bend the shift cable excessively.

B

25. Coat all precision finished surfaces with clean engine oil, then tie plastic bags (B) over the driveshaft ends.

29. Remove the eight drive plate bolts (G) one at a time while rotating the crankshaft pulley. 30. Lift and support the engine/transmission assembly with an engine hanger (P/N AAR-T-1256, available through the American Honda Tool and Equipment program, or equivalent).

(cont'd)

BACK

14-117

Automatic Transmission Transmission Removal (cont'd) 31. Place a transmission jack under the transmission. 32. Remove the transmission mount bracket.

34. Pull the transmission away from the engine until it clears the dowel pins, then lower it on the transmission jack. 35. Remove the torque converter assembly. 36. Remove the starter from the torque converter housing. 37. Inspect the drive plate, and replace it if it's damaged.

33. Remove the rear mount bracket bolts: • 12 x 1.25 mm bolts (2) (A) for all models . • 10 x 1.25 mm bolts (2) (8) for '01-02 models.

14-118

BACK

Transmission Installation 1. Flush the ATF cooler (see page 14-125).

6. Attach the transmission to the engine, then install the rear mount bracket bolts:

2. Install the torque converter assembly (A) on the mainshaft (S) with a new O-ring (e).

• 12 x 1.25 mm bolts (2) (A) for all models. • 10 x 1.25 mm bolts (2) (S) for '01-02 models.

E

C

D

3. Install the 14 mm dowel pins (D) in the torque converter housing (E). 4. Install the starter (F) on the torque converter housing.

7. Install the transmission housing mounting bolts.

5. Place the transmission on a transmission jack, and raise it to engine level.

(cont'd)

BACK

14-119

Automatic Transmission Transmission Installation (cont'd) 8. Face the dot mark (A) on the breather tube (B) up. E

~2X1.25mm

10x 1.25mm 38 N·m 13.9 kgf·m, 28 Ibf·ftl

~o

11. Attach the torque converter to the drive plate (A) with eight bolts (B). Rotate the crankshaft pulley as necessary to tighten the bolts to 1/2 of the specified torque, then to the final torque, in a crisscross pattern. After tightening the last bolt, check that the crankshaft rotates freely. 6x1.0mm 10 N·m 11.0 kgf·m, 7.2Ibf·ft)

54 N·m 15.5 kgf·m, 40 Ibf·ftl

B 6x 1.0 mm 12 N·m 11.2 kgf·m, 8.7Ibf·ft)

D

10x 1.25 mm 44 N·m 14.5 kgf·m, 33lbf·ftl

'\ I

I

8x 1.25mm 26 N·m 12.7 kgf·m, 20Ibf·ft)

F 6x1.0mm 14 N·m 11.4 kgf·m, 10 Ibf·ft)

I-f---B

12. Tighten the crankshaft pulley bolt as necessary (see page 6-18). 9. Install the transmission mount bracket (C). Tighten the bolt (D) loosely, and tighten the nuts (E) to the specified torque, then tighten the bolt to the specified torque. 10. Remove the transmission jack and hoist bracket.

13. Install the control lever (C) with the shift cable (D) on the control shaft (E). Do not bend the shift cable excessively. 14. Install the lock bolt (F) with a new lock washer (G), then bend the lock washer tab against the bolt. 15. Install the engine stiffener (H). 16. Install the shift cable cover (I), then install the shift cable holder (J) on the shift cable cover. NOTE: To prevent damage to the control lever joint, be sure to install the shift cable holder after installing the shift cable cover to the torque converter housing.

14-120

BACK

17. Install new set rings on the right and left driveshafts.

20. Install the front mount bracket bolts. 10 x 1.25 mm 38 N·m 13.9 kgf·m. 28 Ibf·ft)

18. Install the right and left driveshaft (see page 16-20). While installing the driveshaft in the differential, be sure not to allow dust or other foreign particles to enter the transmission. NOTE: o Clean the areas where the driveshaft contacts the transmission (differential) with solvent or carburetor cleaner, and dry with compressed air. o Turn the right and left steering knuckle fully outward, and slide the driveshaft into the differential until you feel its spring clip engage the side gear.

19. Install the front beam (A) by aligning the reference marks (B) on the rear beam (C). A

21. Install the damper forks (A), then install the ball joints on each lower arms (B) with the castle nuts (C) and new cotter pins (0). 10x 1.25mm 43 N·m 14.4 kgf'm, 32 Ibf·ft)

14x 1.5 mm 103N·m (10.5 kgf·m, 75.9 Ibf·ftl

'~l'

12 x 1.25 mm 64 N·m (6.5 kgf.m. 47lbf·ftl

~~~6~':.t: '~. ~

"14x 1.5 mm 103N·m (10.5 kgf·m. 75.9 Ibf·ftl

471bf·ftl

.

E

12x 1.25mm 49-59 N·m (5.0-6.0 kgf·m, 36-43 Ibf·ft)

B

22. Install the radius rods (E) on each lower arm.

(cont'd)

BACK

14-121

Automatic Transmission Transmission Installation (cont'd) 25. Connect the connectors to the shift solenoid valve 8 (A) and C (8), and install the clamp (C) on the clamp bracket (0).


c 24. Connect the 2nd clutch pressure switch connector (A), and install the rear stiffener (8) ('98-00 models). 00 not allow water, fluid, oil, dust, or other foreign particles to get inside the 2nd clutch pressure switch connector. 26. Connect the ATF cooler hoses (E) to the cooler lines (F) (see page 14-126).

10 x 1.25 mm 38 N·m (3.9 kgf·m, 28 Ibf·ttl

27. Connect the torque converter clutch solenoid valve/ shift solenoid valve A connector (G).

\

28. Connect the connector to the countershaft speed sensor (A) and transmission range switch (8), and install the harness clamp and transmission range switch connector on the connector/clamp bracket (0).

c

B

A

A

14-122

BACK

29. Install the transmission ground cable terminal (A). E

6x 1.0mm 10 N·m (1.0 kgf.m,

7.2Ibf·ftl

31. Install the starter cables (A) with crimped side of the ring terminals facing out. G

H

D

A

30. Connect the connectors to the mainshaft speed sensor (8), AfT clutch pressure control solenoid valves A and 8 (C) and 3rd clutch pressure switch (D), and install the harness clamps (E) on the clamp brackets. Do not allow water, fluid, oil, dust, or other foreign particles to get inside the 3rd clutch pressure switch connector.

9 N·m (0.9 kgf.m,

6.5Ibf·ftl

C

32. Install the harness clamps (8) on the clamp brackets (C). 33. Install the radiator hose (D) on the clamp (E). 34. Install the breather tube (F) on the clamp (G) with the dot (H) on the tube facing up.

(cont'd)

14-123

Automatic Transmission Transmission Installation (co nt' d) 35. Install the battery base. 36. Install the battery cable clamps on the battery base.

47. Loosen the front mount bracket bolt (A) after the road test, then retighten the bolts to the specified torque. A

37. Install the battery tray and battery, then secure the battery with its hold-down bracket. 38. Install the intake air duct and air cleaner housing assembly. 39. Refill the transmission with ATF (see page 14-113). 40. Connect the battery positive terminal, then connect the negative terminal. 41. Set the parking brake. Start the engine, and shift the transmission through all gears three times. 42. Check the shift lever operation, AfT gear position indicator operation, and shift cable adjustment. 43. Check and adjust the front wheel alignment (see page 18-5). 44. Start the engine and let it reach normal operating temperature (the radiator fan comes on) with the transmission in ~ or lID position, then turn it off and check the ATF level (see page 14-113). 45. Perform a road test (see page 14-101). 46. Enter the anti-theft code for the radio, then enter the customer's radio station presets.

14-124

BACK


ATF Cooler Flushing 7. With the water and air valves (A) off, attach the water and air supplies to the flusher. (Hot water if available.)

Special Tools Required Commercially available transmission cooler flusher Kent-Moore J38405-A or equivqlent

OFF

This procedure should be performed before reinstalling the transmission. 1. Check the equipment for wear and cracks before using it. Replace any worn or cracked components. 2. Using the measuring cup, fill the flusher (A) with 21 ounces (approximately 2/3 full) of biodegradable flushing fluid (J35944-20). Do not substitute with any other fluid. Follow the handling procedure on the fluid container. 3. Secure the flusher filler cap, and pressurize the flusher with compressed airto 550-829 kpa (5.68.45 kgf/cm2, 80-120 psi). The air line should be equipped with a water trap to ensure a dry air system.

8. Turn on the water valve for 10 seconds. If water does not flow through the cooler, it is completely plugged, cannot be flushed, and must be replaced.

4. Hang the flusher under the vehicle. 5. Attach the flusher discharge hose (8) to the return line of the ATF cooler using a clamp.

9. Depress the trigger to mix the flushing fluid into the water flow. Use the wire clip to hold the trigger down. 10. While flushing with the water and flushing fluid for two minutes, turn the air valve on for five seconds every 15-20 seconds to create a surging action. AIR PRESSURE: MAX 845 kpa (8.45 kgf/cm 2, 120 psi) 11. Turn the water valve off. Release the trigger, then reverse the hoses to the cooler so you can flush in the opposite direction. Repeat steps 8 through 10. 12. Release the trigger, and rinse the cooler with water for one minute. 13. Turn the water valve and the water supply off.

D

6. Connect the drain hose (C) to the inlet line on the ATF cooler using a clamp. Securely clamp the opposite end of the drain hose to a bucket (D) or floor drain.

14. Turn the air valve on for two minutes, or until no moisture is visible leaving the drain hose. Residual moisture in the cooler or lines can damage the transmission. 15. Remove the flusher form the cooler line. Attach the drain hose to an ATF container. 16. Install the transmission, and leave the drain hose attached to the cooler line.

(cont'd)

BACK

14-125

Automatic Transmission ATF Cooler Flushing (cont'd)

ATF Cooler Hoses Replacement

17. Make sure the transmission is in [f] position. Fill the transmission with ATF, and run the engine for 30 seconds or until approximately 0.95 ~ (1.0 US qt., 0.8 Imp qt.) is discharged.

1. Connect the cooler hoses (A) to the lines (8) and the ATF cooler (C), and secure them with the clips (D) as shown. 2. Install the clamp (E) on the cooler hoses.

18. Remove the drain hose, and reconnect the cooler return hose to the transmission. 19. Refill the transmission with ATF to the proper level (see page 14-113).

14-126

BACK

Shift Lever Removal 1. Shift the transmission into [RJ position.

5. Disconnect the shift lock solenoid connector (AI and park pin switch 4P connector (BI.

2. Remove the center console (see page 20-831. 3. Remove the nut securing the shift cable end (AI, then separate the shift cable end from the shift lever assembly.

6. Remove the four bolts (CI securing the shift lever bracket base, then remove the shift lever assembly.

4. Rotate the socket holder (AI on the shift cable (BI counterclockwise a quarter turn, then slide the holder to remove the shift cable from the shift lever bracket base (CI. NOTE: Do not remove the shift cable by twisting the shift cable guide pipe (01.

\\ D

BACK

14-127

Automatic Transmission Shift Lever Installation 1. Install the shift lever assembly. 2. Turn the ignition switch ON (11), and verify that the [RJ position indicator comes on.

5. Insert a 6.0 mm (0.24 in.) pin (A) into the positioning hole (B) on the shift lever bracket base through the positioning hole on the shift lever assembly.

CD 3. If necessary, push the shift cable until it stops, then release your hand. Pull the shift cable back one step so that the shift position is in [RJ.

I~ +++++[8]+ (g)-U

6. Rotate the socket holder (A) on the shift cable (B) counterclockwise a quarter turn, then slide the holder onto the shift lever bracket base (C). Install the shift cable end (D) over the mounting stud (E) by aligning its square hole (F) with the square shape (G) at the bottom of the stud. Rotate the holder clockwise a quarter turn to secure the shift cable. NOTE: Do not install the shift cable by twisting the shift cable guide (H).

)


D

14-128

BACK

F

7. Verify that the shift cable end (A) is properly installed on the mounting stud (8).

10. Remove the 6.0 mm (0.24 in.) pin that was installed to hold the shift lever.

Properly Installed:

@D= I A

T\

11. Connect the shift lock solenoid connector and park pin switch 4P connector. 12. Move the shift lever to each gear, and verify that the AfT gear position indicator follows the transmission range switch. B

13. Push the shift lock release, and verify that the shift lever releases.

Not Properly Installed:

Cable end rides on the bottom of the mounting stud.

8. If not properly installed, remove the shift cable from the shift lever bracket base, and reinstall the shift cable. Do not install the shift cable end on the mounting stud while the shift cable is on the shift cable bracket base. 9. Install and tighten the nut.


BACK

14-129

Automatic Transmission Shift lever DisassemblyIReassembly SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-28). Apply silicone grease to these parts: • Movable parts of the shift lever. • Movable parts of the shift lock mechanism. • Sliding surfaces on the detent spring.

SHIFT LOCK SOLENOID PLUNGER SCREW

o

PLUNGER SPRING

/

3 N·m (0.3 kgf·m, 2lbf·ftl Apply non-hardening thread lock sealant.

~ SHIFT LOCK

so~~~~~ /

SHIFT LOCK SOLENOID ----LEVER COVER

AfT GEAR POSITION INDICATOR BULB

- - - - - - 8 x 1.25mm 22 N·m (2.2 kgf·m, 16 Ibf·ftl

SHIFT LOCK STOP CUSHION

~

~

DETENT SPRING

SHIFT CABLE

SHIFT LEVER BRACKET BASE


14-130

BACK

Shift Cable Replacement 7. Remove the floor heat shield.

1. Raise the front of the vehicle, and make sure it is securely supported (see page 1-17).

8. Remove the shift cable guide bracket (A) and grommet (B).

2. Set the parking brake, and block the rear wheels securely. 3. Shift the transmission into IBJ position. 4. Remove the console panel (see page 20-83). 5. Remove the nut securing the shift cable end (A), then separate the shift cable end from the shift lever assembly.

6x 1.0mm 12 N·m(1.2 kgf·m, 8.7Ibf·ftl

9. Remove the bolts securing the shift cable holder (A), then remove the shift cable cover (B). NOTE: To prevent damage to the control lever joint, remove the bolts securing the shift cable holder before removing the bolts securing the shift cable cover. A

6. Rotate the socket holder (A) on the shift cable (B) counterclockwise a quarter turn, then slide the holder to remove the shift cable from the shift lever bracket base (C). NOTE: Do not remove the shift cable by twisting the shift cable guide pipe (D).

) 10. Remove the lock bolt (C) securing the control lever (D), then remove the shift cable (E) with the control lever.

(cont'd)

BACK

14-131

Automatic Transmission Shift Cable Replacement (cont'd) 11. Insert the new shift cable through the grommet hole, then install the shift cable guide bracket.

17. Turn the ignition switch ON (II), and verify that the [RJ position indicator light comes on.

12. Verify that the transmission is in [RJ position on the control shaft.

18. If necessary, push the shift cable until it stops, then release your hand. Pull the shift cable back one step so that the shift position is in [RJ.

13. Install the control lever (A) with the shift cable (B) on the control shaft (e). Do not bend the shift cable excessively. G

6x1.0mm 9.a N·m (1.0 kgf·m, 7.2Ibf·ft)

@ljl~

c

•• +++[B]+ 19. Turn the ignition switch OFF. 20. Insert a 6.0 mm (0.24 in.) pin (A) into the positioning hole (B) on the shift lever bracket base through the positioning hole on the shift lever assembly.

6x 1.0mm 14 N·m (1.4 kgf.m, 10Ibf·ft) ax 1.2Smm 26 N·m (2.7 kgf·m, 20 Ibf.ft)

14. Install the lock bolt (D) with a new lock washer (E), then bend the lock washer tab against the bolt. 15. Install the shift cable cover (F), then install the shift cable holder (G) on the cover. NOTE: To prevent damage to the control lever joint, be sure to install the shift cable holder after installing the shift cable cover to the torque converter housing. 16. Install the floor heat shield.

14-132

BACK

21. Rotate the socket holder (A) on the shift cable (B) counterclockwise a quarter turn, then slide the holder onto the shift lever bracket base (e). Install the shift cable end (D) over the mounting stud (E) by aligning its square hole (F) with the square shape (G) at the bottom of the stud. Rotate the holder clockwise a quarter turn to secure the shift cable.

23. If not properly installed, remove the shift cable from the shift lever bracket base, and reinstall the shift cable. Do not install the shift cable end on the mounting stud while the shift cable is on the shift cable bracket base. 24. Install the tighten the nut.

NOTE: Do not install the shift cable by twisting the shift cable guide (H).

8x1.25mm 22 N·m (2.2 kgf.m, 16 Ibf·ft)

25. Remove the 6.0 mm (0.24 in.) pin that was installed to hold the shift lever. 26. Move the shift lever to each gear, and verify that the AfT gear position indicator follows the transmission range switch. D

F

27. Start the engine, and check the shift lever operation in all gears.

22. Verify that the shift cable end (A) is properly installed on the mounting stud (B). Properly Installed:

@D= /

T

\

A

B


Cable end rides on the bottom ofthe mounting stud.

BACK

14-133

Automatic Transmission Shift Cable Adjustment 1. Shift the transmission into 00 position.

5. Push the shift cable until it stops, then release your hand. Pull the shift cable back one step so that the shift position is in 00.

2. Remove the console panel (see page 20-83). 3. Remove the nut securing the shift cable end (A), then separate the shift cable end from the shift lever assembly.

@,...-)

-----'""'-'11I)[)=

""","-I)

+ •• ++[B]+ 6. Turn the ignition switch ON (II), and verify that the 00 position indicator light comes on. 7. Turn the ignition switch OFF.

4. Rotate the socket holder (A) on the shift cable (B) counterclockwise a quarter turn, then slide the holder to remove the shift cable from the shift lever bracket base (e).


NOTE: Do not remove the shift cable by twisting the shift cable guide (D).

/

\1

14-134

BACK

9. Rotate the socket holder (A) on the shift cable (8) counterclockwise a quarter turn, then slide the holder onto the shift lever bracket base (e). Install the shift cable end (D) over the mounting stud (E) by aligning its square hole (F) with the square shape (G) at the bottom of the stud. Rotate the holder clockwise a quarter turn to secure the shift cable.


J


8x 1.25mm 22 N·m 12.2 kgf.m, 16Ibf·ft)

13. Remove the 6.0 mm (0.24 in.) pin that was installed to hold the shift lever. 14. Move the shift lever to each gear, and verify that the AfT gear position indicator follows the transmission range switch. D

F


10. Verify that the shift cable end (A) is properly installed on the mounting stud (8). Properly Installed:

@D=

I

A

r

\

B


Cable end rides on the bottom of the mounting stud.

BACK

14-135

AfT Gear Position Indicator Component Location Index

AIT GEAR POSITION INDICATOR Indicator Input Test, page 14-141 Indicator Bulb Replacement, page 14-142


TRANSMISSION RANGE SWITCH Test, page 14-138 Replacement, page 14-139

14-136

BACK

Circuit Diagram DRIVER'S UNDER·DASH FU5ElRELAY BOX

UNDER·HooD FU5ElRELAY BOX

No 41(IOOA)

No'2 (SDA)

r-----------------------------------YEL------------------~


VSP OUT

D4 IND

ATP NP

A9

A,.

013

BLUIWHT

GRNlBLK

DRIVERS UNDER·DASH FUSElRELAY BOX

WHT

YEL

BLU

I


GAUGE ASSEMBLY

BLUIWHT I

BRN

PNK

I

I

I

I

CI2

.,

CIS

l-------~

C'

l-------~ c"

,

BLKlBLU

WHi---i REDIBLK

---l

17

WHT----l RED/BLK

C7

...

PNK---i

l

STARTER CUT RELAY

--l !•

811

C6

r.

BLKlBLU

PNK ----l

[M"

i I

r- LT BLU

-{>

CRUISE CONTI'IOL UNIT

PNK

I

I.

BLU--i

BLU ----l r

BRN---i

-BRNBRN----lJ~

BLU

11

Bn

BLK

1

,"

9

,

7

6

BLIulll I

G5D1

WHT

YEL

N

D.

S

•

I

,l

2

11111

BLU

GRY

5T

G~'

REDIWHT

A


BACK

14-137

AfT Gear Position Indicator Transmission Range Switch Test 1. Remove the transmission range switch connector (A) from the connector bracket (8), then disconnect the transmission range switch connector. 2. Check for continuity between the terminals in each switch position according to the table below. NOTE: Terminal No.1: Neutral position switch A

Transmission Range Switch Continuity Check

\

Terminal Position

[f]

\

1

2

,...

14-138

5

6

7

8

9

,... ,...

,... '"'

v

~

v

.'-'

00

v

v

v

10

<>

-

~

III

4

~

IRl IN]

3

,...

'"' v

BACK

-

-

Transmission Range Switch Replacement 1. Raise the front of the vehicle, and make sure it is securely supported (see page 1-17).

7. Set the transmission range switch to [I!I position. NOTE: The transmission range switch clicks in [NJ position.

2. Set the parking brake, and block both rear wheels securely. 3. Shift to [I!I position. 4. Remove the transmission range switch connector (A) from the connector bracket (8), then disconnect transmission range switch connector.

B

5. Remove the clamp from clamp bracket on the transmission housing, and remove the harness clamp (A) from the end cover (8).

/A

/

B

6. Remove the transmission range switch cover (e), then remove the transmission range switch (D) from the end cover.

(cont'd)

BACK

14-139

AfT Gear Position Indicator Transmission Range Switch Replacement (cont'd) 9. Install the transmission range switch (A) gently on the control shaft (8), then secure it with the bolts. NOTE: Do not move the transmission range switch when tightening the bolts.

12. Turn the ignition switch ON (II). Move the shift lever through all gears, and check the transmission range switch synchronization with the AfT gear position indicator (A).

A

13. Start the engine. Move the shift lever through all gears, and verify the following: 10. Install the transmission range switch cover (C) and the harness clamp (D) on the end cover (E). 11. Connect the transmission range switch connector (A), then install it on the connector bracket (8).

14-140

BACK

• The engine will not start in any position other than IHl or [fl. • The back-up lights come on when the shift lever is in lID position.

Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-28). 1. Remove the instrument panel (see page 20-84). 2. Remove the gauge assembly from the dashboard (see page 22-68), then disconnect the gauge assembly B (22P) and C (16P) connectors. 3. Inspect the connectors and connector terminals to be sure they are all making good contact. • If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system . • If the terminals look OK, make the following input tests at the gauge assembly B (22P) and C (16P) connectors. - If a test indicates a problem, find a correct the cause, then recheck the system. - If all the input tests prove OK, but the indicator is faulty, replace the printed circuit board.

GAUGE ASSEMBLY CONNECTORS


Cavity Wire Color

Test Condition

Test: Desired Result

Possible Cause (If result is not obtained)

B11

VEL


Check for voltage to ground: There should be battery voltage.

B16

BLK


C4

WHT

CS

BRN

C6

PNK

C7

BLU

C12

GRN/BLK

Ignition switch ON (II) and shift lever in !RI Ignition switch ON (II) and shift lever in Ignition switch ON (II) and shift lever in ~ Ignition switch ON (II) and shift lever in [!] Ignition switch ON (II) and shift lever in ~

Check for continuity to ground: There should be continuity. Check for voltage to ground: There should be 1 V or less. NOTE: There should be battery voltage in any other shift lever position.

C1S

BLK/BLU

Shift lever in ~

C16

RED/BLK

Ignition switch ON (II) and shift lever in [HJ

rn


Check for continuity to ground: There should be no continuity in anxother shift lever position. Check for voltage to ground: There should be 1 V or less. NOTE: There should be battery voltage in any other shift lever position.

BACK

• Blown No.9 (7.S A) fuse in the driver's under-dash fuse/relay box • An open in the wire • Poor ground (GS01) • An open in the wire • Faulty transmission range switch • An open in the wire

• Faulty transmission range switch • Faulty PCM • An open in the wire • Faulty transmission range switch • An open in the wire

14-141

AIT Gear Position Indicator Indicator Bulb Replacement SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-28). 1. Remove the instrument panel (see page 20-84). 2. Remove the gauge assembly, and disassemble it (see page 22-68). 3. Replace the bulbs (A) at the gauge assembly (8).

14-142

BACK

AfT Interlock System Component Location Index

BRAKE PEDAL POSITION SWITCH STEERING LOCK ASSEMBLY KEY INTERLOCK SOLENOID KEY INTERLOCK SWITCH Test, page 14-147

POWERTRAIN CONTROL MODULE (PCMI

MULTIPLEX CONTROL UNIT (DRIVER'SI Input Test, page 14-145

PARK PIN SWITCH Test, page 14-148 SHIFT LOCK SOLENOID Test, page 14-147 Replacement, page 14-148

BACK

14-143

AfT Interlock System Circuit Diagram UNDER·HOOD FUSE/RELAY BOX BATIERY

NO.47 (20A)

1-~+-~~~r---------~---------------------------WHTNEl--------~~----~

IGNITION SWITCH No.41 (100A)

No.42 (SOA)

DRIVER'S UNDER·DASH FUSEIRELAY BOX WHT/YEl

NO.9 (7.5A)

BAT

IGI

YEl

STEERING lOCK ASSEMBLY

KEY INTERLOCK SWITCH

SHIFT LOCK SOLENOID

WHT/RED

GRN

YEl

1

B22

A12

IGI

SHIFT lOCK SOLENOID


PG

lG

ATPP A15

BlK

BlK

BlKIBLU


PARK PIN SWITCH

IlU B12

WHT/RED

~

BlK

WHTlBlK

1 GSOI


A28

A32

IlU

BKSW

~ POWERTRAIN CONTROL MODULE (PCM)

G401

14-144

BACK

:

H

Control Unit Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-28). 1. Disconnect the multiplex control unit 22P connector driver's, then remove the multiplex control unit (driver's) from the driver's under-dash fuse/relay box. 2. Inspect the connectors and connector terminals to be sure they are all making good contact. • If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. • If the terminals look OK, go to step 3. NOTE: If the shift lock solenoid clicks when the ignition switch is turned ON (II) while depressing the brake pedal with the shift lever in [f] position, the shift lock system is OK. If the shift lever cannot be shifted from [f] position, test the transmission range switch. 3. With the driver's unit still disconnected from its connector and the fuse/relay box, make these input test at its connector or its fuse/relay box socket. • If a test indicates a problem, find and correct the cause, then recheck the system. • If all the input tests prove OK, go to step 4.

(cont'd)

BACK

14-145

AfT Interlock System Control Unit Input Test (cont'd)

MULTIPEX CONTROL UNIT, DRIVER'S CONNECTORS B(22P)

A (24P)



Multiplex Control Unit (Driver'sI24P Connector

A3

Wire Color --

Shift lever in [f]


A12

--



Cavity

Test Condition

Test: Desired Result • • • • •

---

A14 A24

Under all conditions Ignition switch turned ON (III

Check for continuity to ground: There should be continultv. Check for voltage to ground: There should be battery voltage.

• • • • •

Possible Cause Ilf result is not obtainedl Faulty transmission range switch Poor ground IG1011 An ODen in the wire Blown No.13 (7.5AI fuse in the passenger's under-dash fuse/relay Faulty passenger's under-dash fuse/relay box An ODen in the wire Poor ground (G4011 An open in the wire Blown No.9 (7.5 AI fuse in the driver's under-dash fuse/relay box Faultv driver's under-dash fuse/relav box

Multiplex Control Unit (Driver'sl22P Connector

B11

Wire Color BLK


B22

GRN

Ignition switch ON 1111

Cavity

Test Condition


Possible Cause

lit result is not obtainedl Check for continuity to ground: There should be continuitv. Check for voltage to ground: There should be battery voltage.

• Poor ground (G503) • An ODen in the wire • Blown No.9 (7.5 AI fuse in the driver's under-dash fuse/relay box • Faulty shift lock solenoid • An open in the wire

4. Reconnect the connectors to the multiplex control unit (driver's), and make this input test. Cavity

Wire Color

B12

WHT/RED

Test Condition Ignition switch ON 1111, and brake Dedal Dushed Ignition switch ON (III, brake pedal and accelerator pedal pressed at the same time

Test: Desired Result Check for voltage to ground: There should be battery voltaae. Check for voltage to ground: There should be 1 V or less.

• • • •

Possible Cause Ilf result is not obtained) Faulty brake pedal position switch Faulty PCM Faulty multiplex control unit (driver's) An open in the wire

• If a test indicates a problem, find and correct the cause, then recheck the system . • If all the input tests prove OK, substitute a known-good mUltiplex control unit (driver's), and recheck the system. If the system is OK, the multiplex control unit (driver's) must be faulty; replace it.

14-146

BACK

Key Interlock Solenoid/Switch Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-28).

Shift Lock Solenoid Test 1. Remove the center console (see page 20-83). 2. Disconnect the shift lock solenoid 2P connector.

1. Remove the driver's dashboard lower cover (see page 20-84). 2. Disconnect the key switch 7P connector from the steering lock assembly. 3. Check for continuity between the No.5 and No.7 terminals when the key is pushed, and check for no continuity when the key is released. KEY SWITCH CONNECTOR (7P)

3. Connect the No.1 terminal of the shift lock solenoid connector to the battery positive terminal, and connect the No.2 terminal to the battery negative terminal. 4. Check that the shift lever can be moved from the ~ position. Release the battery terminals from the shift lock solenoid connector. Move the shift lever back to the ~ position, and make sure it locks.


NOTE: Do not connect power to the No.2 terminal (reverse polarity) or you will damage the diode inside the solenoid.

4. Check that the key cannot be removed with power connected to the No.7 terminal and ground connected to the No.3 terminals. • If the key cannot be removed, the key interlock solenoid is OK. • If the key can be removed, replace the steering lock assembly (the key interlock solenoid is not available separately).

5. Check that the shift lock releases when the release lever is pushed, and check that it locks when the release lever is released . 6. If the solenoid does not work, replace it.

BACK

14-147

AfT Interlock System Shift Lock Solenoid Replacement

Park Pin Switch Test

1. Remove the center console (see page 20-83).


2. Disconnect the shift lock solenoid 2P connector.

2. Disconnect the park pin 4P connector.

3. Pry the shift lock solenoid clamp (A) with a screwdriver, then remove the shift lock solenoid (8).

3. Shift the shift lever into the [f.J position, then check for continuity between the No.3 and No.4 terminals. There should be no continuity. 4. Install the shift lock solenoid plunger (e) and plunger spring (D) in the new shift lock solenoid.

4. Shift the shift lever out of the [f.J position, and check for continuity between the terminals in step 3. There should be continuity.

5. Install the shift lock solenoid by aligning the joint of the shift lock solenoid with the tip of the shift lock stop (E).

5. Ifthe park pin switch is faulty, replace the shift lever bracket base.

6. Secure the shift lock solenoid with the clamp, then connect the shift lock solenoid connector.

NOTE: The park pin switch is not available separately from the shift lever bracket base.

14-148

BACK

Transmission End Cover End Cover and Idler Gears Removal Exploded View

END COVER GASKET

Replace.

CONICAL SPRING WASHER

Replace.

MAINSHAFT LOCKNUT

Left-hand threads Replace.

SECONDARY SHAFT LOCKNUT

Replace.

~.·E

CONICAL SPRING WASHER

ooP,.... / SECONDARY SHAFT IDLER GEAR

PARK GEAR ATFCOOLER LINE

ATF COOLER LINE

LINE BOLT

(cont'd)

BACK

14-149

Transmission End Cover End Cover and Idler Gears Removal (cont'd) 5. Slip the special tool onto the mainshaft.


Mainshaft holder 07GAB-PF50101 or 07GAB-PF50100 NOTE: Refer to the Exploded View as needed during this procedure. 1. Remove the transmission range switch cover. 2. Remove the bolts securing the harness clamp (two bolts), then remove the transmission range switch. 3. Remove the bolts securing the end cover (14 bolts), then remove the cover. 4. For '00-02 models: Remove the lubrication pitot pipe (A) and the pitot pipe (B), then remove the pitot flange (e) from the mainshaft 1st gear (D).

07GAB-PF50101 or 07GAB-PF50100

6. Engage the park pawl with the park gear.

14-150

BACK

7. Cutthe lock tabs (A) of each shaft locknut (8) using a chisel (C). Then remove the locknuts and conical spring washers from each shaft. NOTE: • Mainshaft locknut has left-hand threads. • Clean the old locknuts; they are used to install the press fit idler gears on the mainshaft and secondary shaft, and the park gear and bearing hub on the countershaft. • Keep all of the chiseled particles out of the transmission.

8. Remove the special tool (mainshaft holder) from the mainshaft. 9. Remove the mainshaft idler gear (A) and the secondary shaft idler gear (8) with a puller (C).

o

A

/

B

B

c

10. With the puller, remove the bearing hub (D) from the countershaft, then remove the countershaft idler gear (E) and bearings. 11. Remove the park gear (F) with the puller. 12. Remove the park pawl, spring, shaft, and shaft stop. 13. Remove the park lever from the control shaft. 14. Remove the line bolts, then remove the ATF cooler lines.

BACK

14-151

Transmission End Cover Park Lever Stop Inspection and Adjustment 1. Set the park lever in the ~ position. 2. Measure the distance (A) between the park pawl shaft (8) and the park lever roller pin (e).

3. If the measurement is out of tolerance, select and install the appropriate park lever stop (A) from the table below.

STANDARD:

69.5-70.5 mm (2.74-2.78 in.) B

PARK LEVER STOP

Mark 1

Part Number 24537 -PA9-003

2

24538-PA9-003

3

24539-PA9-003

14 N·m(1.4 kgf.m, 10 Ibf·ft)

L,

L2

11.00 mm (0.433 in.) 10.80 mm (0.425 in.) 10.60 mm (0.417 in.)

11.00 mm (0.433 in.) 10.65 mm (0.419 in.) 10.30 mm (0.406 in.)

4. After replacing the park lever stop, make sure the distance is within tolerance.

14-152

BACK

Transmission Housing Housing and Shaft Assemblies Removal Exploded View

HARNESS CLAMP BRACKET AfT CLUTCH PRESSURE CONTROL SOLENOID VALVES A and B

AfT CLUTCH PRESSURE CONTROL SOLENOID VALVE GASKET Replace. ATF FEED PIPE TRANSMISSION GROUND TERMINAL BRACKET

~

/

TRANSMISSION HOUSING MOUNTING BOLTS REVERSE IDLER GEAR SHAFTIHOLDER / Y ASSEMBLY

!

- 0

SPECIAL BOLT ('01-02 models) Replace.

TRANSMISSION HOUSING COUNTERSHAFT 2ND GEAR

/(;

COUNTERSHAFT REVERSE GEAR

WASHER £,/LOCK Replace.

t!

MAINS HAFT SUB-ASSEMBLY

---------

.

\

COUNTERSHAFT SUB-ASSEMBLY

SECONDARY SHAFT SUB-ASSEMBLY

DIFFERENTIAL ASSEMBLY

~

TORQUE CONVERTER HOUSING

REAR STIFFENER ~ ('01-02 models) ~

(cont'd)

BACK

14-153

Transmission Housing Housing and Shaft Assemblies Removal (cont'd) 5. Align the spring pin (A) on the control shaft (B) with the transmission housing groove (e) by turning the control shaft.

Special Tools Required Housing puller 07HAe-PK40102

NOTE: Refer to the Exploded View as needed during this procedure.

07HAC-PK40102

C

A

1. Remove the AfT clutch pressure control solenoid valves A and B. 2. Remove the transmission housing mounting bolts. • '98-00 models: Remove the 16 bolts, hangers, and brackets . • 'Q1-02 models: Remove the rear stiffener and special bolt, then remove 15 bolts, hanger, and brackets.

B

3. Install a 5 x 0.8 mm bolt (A) in the reverse idler gear shaft (B), then remove the reverse idler gear shaft! holder assembly (e).

6. Install the special tool over the mainshaft, then remove the transmission housing.

A

NOTE: If the top arm of your housing puller is too short, replace it with Housing Puller Arm, 205 mm, 07SAe-POZ0101. 7. Remove the reverse idler gear from the transmission housing. 8. Remove the countershaft 2nd gear, then slide and remove the countershaft reverse gear and the needle bearing.

B

9. Remove the bolt securing the shift fork, then remove the shift fork, reverse selector, reverse selector hub, and countershaft 4th gear. If the reverse selector hub is press-fitted, leave it and 4th gear on the countershaft.

c

4. When removing the transmission housing from the torque converter housing, move the reverse idler gear out of way of the countershaft 2nd gear in the direction shown. NOTE: The transmission housing will not separate from the torque converter housing if the reverse idler gear is not moved.

10. Remove the secondary shaft sub-assembly. If the reverse selector hub is press-fitted, remove the secondary shaft sub-assembly, countershaft sub-assembly and mainshaft sub-assembly together. 11. Remove the mainshaft sUb-assembly. 12. Remove the countershaft sub-assembly. 13. Remove the differential assembly.

14-154

BACK

Bearing Replacement 4. Release the pliers, then push the bearing down into the housing until the snap ring snaps in place around it.


• Driver 07749-0010000 • Driver 07949-3710001 • Driver attachment 07JAD-PH80101 • Attachment, 72 x 75 mm, 07746-0010600 NOTE: Coat all parts with ATF before assembly. 1. To remove the mainshaft bearing (A), countershaft bearing (8), and secondary shaft bearing (C) from the transmission housing, expand each snap ring with the snap ring pliers, then push the bearing out using the special tools and a press. NOTE: Do not remove the snap rings unless it's necessary to clean the grooves in the housing.

5. After installing the bearings verify the following: • The snap rings (A) are seated in the bearing and housing grooves . • The ring end gaps (8) are correct. B:0-7mm (0-0.28 in.)

A

B

2. Install the bearings in the direction shown. 3. Expand each snap ring with the snap ring pliers, and insert the bearing part-way into the housing using the special tools and a press.

BACK

14-155

Valve Body Valve Bodies and ATF Strainer Removal Exploded View

6x 1.0mm

ATF FEED PIPES. 8x71 mm

Bx

Eight Bolts

\

ATF FEED PIPE.

"n n_n_-lh.. ----""'u ~~ U

2~

:~%~LATOR VALVE

/

SrATOR SHAFT

~ 0

o

STATOR SHAFT STOP

<> lb

~ DOWEL PIN

~

ATF FEED PIPE

~

6x1'.!''?lm

One Bolt

ATF FEED PIPES

SERVO DETENT BASE

1/

o

REGULATOR SEPARATOR PLATE

Two Bolts

/ 6 X 1.0mm

.

~

'

~

,

DETENT ARM SHAFT /O-RING Replace. 8 x 1.25 mm

"'"

Three Bolts 0

6x1.0mm

Two Bolts

'~~~V

MAIN VALVE BODY

COOLER CHECK VALVE SPRING

SERVO BODY

COOLER CHECK ~ TORQUE CONVERTER ~ CHECK VALVE ~ /

DOWEL PIN

TORQUE CONVERTER CHECK VALVE SPRING

SERVO SEPARATOR PLATE

ATF PUMP DRIVEN GEAR SHAFT

DOWEL PINS

6x 1.0mm

MAIN SEPARATOR PLATE

Six Bolts ACCUMULATOR BODY

\ 14-156

BACK



15. Clean the inlet opening (A) ofthe ATF strainer (8) thoroughly with compressed air, then check that it is in good condition, and the inlet opening is not clogged or damaged.

1. Remove the ATF feed pipes from the main valve body, regulator valve body, and servo body.

B

2. Remove the servo detent base (two bolts). ---------~~--------------

r-_

3. Remove the ATF strainer (two bolts). 4. Remove the accumulator cover (two bolts). NOTE: The accumulator cover is spring loaded. To prevent stripping the threads in the servo body, press down on the accumulator cover while unscrewing the bolts in a crisscross pattern. 5. Remove the bolts securing the servo body (nine bolts), then remove the servo body and servo separator plate.

16. Test the ATF strainer by pouring clean ATF through the inlet opening, and replace it if it is clogged or damaged.

6. Remove the accumulator body (six bolts). 7. Remove the regulator valve body (eight bolts). 8. Remove the stator shaft and stator shaft stop. 9. Unhook the detent spring from the detent arm, then remove the detent arm shaft, detent arm, and control shaft. 10. Remove the cooler check valve spring and cooler check valve (steel ball). 11. Remove the main valve body (four bolts). 12. Remove the torque converter check valve and spring. 13. Remove the ATF pump driven gear shaft, then remove the ATF pump gears. 14. Remove the main separator plate and dowel pins (three).

BACK

14-157

Valve Body Valve Body Repair NOTE: This repair is only necessary if one or more of the valves in a valve body do not slide smoothly in their bores. Use this procedure to free the valves.

5. Remove the # 600 paper. Thoroughly wash the entire valve body in solvent, then dry it with compressed air.

1. Soak a sheet of # 600 abrasive paper in ATF for about 30 minutes. 2. Carefully tap the valve body so the sticking valve drops out of its bore. It may be necessary to use a small screwdriver to pry the valve free. Be careful not to scratch the bore with the screwdriver.

6. Coat the valve with ATF, then drop it into its bore. It should drop to the bottom of the bore under its own weight. If not, repeat step 4, then retest. If the valve still sticks, replace the valve body.

3. Inspect the valve for any scuff marks. Use the ATFsoaked # 600 paper to polish off any burrs that are on the valve, then wash the valve in solvent and dry it with compressed air. 4. Roll up half a sheet of ATF-soaked # 600 paper and insert it in the valve bore of the sticking valve. Twist the paper slightly, so that it unrolls and fits the bore tightly, then polish the bore by twisting the paper as you push it in and out. NOTE: The valve body is aluminum and doesn't require much polishing to remove any burrs. 7. Remove the valve, and thoroughly clean it and the valve body with solvent. Dry all parts with compressed air, then reassemble using ATF as a lubricant.

14-158

BACK

Valve Body Valve Installation 1. Coat all parts with ATF before assembly. 2. Install the valves and springs in the sequence shown for the main valve body (see page 14-160), regulator valve body (see page 14-163), and servo body (see page 14-164). Refer to the following valve cap illustrations, and install each valve cap so the end shown facing up will be facing the outside ofthe valve body.

3. Install all the springs and seats. Insert the spring (A) in the valve, then install the valve in the valve body (8). Push the spring in with a screwdriver, then install the spring seat (C).

~~ A

/~

B

BACK

14-159

Valve Body Main Valve Body Disassembly, Inspection, and Reassembly 1. Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blowout all passages. 2. Do not use a magnet to remove the check valve ball; it may magnetize the ball. 3. Check all valves for free movement. If any fail to slide freely, refer to Valve Body Repair (see page 14-158). 4. Replace the valve body as an assembly if any parts worn or damaged. 5. Coat all parts with ATF during assembly. 6. Install the filter in the direction shown.

MODULATOR VALVE

MAIN VALVE BODY

Inspect for scoring and damage. REVERSECPC VALVE

Q)~

LOCK-UP SHIFT VALVE

LOCK·UP CONTROL VALVE

1'"0

~~/ \1

@(@

\!!!I

COOLERCHECKVALVEIBA~ ~ TORQUE CONVERTER CHECK VALVE

/

®

CL /

SERVO CONTROL VALVE @

'i{~-~~

//\1

I

MANUAL VALVE VALVE CAP CLIP

14-160

SLEEVE

BACK

Sectional View

®

®

SPRING SPECIFICATIONS No.

CD ® ®

CD ® ® ill ® ® ®l

Spring Lock-up control valve spring Lock-up shift valve spring Shift valve E spring Shift valve 0 spring Shift valve C spring Modulator valve spring Reverse CPC valve spring Servo control valve spring Torque converter check valve spring Cooler check valve spring

WireOia. 0.7 (0.028) 0.9 (0.035) 0.7 (0.028) 0.7 (0.028) 0.8 (0.031) 1.6 (0.063) 0.7 (0.028) 0.7 (0.028) 1.1 (0.043) 0.6 (0.024)

BACK

Standard (New) Unit: mm (in.) 0.0. Free Length No. of Coils 6.6 (0.260) 42.9 (1.689) 14.2 63.0 (2.480) 7.6 (0.299) 22.4 6.6 (0.260) 32.2 (1.268) 13.4 6.6 (0.260) 35.7 (1.406) 17.2 6.6 (0.260) 49.1 (1.933) 21.7 10.4 (0.409) 33.5 (1.319) 9.8 6.1 (0.240) 17.8 (0.701) 7.9 35.7 (1.406) 6.6 (0.260) 17.2 38.2 (1.504) 14.0 8.4 (0.331) 5.8 (0.228) 14.5 (0.571) 6.8

14-161

Valve Body ATF Pump Inspection 1. Install the ATF pump drive gear (A), driven gear (B) and ATF pump driven gear shaft (C) in the main valve body (0). Lubricate all parts with ATF, and install the ATF pump driven gear with its grooved and chamfered side facing up.

2. Measure the side clearance of the ATF pump drive gear (A) and driven gear (B). ATF Pump Gears Side (Radial) Clearance: Standard (New): ATF Pump Drive Gear 0.210-0.265 mm (0.0083-0.0104 in.) ATF Pump Driven Gear 0.070-0.125 mm (0.0028-0.0049 in.)

A

/

3. Remove the ATF pump driven gear shaft. Measure the thrust clearance between the ATF pump driven gear (A) and the valve body (B) with a straight edge (C) and a feeler gauge (0).

c

D

ATF Pump Drive/Driven Gear Thrust (Axial) Clearance: Standard (New): 0.03-0.05 mm (0.001-0.002 in.' Service Limit: 0.07 mm (0.003 in.' C

D

14-162

BACK

Regulator Valve Body Disassembly, Inspection, and Reassembly 1. Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blowout all passages. 2. Check all valves for free movement. If any fail to slide freely, refer to Valve Body Repair (see page 14-158). 3. Replace the valve body as an assembly if any parts are worn or damaged. 4. Hold the regulator spring cap in place while removing the stop bolt. The regulator spring cap is spring loaded. Once the stop bolt is removed, release the spring cap slowly so it does not pop out. 5. Reassembly is the reverse ofthe disassembly. Install the filter in the direction shown. 6. Align the hole in the regulator spring cap with the hole in the valve body, then press the spring cap into the valve body, and tighten the stop bolt. 7. Coat all parts with ATF during reassembly. REGULATOR VALVE STOP BOLT 6x 1.0mm 12 N·m (1.2 kgf·m, 8.7Ibf·ft)

SPRING SEAT

RELIEF VALVE

o (~

~

/LOCK-UP TIMING VALVE

~"",/®

FILTER Replace. Install in this direction.

/ALVE CAP

'{(?@~

REGULATOR VALVE BODY Inspect for scoring and damage.


CD ® ® (1)

®

0_____

'41.{9/

Spring

Regulator valve spring B Regulator valve spring A Stator reaction spring Relief valve spring Lock-up timing valve spring

Wire Dia. 1.6 (0.063) 1.9 (0.075) 4.5 (0.177) 0.9 (0.035) 0.65 (0.026)

BACK

VALVE CAP CLIP

Standard (New) Unit: mm (in.) 0.0. Free Length No. of Coils 44.0 (1.732) 12.5 9.2 (0.362) 15.2 14.7 (0.579) 77.4 (3.047) 35.4 (1.394) 30.3(1.193) 1.92 20.4 6.6 (0.260) 39.8 (1.567) 6.6 (0.260) 34.8 (1.370) 15.6

14-163

Valve Body Servo Body Disassembly, Inspection, and Reassembly 1. Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blowout all passages. 2. Check all valves for free movement. If any fail to slide freely, refer to Valve Body Repair (see page 14-158). 3. Replace the valve body as an assembly if any parts are worn or damaged. 4. Coat all parts with ATF during assembly. SHIFT VALVE A

®

VALVE SEAT

®

oJ~ '"Il/~

\

I

: I

:

~~,

/m

:

I

I :

~

VALVE CAP

VALVE CAP CLIP

@

~ !~/ :

CPCVALVEA

3RD ACCUMULATOR PISTON

~

/

4TH ACCUMULATOR PISTON

O-RINGS

Replace.

SHIFT VALVE B

SERVO BODY

Inspect for scoring and damage.

SHIFT FORK SHAFT/SERVO VA~ O-RING

/RePlace.


CD ® ® G)

® ®

Spring

Shift valve B spring Shift valve A spring CPC valve A spring CPC valve B spring 3rd accumulator spring 4th accumulator spring

14-164

WireOia. 0.8 (0.031) 0.8 (0.031) 0.7 (0.028) 0.7 (0.028) 3.8 (0.150) 3.8 (0.150)

BACK

Standard (New) Unit: mm (in.) No. of Coils Free Length 0.0. 16.9 40.4 (1.591) 7.1 (0.280) 40.4 (1.591) 16.9 7.1 (0.280) 17.8 (0.701) 7.9 6.1 (0.240) 17.8 (0.701) 7.9 6.1 (0.240) 7.8 59.8 (2.354) 19.6 (0.772) 59.8 (2.354) 7.8 19.6 (0.772)

Accumulator Body Disassembly, Inspection, and Reassembly 1. Do not use a magnet to remove the check balls; it may magnetize the balls. 2. Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blowout all passages. 3. Coat all parts with ATF during reassembly. LUBRICATION CHECK VALVE

~ /V~~CUP

'., g

o

/~~v

ACCUMULATOR BODY Inspect for scoring and damage.

CD

---------ACCUMULATOR BODY COVER

bJ _____

--------~

~

~

----.....1~

-------

1ST ACCUMULATOR PISTON /

/

l

O-RING Replace.


----@

:~I'-.-/'____ ®

I1

~

CD

CHECK BALLS, 2

~

®

® ® ill

STOP BOLT 6x1.0mm 12 N·mI1.2 kgf·m, 8.7Ibf·ft)

0

lJ ~

O-RING Replace.

SNAP RINGS

Springs

1st accumulator spring B 1st accumulator spring A 2nd accumulator spring B 2nd accumulator spring A

WireOia. 2.5 (0.098) 2.6 (0.102) 2.7 (0.106) 2.6 (0.102)

BACK

Standard (New) Unit: mm (in.) Free Length No. of Coils 0.0. 8.5 12.8 (0.504) 49.5 (1.949) 10.8 19.6 (0.772) 69.7 (2.744) 14.8 (0.583) 51.0 (2.008) 9.6 21.6 (0.850) 73.2 (2.882) 10.0

14-165

Torque Converter Housing Mainshaft Bearing and Oil Seal Replacement 3. Install the new oil seal flush with the housing using the special tools.


• Adjustable bearing puller, 25 - 40 mm 07736-A01000B or 07736-A01 OOOA

07749-0010000

• Driver 07749-0010000

• Attachment, 62 x 68 mm 07746-0010500 • Attachment, 72 x 75 mm 07746-0010600 1. Remove the mainshaft bearing and oil seal with the

special tool. SLIDE HAMMER,

3/S" -16 (Commercially available)

(/~ r?fi-2\ y/

~J\I

07746-0010600

J 0

/"P

,,~~/-

~~/ 07736-A01000B or 07736-A01000A

2. Drive in the new mainshaft bearing until it bottoms

in the housing with the special tools. 07749-0010000

a

1"'(

r~~

~.

0

~ -~

~\

1

07746-0010500

14-166

BACK

Countershaft Bearing Replacement Special Tools Required • Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A • Driver 07749-0010000 • Attachment, 62 x 68 mm 07746-0010500

Secondary Shaft Bearing Replacement Special Tools Required • Adjustable bearing puller, 25 - 40 mm 07736-A01000B or 07736-A01000A • Driver 07749-0010000 • Driver attachment 07947-6340500

1. Remove the countershaft bearing (A) with the special tool.

1. Remove the secondary shaft bearing (A) with the special tool.

SLIDE HAMMER,

3/S -16 N

(Commercially available)

A

A

2. Install the ATF guide plate (A).

2. Install the ATF guide plate (A). 07149-0010000

B B

0-0.03mm (0-0.001 in.)

3. Install the new bearing (B) into the housing (C) with the special tools.


BACK

14-167

Shafts and Clutches Mainshaft Disassembly, Inspection, and Reassembly 1. Lubricate all parts with ATF during reassembly. 2. Check clearance of 3rd/4th clutch assembly (see page 14-169). 3. Inspect the thrust needle bearing and the needle bearing for galling and rough movement. 4. Inspect the splines for excessive wear and damage. 5. Check shaft bearing surfaces for scoring and excessive wear. 6. Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings. 7. Install the conical spring washer and 41 x 72 mm thrust shim in the direction shown. 8. Inspect condition of the sealing rings. If the sealing rings are worn, distorted, or damaged, replace them (see page 14-170).

THRUST WASHER 27 x47x5 mm

HEXHEDBOLT 6x 1.0 mm 12 N·m (1.2 kgf·m, 8.7Ibf·ft) ('00-02 models)

-------::

THRUST NEEDLE BEARING

~

LOCKNUT (FLANGE NUT) Replace. Left-hand threads 226 N·m(23.0 kgf.m, 166Ibf·ft)--+ 0 .... 167 N·m(17.0 kgf·m, 123Ibf·ft)

/ ~-,

a

--e

CONICAL """""'" SPRING WASHER Replace.

------- PITOT FLANGE ('00-02 models)

~IDLERGEAR 4TH GEAR COLLAR

:B SET RING

14-168

""TRANSMISSION HOUSING BEARING

NEEDLE BEARING

\j

----.......... Install sealing rings mating faces as shown.

BACK


3rd/4th Clutch Clearance Inspection 1. Remove the O-rings from the mainshaft. 2. Assemble the 41 x 72 mm thrust shim (AI. 3rd/4th clutch assembly (8) and 4th gear collar (C) on the mainshaft (D).

3. Hold the 4th gear collar (C) against the clutch assembly (81. then measure the clearance between the clutch guide (E) and the 4th gear collar with a feeler gauge (F) in at least 3 places. Use the average as the actual clearance. STANDARD: 0.03 - 0.11 mm (0.001 - 0.004 in.)

/

B

4. If the clearance is out of standard, remove the thrust shim and measure its thickness. 5. Select and install a new shim, then recheck. THRUST SHIM, 41 x 72 mm

No. 1 2 3 4 5 6

Part Number 90414-P6H-0 10 904 15-P6H-0 10 904 16-P6H-0 10 90417-P6H-010 90418-P6H-010 90419-P6H-010

6.35 6.40 6.45 6.50 6.55 6.60

Thickness mm (0.250 in.) mm (0.252 in.) mm (0.254 in.) mm (0.256 in.) mm (0.258 in.) mm (0.260 in.)

6. After replacing the thrust shim, make sure the clearance is within standard.

BACK

14-169

Shafts and Clutches Mainshaft Sealing Rings Replacement The sealing rings on the mainshaft are synthetic resin with chamfered ends. Check condition of the sealing rings, and replace them only if they are worn, distorted, or damaged. 1. For a better fit, squeeze the sealing ring together slightly before installing them.

2. Apply ATF to the new sealing rings then install them on the mainshaft.

3. After installing the sealing rings, verify the following: • The rings are fully seated in the groove. • The rings are not twisted. • The chamfered ends of the rings are properly joined.

14-170

BACK

Countershaft Disassembly, Inspection, and Reassembly 1. Remove the locknut, and take off components down to the reverse selector hub. 2. Remove the reverse selector hub, 3rd gear, and 1st gear (see page 14-172). 3. Check the bearing in the bearing hub for wear and rough movement. If the bearing is worn or damaged, replace it (see page 14-174). 4. Inspect the thrust needle bearing and the needle bearing for galling and rough movement. 5. Check the splines for excessive wear and damage. 6. Check the shaft bearing surfaces for scoring and excessive wear. 7. Lubricate all parts with ATF, and reassemble the shaft and gears. 8. Install the conical spring washer, idler gear, reverse selector, reverse selector hub, and distance collar in the direction shown.

--PARK GEAR

BACK

14-171

Shafts and Clutches Countershaft Reverse Selector Hub, 3rd Gear, and 1st Gear Replacement 2. Remove the needle bearing, snap ring, distance collar, and 29 mm cotters from the countershaft.


Driver 40 mm I.D. 07746-0030100

Removal 1. Remove the reverse selector hub (A) and the 4th gear (B) with a universal 2-jaw (or 3-jaw) puller (e). Place a shaft protector (D) between the puller and countershaft (E) to prevent damaging the countershaft.

3. Remove the 1st gear (A) and 3rd gear (B) together from the countershaft (e) with a puller (D). Place a shaft protector (E) between the puller and countershaft to prevent damaging the countershaft. D E

NOTE: Some of the reverse selector hubs are not pressfitted, and can be removed without using a puller.

c

c

A

B

B

E

14-172

BACK

A

Installation 1. Apply ATF to the parts.

4. Install the 29 mm cotters, distance collar, snap ring, needle bearing, and 4th gear (A) on the countershaft.

2. Align the shaft splines with those on 1st gear, then press the countershaft (A) into the 1st gear (8) with a press.

5. Slide the reverse selector hub (8) over the countershaft (C), and then press it into place with the special tool and a press.

• Place an attachment (C) between the press and countershaft to prevent damaging the countershaft. • Stop pressing the countershaft when the 1st gear contacts the final drive gear (0).

NOTE: Some of the reverse selector hubs are not press-fitted and can be installed without using the special tool and a press.

3. Align the shaft splines with those on 3rd gear, then press the countershaft into the 3rd gear with a press. • Place an attachment between the press and countershaft to prevent damaging the counters haft. • Stop pressing the countershaft when the 3rd gear contacts the 1st gear.

BACK

14-173

Shafts and Clutches Countershaft Bearing Hub/Bearing Replacement Special Tools Required • Driver 07749-0010000 • Attachment, 42 x 47 mm 07746-0010300 • Attachment, 62 x 68 mm 07746-0010500 1. Check the bearing for wear, damage, and rough movement. If the bearing is worn or damaged, replace it. 2. Remove the bearing (A) from the bearing hub with the special tools, a bearing separator (8), and a press.

07746-0010300

A

3. Install the new bearing on the bearing hub with the special tools and a press.

~

077....., ....

/

14-174

BACK

Secondary Shaft Disassembly, Inspection, and Reassembly 1. 2. 3. 4. 5. 6.

Remove the locknut, and disassemble the shaft and gears. Inspect the thrust needle bearing and the needle bearing for galling and rough movement. Check clearance of the secondary shaft assembly (see page 14-176). Check the splines for excessive wear and damage. Check the shaft bearing surfaces for scoring and excessive wear. Check the idler gear bearing for wear and rough movement. If the bearing is worn or damaged, replace it (see page 14-178). 7. Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings. 8. Lubricate all parts with ATF during reassembly. 9. Install the conical spring washer and 38 x 56.5 mm splined washer in the direction shown.

LOCKNUT (FLANGE NUT) Replace. 226 N·m(23.0 kgf·m, 166Ibf·ft)-- 0 -167 N·m(17.0 kgf·m, 123 Ibf·ft) SECONDARY SHAFT



2ND GEAR

0

o

1ST GEAR

0

~ ---::%/ / . ~

~

000

O.

-0

o

0

0

0

0

'-

THRUSTSHIM,37x55mm

~ Selective part

~ ~1ST/2NDCLUTCH ~ASSEMBLY O-RING Replace. SPLINED WASHER, 38x56.5mm Selective part

\1 ....I----COTTERS, 32 mm -COTTER RETAINER ----SNAP RING ls::""":2I'_~=-

SEALING RINGS

BACK

14-175

Shafts and Clutches Secondary Shaft Clearance Inspection 1. Remove all O-rings from the shaft.

3. Measure the clearance between the 38 x 56.5 mm

splined washer (E) and cotters (F) with a feeler gauge (J) in at least three places. Use the average as the actual clearance.

2. Assemble the thrust needle bearing (A), needle bearing (8), 1st gear (e), thrust needle bearing (0), 38 x 56.5 mm splined washer (E), 32 mm cotters (F), cotter retainer (G), and snap ring (H) on the secondary shaft (I).

STANDARD: 0.07-0.15 mm (0.003-0.006 in.)

A B

c

D

-----F

4. If the clearance is out of standard, remove the splined washer, and measure its thickness. . 5. Select and install a new splined washer, then recheck.

-----G

SPLINED WASHER, 38 x 56.5 mm

H

No. 1 2 3 4 5 6

14-176

BACK

Part Number 90502-POZ-000 90503-POZ-000 90504-POZ-000 90S0S-POZ-000 90S06-POZ-000 90507 -POZ-OOO

6.85 6.90 6.95 7.00 7.05 7.10

Thickness mm (0.270 mm (0.272 mm (0.274 mm (0.276 mm (0.278 mm (0.280

in.) in.) in.) in.) in.) in.)

6. Remove the 27 x 47 x 5 mm thrust washer from the mainshaft. 7. Assemble the 1st/2nd clutch assembly (A), 37 x 55 mm thrust shim (8), thrust needle bearing (e), needle bearing (D), 2nd gear (E), thrust needle bearing (F), and 27 x 47 x 5 mm thrust washer (removed from mainshaft) (G) on the secondary shaft (H).

9. Hold the 27 x 47 x 5 mm thrust washer (G) against the clutch assembly (A), and measure the 2nd gear axial clearance in at least three places while moving the 2nd gear (E). Use the average as the actual clearance. STANDARD: 0.04-0.12 mm (0.002-0.005 in.'

@~G _____ F

D

B

A

10. Ifthe clearance is out of standard, remove the 37 x 55 mm thrust shim and measure its thickness. 11. Select and install a new thrust shim, then recheck. THRUST SHIM, 37 x 55 mm

No. 1 2 3 4 5 6 7

8. Set the dial indicator (I) on 2nd gear (E).

~

Part Number 90406-POZ-000 90407 -POZ-OOO 90408-POZ-000 90409-POZ-000 9041 O-POZ-000 90411-POZ-000 90412-POZ-000

Thickness 4.90 mm (0.193 in.) 4.95 mm (0.195 in.) 5.00 mm (0.197 in.) 5.05 mm (0.199 in.) 5.10 mm (0.201 in.) 5.15 mm (0.203 in.) 5.20 mm (0.205 in.)

12. Disassemble the shaft and gears. 13. Reinstall the 27 x 47 x 5 mm thrust washer on the mainshaft.

BACK

14-177

Shafts and Clutches Secondary Shaft Idler Gear Bearing Replacement 4. Install the new bearing on the secondary shaft idler gear with the special tool and a press .


• Driver 07749-0010000 • Attachment, 78 x 90 mm 07GAD-SD40101 1. Check the bearing for wear, damaged, and rough movement. If the bearing is worn or damaged, replace it.

~ .7GAD-SD. .,.,

2. Place the secondary shaft idler gear in a vise with soft jaws. 3. Remove the bearing (A) from the secondary shaft idler gear (8) with a commercially availables, 1-1/2"-2" blind hole bearing puller (C), and 1-5/8"-3" slide hammer (D).

A

14-178

BACK

/

077.....' ....

Clutch Disassembly Special Tools Required

3. Remove the wave spring from the 1st clutch.

• Clutch spring compressor attachment 07LAE-PX40100 • Clutch spring compressor attachment 07HAE-PL50101 • Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A 1. Remove the snap ring (A), then remove the clutch end plate, the clutch discs, and the plates with a screwdriver (B). B

A

4. Install the special tools on the 3rd/4th clutch assembly. 07LAE-PX40100

2. Remove the disc spring from the 3rd and 4th clutches.

07LAE-PX40100 or 07HAE-PL50100 07GAE-PX40200 or 07GAE-PG4020A

(cont'd)

BACK

14-179

Shafts and Clutches Clutch Disassembly (cont'd) 5. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 3rd and 4th clutches.

7. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.

B

6. Set the special tool (A) on the spring retainer (B) of the 1st and 2nd clutches in such a way that the special tool works on the clutch return spring (C).

14-180

8. Compress the spring until the snap ring can be removed.

BACK

9. Remove the snap ring (A). Then remove the special tools (8), spring retainer (e), return spring.

10. For 3rd and 4th clutch: Wrap a shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove the piston (8). Place a finger tip on the other end while applying air pressure.

c

B

BACK

14-181

Shafts and Clutches Clutch Inspection 1ST/2ND CLUTCH

CLUTCH DISCS

Standard thickness: 1.94 mm (0.076 in.)

I /

~~~(/

CLUTCH END PLATE

CLUTCH PLATES


SPRING RETAIN~

SNAP RING

~SNAPRING

~.........~

CLUTCH DISCS


~

___ SPRING

~---

RETAINER

~ RETURN SPRING

)/O-RINGS

_ _ _/ "

Replace .

......-2ND CLUTCH DRUM

~

____ 1ST CLUTCH DRUM

CLUTCH PLATES Standard thickn~.is: /

~

2.0 mm (0.079 in/, CLUTCH END PLATE

I

SNAP RING

14-182

BACK

3RD/4TH CLUTCH

CLUTCH DISCS


~=::::.../ SNAP RING t?§::i6~~ /

CLUTCH END PLATE

CLUTCH PLATES


O·RINGS

Replace.

CHECK VALVE CLUTCH PISTON

DISC SPRING RETURN SPRING

CLUTCH PLATES


CLUTCH DISCS

Standard thickness: 1.94 mm (0.076 in.) ""-_/~-- O·RINGS

Replace.

4TH CLUTCH DRUM CLUTCH END

PLAT~

- - - - 3RD CLUTCH DRUM

BACK

14-183

Shafts and Clutches Clutch Reassembly 2. Install new O-rings (A) on the piston (B).

Special Tools Required • Clutch spring compressor attachment 07LAE-PX40100 • Clutch spring compressor attachment 07HAE-PL50101 • Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A • Clutch compressor attachment 07ZAE-PRP0100

A

NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. • Blowout all passages. • Apply ATF to all parts before assembly.

3. Install the piston (A) in the clutch drum (B). Apply pressure and rotate to ensure proper seating. Lubricate the piston O-ring with ATF before installing. NOTE: Do not pinch the O-ring by installing the piston with too much force. A

14-184

BACK

4. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the retainer.

6. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 3rd and 4 the clutches.

____ A

B 7. Set the special tool (A) on the spring retainer (B) of the 1st and 2nd clutches in such a way that the special tool work on the clutch return spring (C).

5. Insta" the special tools on the 3rd/4th clutch assembly. 07LAE-PX40100

~

07LAE-PX40100 or 07HAE-PL50101 07GAE-PG40200 or 07GAE-PG4020A

(cont'd)

BACK

14-185

Shafts and Clutches Clutch Reassembly (cont'd) 8. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring. the retainer may be damaged.

11. Remove the special tools. 12. Install the disc spring in the 3rd. and 4th clutches in the direction shown.

9. Compress the return spring. 13. Install the wave spring in the 1st clutch.

10. Install the snap ring (A).

14-186

BACK

14. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes. Before installing the plates and discs, make sure the inside of the clutch drum is free of dirt and other foreign matter.

17. Set a dial indicator (A) on the clutch end plate (B).

15. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate (A) with the flat side toward the disc (B). A

B

18. Zero the dial indicator with the clutch end plate lifted up to the snap ring (e).

16. Install the snap ring (A) with a screwdriver (8).

(cont'd)

BACK

14-187

Shafts and Clutches Clutch Reassembly (cont'd) 19. Release the clutch end plate to lower the clutch end plate, then put the special tool on the end plate (A).

21. If the clearance is not within the service limits, select a new clutch end plate from the following table. NOTE: If the thickest clutch end plate is installed, but the clearance is still over the standard, replace the clutch discs and clutch plates.

0 40N ""Q~J 14 kgf, 9 ~bf)

B..........

~

07ZAE-PRP0100

o

l..

20. Press the special tool down with 40 N (4 kgf, 9 Ibf) using a force gauge, and read the dial indicator (B). The dial indicator reads the clearance (e) between the clutch end plate and top disc (0). Take measurements in at least three places, and use the average as the actual clearance.

1ST and 2ND CLUTCH END PLATES Mark 6 7 8

Clutch End Plate-to-Top Disc Clearance:

9 Clutch 1st 2nd 3rd 4th

I

Service Limit 1.15- 1.35 mm (0.045-0.053 in.) 0.7-0.9 mm (0.028-0.035 in.) 0.6-0.8 mm (0.024-0.031 in.) 0.4-0.6 mm (0.016-0.024 in.)

0 1 2 3 4

Part Number 22551 -P6H-003 22552-P6H-003 22553-P6H-003 22554-P6H-003 22555-P6H-003 22556-P6H-003 22557-P6H-003 22558-P6H-003 22559-P6H-003

Thickness 2.6 mm (0.102 in.) 2.7 mm (0.106 in.) 2.8 mm (0.110 in.) 2.9 mm (0.114 in-.) 3.0 mm (0.118 in.) 3.1 mm (0.122 in.) 3.2 mm (0.126 in.) 3.3 mm (0.130 in.) 3.4 mm (0.134 in.)

3RD and 4TH CLUTCH END PLATES Mark 1 2 3 4 5 6 7 8 9

14-188

BACK

Part Number 22551 -PX4-003 22552-PX4-003 22553-PX4-003 22554-PX4-003 22555-PX4-003 22556-PX4-003 22557 -PX4-003 22558-PX4-003 22559-PX4-003

Thickness 2.1 mm (0.083 in.) 2.2 mm (0.087 in.) 2.3 mm (0.091 in.) 2.4 mm (0.094 in.) 2.5 mm (0.098 in.) 2.6 mm (0.102 in.) 2.7 mm (0.106 in.) 2.8 mm (0.110 in.) 2.9 mm (0.114 in.)

Valve Body Valve Bodies and ATF Strainer Installation Exploded View

:!F7~~~PIPES. ATF FEED PIPE. 8 x 27 mm

\

6 x 1.0 mm /

n

~

Eight Bolts

IV !

ATFFEEDP,.ES

'o~/"".~ 1!"~c ~~ .

REGULATOR SEPARATOR PLATE

STATOR SHAFT

~n

STATOR SHAFT STOP

• Q

'/

..J"';;,;:

~ DOWEL PIN

6X1.0m~ One Bolt

6 x 1.0 mm Two Bolts

REGULATOR VALVE

~O ~__

ATFFEED PIPE

Torque: - 6 x 1.0 mm: 12 N·m (1.2 kgf·m. 8.7Ibf·ft) - 8 x 1.25 mm: 18 N·m (1.8 kgf·m. 13Ibf·ft)

DETENT ARM SHAFT ,

/O-RING Replace.

~

6x 1.0mm Two Bolts ACCUMULATOR COVER

MAIN VALVE BODY ........... 6x 1.0mm Nine Bolts COOLER CHECK VALVE SPRING COOLER CHECK V~ TORQUE CONVERTER CHECK VALVE / TORQUE CONVERTER CHECK VALVE SPRING ATF PUMP DRIVEN GEAR SHAFT

\

~.

CONTROL SHAFT

;

ATF PUMP DRIVE GEAR

DOWEL PIN

!~PARATOR

DOWEL PIN

MAIN SEPARATOR PLATE \

6x 1.0mm Six Bolts

ACCUMULATOR BODY

(cont'd)

BACK

14-189

Valve Body Valve Bodies and ATF Strainer Installation (cont'd) NOTE: Refer to the Exploded View as needed during this procedure. 1. Install the main separator plate (A) and three dowel pins on the torque converter housing. Then install the ATF pump drive gear (B), driven gear (C) and ATF pump driven gear shaft (0). Install the ATF pump driven gear with its grooved and chamfered side facing down.

4. Install the cooler check valve and spring on the main valve body, then install the two dowel pins and the regulator separator plate. 5. Install the stator shaft and stator shaft stop. 6. Install the regulator valve body (eight bolts). 7. Install the two dowel pins and the servo separator plate on the main valve body. 8. Install the control shaft (A) in the torque converter housing along with the manual valve (B). G

A

~,: ~:: ©'~-

I'

~-_Q:

/ -

2. Install the torque converter check valve and spring, then install the main valve body (one 6 mm bolt and three 8 mm bolts). Make sure the ATF pump drive gear (B) rotates smoothly in the normal operating direction, and the ATF pump driven gear shaft (0) moves smoothly in the axial and normal operating direction.

B

9. Install the detent arm (C) and arm shaft (0) in the main valve body (E), then hook the detent arm spring (F) to the detent arm.

10. Install the servo body (G) (nine bolts). 11. Install the accumulator cover (two bolts). 12. Install the ATF strainer (two bolts). B

D

13. Install the servo detent base (two bolts).

3. If the ATF pump drive gear and ATF pump driven gear shaft do not move smoothly, loosen the main valve body bolts. Realign the ATF pump driven gear shaft, and retighten the bolts to the specified torque, then recheck. Failure to align the ATF pump driven gear shaft correctly will result in a seized ATF pump drive gear or ATF pump driven gear shaft.

14-190

14. Install the accumulator body (six bolts). 15. Install the two ATF feed pipes in the servo body, four pipes in the regulator valve body, and one pipe in the main valve body.

BACK

Transmission Housing Shaft Assemblies and Housing Installation Exploded View

I

AfT CLUTCH PRESSURE CONTROL SOLENOID VALVES A and B HARNESS CLAMP BRACKET

~

TRANSMISSION GROUND TERMINAL BRACKET TRANSMISSION HOUSING MOUNTING BOLTS 10x 1.25 mm 44 N·m 14.5 kgf.m, 33 Ibf·ft)

----- '

~6X1.0mm ~/ 12 N·m 11.2 kgf·m, 8.7 Ibf·ft)

t t ______ SHAFT/HOLDER REVERSE IDLER GEAR ASSEMBLY

6x 1.0mm ' 12N·m 11.2 kgf·m, 8.7Ibf·ft)

TRANSMISSION HOUSING

I

A/T CLUTCH PRESSURE CONTROL SOLENOID VALVE GASKET

COUNTERSHAFT 2ND GEAR

v)

Replace.

~~~

/

TRANSMISSION HANGER

COUNTERSHAFT REVERSE GEAR

6x1.0mm 14N.m 11.4 kgf·m, 10 Ibf·ft)

~ _ _ _ _ LOCK

WASHER

Replace. SPECIAL BOLT l'01-~~e~OdeIS) _______

---SHIFT FORK

e'.!

RePla.:.:-----TRANSMISSION HANGER/CONNECTOR BRACKET

-----

MAINSHAFT SUB-ASSEMBLY

\COUNTERSHAFT SUB-ASSEMBLY



TRANSMISSION HOUSING GASKET

Replace.

(cont'd)

BACK

14-191

Transmission Housing Shaft Assemblies and Housing Installation (cont'd) NOTE: Refer to the Exploded View as needed during this procedure.

5. Place the reverse idler gear in the transmission housing in the direction shown, then move it the direction shown.

1. Install the differential assembly, countershaft subassembly, mainshaft sub-assembly, and secondary shaft sub-assembly in the torque converter housing. 2. Install the countershaft 4th gear and reverse selector hub on the countershaft. Ifthe reverse selector hub is a press-fitted type, refer to the installation (see page 14-173). 3. Turn the shift fork shaft (A) so the large chamfered hole is facing the fork bolt hole. Then install the shift fork (B) and reverse selector (C) together on the shift fork shaft and countershaft (0). Secure the shift fork to the shift fork shaft with the lock bolt (E) and a new lock washer (F), then bend the lock washer against the bolt head. E 6x10mm 14 N·m 11.4 kgf·m. 10 Ibf·ft)

B~____ F ~Q

4. Install the needle bearing, countershaft reverse gear, and countershaft 2nd gear on the countershaft.

14-192

BACK

6. Align the spring pin (A) on the control shaft (B) with the transmission housing groove (C) by turning the control shaft.

7. Install three dowel pins and a new gasket on the torque converter housing. 8. Place the transmission housing on the torque converter housing. then install the housing bolts along with the transmission hanger/connector bracket (A). transmission hangers (B), and transmission ground terminal bracket (C). Tighten the bolts and new special bolt ('01-02 models) (0) in two or more steps in the sequence shown to 44 N· m (4.5kgf·m, 33 Ibf·ft).

9. Install the ATF feed pipes (A) with their filter (B) side into the transmission housing, then install new a-rings (C), new gasket (0), harness clamp bracket (E) and the AfT clutch pressure control solenoid valves A and B (F) over the ATF feed pipes on the transmission housing. E

6x1.0mm 12 N·m 11.2 kgf·m. 8.7Ibf·ft)

10. Coat the reverse idler gear shaft (A), needle bearing (B), and new a-rings (C) with lithium gearse lightly. Assemble the new a-rings and needle bearing on the reverse idler gear shaft, then install the reverse idler gear shaft in the reverse idler gear shaft holder (0). Align the O-shaped cut out of the shaft with the O-shaped area of the holder.

11. Engage the reverse idler gear (A) with the countershaft reverse gear and mainshaft reverse gear, then install the reverse gear shaft/holder assembly (B) on the transmission housing. 6x 1.0mm 12 N·m 11.2 kgf·m. 8.7Ibf·ft)

B

A

BACK

14-193

Transmission End Cover End Cover and Idler Gears Installation Special Tools Required Mainshaft holder 07GAB-PF50101 or 07GAB-PF50100

1. Install the park lever (A) and park lever stop (B) on the control shaft (C), then install the lock bolt (D) with a new lock washer (E). Do not bend the lock tab of the lock washer in this step; bend it after check the park pawl engagement in step 25. D 6x 1.0 mm

"N~/ A

E

2. Coat the following parts with ATF: • Splines of the countershaft, park gear, and old locknut. • Threads of the countershaft and old locknut. • Old conical spring washer. 3. Install the park gear (A) using the old locknut (B) and a collar (C). Engage the park pawl (D) to the park gear, then tighten the old locknut until the shaft splines come out slightly over the park gear splines.

~

NOTE: Do not use an impact wrench.

u----c 4. Remove the locknut and the collar, then install only the bearing hub/bearing assembly fA) and old conical spring washer (B). Tighten the old locknut (C) to seat the park gear to 226 N·m (230 kgf·m, 166 Ibf·ft), then remove the locknut and conical spring washer. NOTE: Do not use an impact wrench. Always use a torque wrench to tighten the locknut.

14-194

BACK

5. Remove the bearing hub/bearing assembly (A) using a puller (B).

7. Set the dial indicator (A) to the countershaft idler gear (B) as shown.

6. Install the thrust needle bearing (A), needle bearing (B), countershaft idler gear (e), thrust needle bearing (D), bearing hub/bearing assembly (E), and the old conical spring washer (F). Then tighten the old locknut (G) to seat the bearing hub/bearing assembly to 164 N·m (17.0 kgf·m, 123Ibf·ft).

8. Measure the countershaft idler gear axial clearance in at least three places while moving the countershaft idler gear(A). Use the avarage as the actual clearance.

STANDARD: 0.015-0.045mm (0.0006-0.0018 in.)

NOTE: Do not use an impact wrench. Always use a torque wrench to tighten the locknut.

(cont'd)

BACK

14-195

Transmission End Cover End Cover and Idler Gears Installation (cont'd) 9. If the clearance is out of standard, remove the bearing hub/bearing assembly using a puller as descriped on the previous page. 10. Select and install the new bearing hub/bearing assembly, then recheck.

14. Lubricate the following parts with ATF: o

o

o

o

ij~ [---I] ~~t I

Splines ofthe mainshaft, secondary shaft, and idler gears. Threads ofthe mainshaft, and secondary shaft. Threads of the old mainshaft and secondary shaft locknuts. Old conical spring washers.

15. Install the mainshaft idler gear (A) and the old conical spring washer (8) on the mainshaft (C). Tighten the old locknut (D) to seat the mainshaft idler gear to 226 N·m (23.0 kgf·m, 166Ibf·ft). NOTE: o Do not use an impact wrench, always use a torque wrench to tighten the locknut. o Mainshaft locknut has left-hand threads.

BEARING HUB Mark A

8 C 0

Part Number 90520-P6H-000 90521-P6H-000 90522-P6H-000 90523-P6H-000

Difference 3.503mm(0.1379 in.) 3.490 mm(0.137 4 in.) 3.477 mm(0.1369 in.) 3.464 mm(0.1364 in.)

11. After replacing the bearing hub/bearing assembly, make sure the clearance is within standard. 12. Remove the old locknut and old conical spring washer from the countershaft. 13. Install the special tool onto the mainshaft. 07GAB-PF50101 or 07GAB-PF50100

16. Install the secondary shaft idler gear (E) and the old conical spring washer (F) on the secondary shaft (G). Tighten the old locknut (H) to seat the sedondary shaft idier gear to 226 N·m (23.0 kgf·m, 166Ibf·ft). NOTE: Do not use an impact wrench, always use a torque wrench to tighten the locknut. 17. Remove the old locknuts and old conical spring washer from the mainshaft and the secondary shaft.

14-196

BACK

18. Lubricate the threads of each shaft and new locknuts, and new conical spring washers with ATF. 19. Install the new conical spring washers (A) in the direction shown, and install the new locknuts (B).

22. For '00-02 models: Install the pitot flange (A) on the mainshaft idler gear (B), then install the lubrication pitot pipe (C) and the pitot pipe (D) on the transmission housing.

6x 1.0 mm 12N·m 11.2 kgf·m, 8.7 Ibf·ft)

20. Tighten the locknuts to 167 N·m (17.0 kgf·m, 123Ibf·ft). NOTE: • Do not use an impact wrench, always use a torque wrench to tighten the locknut . • Mainshaft locknut has left-hand threads. 21. Stake each locknut into its shaft using a 3.5 mm punch.

D

F

E

24. If the park pawl does not engage fully, check the distance between the park pawl shaft (C) and the park lever roller pin (D) (see page 14-152). 25. Tighten the lock bolt (E), and bend the lock tab of the lock washer (F) against the lock bolt head.

(cont'd)

BACK

14-197

Transmission End Cover End Cover and Idler Gears Installation (cont'd) 26. Install the end cover along with two dowel pins and new O-rings. Tighten the 14 bolts to 12 N·m (1.2 kgf·m, 8.7Ibf·ft).

28. Set the control shaft to the [HI position by turning it.

27. Set the transmission range switch to [HI position. NOTE: The transmission range switch clicks in [HI position.

14-198

BACK

NOTE: Be careful not to squeeze the end of the control shaft tips together when turning into position. If the tips are squeezed together it will cause a faulty shift signal or position due to the play between the control shaft and the switch.

29. Install the transmission range switch (A) loosely on the control shaft (B), then secure it with the bolts. Do not move the transmission range switch when tightening the bolts.

For '01-02 models, follow this procedure: 34. Install the rear stiffener (A), then tighten the 10 x 1.25 mm bolt (B) to the specified torque.

~c

I

30. Install the transmission range switch cover (C), and install the harness clamp on the clamp bracket (D) on the transmission housing, then install the harness clamp (E) on the end cover (F). 31. Install the ATF cooler lines and new sealing washers. Tighten the line fittings to 28 N·m (2.9 kgf·m, 21 Ibf·ft).

s--

8x 1.25 mm 26N·m 12.7 kgf·m, 20 Ibf·ftl

10x 1.25mm 44 N·m 14.5 kgf.m, 33 Ibf·ftl

35. Secure the nut (C) by your hand until it contacts the stiffener, then tighten it to the specified torque. If you can not tighten the nut to the stiffener surface by hand, replace the nut and the special bolt (D).

32. Install the breather tube. 33. Install the ATF dipstick.

BACK

14-199

AfT Differential Component Location Index

~F1NAL DRIVEN GEAR Replacement, page 14-201 - - - - - - DIFFERENTIAL CARRIER Backlash Inspection, page 14-201

\TI!i'i;=ii?ff1l - - - - - - CARRIER BEARING Replacement, page 14-202

- - - - - BEARING OUTER RACE Replacement, page 14-204

~

14-200

THRUST WASHER

BACK -

---------

Backlash Inspection


1. Install both axles, and place the differential assembly on V-blocks (A).

1. Remove the final driven gear from the differential carrier.

c

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

B

A

2. Check the backlash of both pinion gears (S) with a

dial indicator (C). Ifthe backlash is out of standard, replace the differential carrier.

2. Install the final driven gear with the chamfered side on the inner bore facing the differential carrier.

STANDARD: 0.05~0.15

mm

(0.002~0.006

in.) 3. Tighten the bolts to the specified torque in a crisscross pattern. TORQUE:

101 N·m (10.3 kgf.m, 74.5Ibf.ft)

BACK

14-201

AfT Differential Carrier Bearing Replacement Special Tools Required Attachment, 40 x 50 mm 07LAO-PW50601 NOTE: • The bearing and outer race should be replaced as a set . • Inspect and adjust the bearing preload whenever bearing is replaced. 1. Remove the tapered roller bearing (A) with a bearing puller (B), a bearing separator (e), and a stepper adapter (0). A

D

14-202

BACK

2. Using the small end ofthe special tool, install the new tapered roller bearings with a press. Press the bearings on securely so there is no clearance between the bearings and the differential carrier.

Oil Seal Replacement Special Tools Required • Driver 07749-0010000 • Seal driver attachment 07GAD-PG40101 or 07GAD-PG 40100 • Pilot. 28 x 30 mm 07JAD-PH80400

4. Install the oil seal (A) in the transmission housing with the special tools. 07749-0010000

1. Remove the differential assembly. 2. Remove the oil seal (A) from the transmission housing (B).

A

07JAD-PH80400

07GAD-PG40100

5. Install the oil seal (A) in the torque converter housing with the special tools. 07749-0010000

A 3. Remove the oil seal (A) from the torque converter housing (B).

07JAD-PH80400

BACK

14-203

AfT Differential Carrier Bearing Outer Race Replacement 4. Install the thrust washer (A) and outer race (8) in the torque converter housing (C), and be sure to install the outer race until it bottoms is the housing with the special tools.

Special Tools Required • Driver 07749-0010000 • Driver attachment 07HAD-SF10100

NOTE: • Replace the bearing with a new one whenever the outer race is to be replaced. • Do not use shim (s) on the torque converter housing side. • Adjust preload after replacing the bearing and outer race. • Coat all parts with ATF during installation. 1. Remove the bearing outer race from the transmission housing by heating the housing to about 212°F (100°C) with a heat gun. Do not heat the housing more than 212°F (100°C). 2. Remove the bearing outer race from the torque converter housing. 3. Install the thrust shim (A), thrust washer (8) and outer race (C) in the transmission housing (D) with the special tools.

077 49-0010000

07HAD-SF10100

14-204

BACK

Carrier Bearing Preload Inspection 4. Select the 2.60 mm (0.102 in.) thrust shim from the middle of the table below.

Special Tools Required • Driver 07749-0010000 • Driver attachment 07HAD-SF10100 • Preload inspection tool 07HAJ-PK40201

THRUST SHIM, 76 mm

NOTE: If the transmission housing, torque converter housing, differential carrier, tapered roller bearing, outer race, or thrust shim were replaced, the bearing preload must be adjusted.

No. S

T

1. Remove the bearing outer race (A), thrust washer (B) and thrust shim (e) from the transmission housing (D) by heating the housing to about 212°F (100 0 e) with a heat gun (E). Do not heat the housing more than 212°F (100 0 e). NOTE: Let the transmission housing cool to room temperature before adjusting the bearing preload. 2. Replace the tapered roller bearing when the outer race is to be replaced. 3. Do not use a shim on the torque converter housing side.

U A B

e 0 E

F G H I J K L M N 0 P Q R

Part Number 41438-PX4-700 41439-PX4-700 41440-PX4-700 41441-PK4-000 41442-PK4-000 41443-PK4-000 41444-PK4-000 41445-PK4-000 41446-PK4-000 41447 -PK4-000 41448-PK4-000 41449-PK4-000 41450-PK4-000 41451-PK4-000 41452-PK4-000 41453-PK4-000 41454-PK4-000 41455-PK4-000 41456-PK4-000 41457 -PK4-000 41458-PK4-000

Thickness 2.05 mm (0.081 in.) 2.01 mm (0.083 in.) 2.15 mm (0.085 in.) 2.20 mm (0.087 in.) 2.25 mm (0.089 in.) 2.30 mm (0.091 in.) 2.35 mm (0.093 in.) 2.40 mm (0.094 in.) 2.45 mm (0.096 in.) 2.50 mm (0.098 in.) 2.55 mm (0.100 in.) 2.60 mm (0.102 in.) 2.65 mm (0.104 in.) 2.70 mm (0.106 in.) 2.75 mm (0.108 in.) 2.80 mm (0.110 in.) 2.85 mm (0.112 in.) 2.90 mm (0.114 in.) 2.95 mm (0.116 in.) 3.00 mm (0.118 in.) 3.05 mm (0.120 in.)

I_----D

~_-----c

(cant'd)

BACK

14-205

AfT Differential Carrier Bearing Preload Inspection (cont'd) 5. Install the thrust shim (A), thrust washer (B) and bearing outer race (C) in the transmission housing (0).

8. Install the differential assembly (A), gasket IB), and dowel pins (C) on the torque converter housing (D). Align the spring pin on the control shaft (E) with the transmission housing groove. 9. Install the transmission housing (F) with the transmission hangers (G), hanger/connector bracket (H) and ground terminal bracket (I), then tighten the bolts.

NOTE: For '01-02 models: Use old special bolt (J) during inspection, install the new special bolt when assembling the transmission.

'~

6. Drive the outer race with the special tools, and install it securely in the transmission housing. 7. Check that there is no clearance between the thrust washer, outer race, shim and transmission housing. 07749-0010000

G

~

J

G

D

14-206

BACK

c

10. Rotate the differential assembly in both directions to seat the bearings. 11. Measure the starting torque of the differential assembly with the special tool and a torque wrench (A). Measure the starting torque at normal room temperature in both directions. STANDARD: New bearing: 2.7-3.9 N·m (28-40 kgf.cm, 24-35Ibf·in.) Reused bearings: 2.5-3.6 N·m (25-37 kgf·cm, 22-32Ibf·in.)

07HAJ-PK40201

12. To increase the starting torque, increase the thickness of the shim. To decrease the starting torque, decrease the thickness of the shim. Changing the shim to the next size will increase or decrease starting torque about 0.3-0.4 N·m (3-4 kgf·cm, 3-3 ibf·in.)

BACK

14-207

BACK

Transaxle DrivelinelAxle Special Tools ................................................................. Driveshaft Inspection ................................................... Driveshafts Removal .................................................... Driveshafts Disassembly ............................................. Driveshafts Reassembly .............................................. Driveshafts Installation ................................................ Intermediate Shaft Removal........................................ Intermediate Shaft Disassembly ................................. Intermediate Shaft Reassembly .................................. Intermediate Shaft Installation ....................................

BACK

16-2 16-3 16-3 16-5 16-9 16-20 16-21 16-22 16-24 16-26

Drivelinel Axle Special Tools Ref. No.

CD @

® (!)

® ® ill ®

® @

Tool Number 07LAF-SM40300 07 MAC-SL00200 07XAC-001020A 017 46-0010300 07746-0030100 017 49-0010000 07947-5090101 07947-4630100 07947 -6340500 07965-5090100

DescriPtion Support Base Attachment Ball Joint Remover, 28 mm Threaded Adapter, 24 x 1.5 mm Attachment, 42 x 47 mm Driver, 40 mm 1.0. Driver Oil Seal Driver Attachment Fork Seal Driver, 39.2 x 49.5 x15 mm Driver Attachment Support Base

®

CD

(!)

Qty 1 1 1 1 1 1 1 1 1 1

®

®

~ .~'~~": .... ~:.

"-

ill

16-2

.. ~??£.::?:,

-_ ..-

®

BACK

®

Driveshaft Inspection

Driveshafts Removal

1. Check the inboard boot (A) and the outboard boot (B) on the driveshaft (C) for cracks, damage, leaking grease, and loose boot bands (D). If any damage is found, replace the boot and boot bands.

Special Tool Required Ball joint remover, 28 mm 07MAC-SL00200

1. Loosen the wheel nuts slightly. 2. Raise the front of the vehicle, and support it with safety stands in the proper locations (see page 117). 3. Remove the wheel nuts and front wheels.

D

2. Turn the driveshaft by hand, and make sure the splines (E) and joint are not excessively loose. 3. Make sure the driveshaft is not twisted or cracked; if it is, replace it. 4. Lift up the locking tab (A) on the spindle nut (B), then remove the nut. 5. If the right driveshaft is removed, drain the MTF (see page 13-3) or the ATF (see page 14-113). It is not necessary to drain the transmission fluid when the left driveshaft is removed (for vehicles with intermediate shaft). 6. Remove the self-locking nut (A) and 10 mm flange bolts (B and C), then remove the damper fork (D). D

A

(cont'd)

BACK

16-3

Drivelinel Axle Driveshafts Removal (cont'd) 7. Remove the cotter pi n (A) from the lower arm ball joint castle nut (8), and remove the nut.

10. Pry out the inboard joint (A) with a prybar, and remove the driveshaft from the differential case or bearing support as an assembly. Do not pull on the driveshaft (8), because the inboard joint may come apart. Draw the driveshaft straight out to avoid damaging the differential oil seal or the intermediate shaft outer seal. A

~YII"'''''~''''

07MAC-SLOO200

B~8. Separate the ball joint from the lower arm (C) with the special tool (see page 18-9). 9. Pull the knuckle outward, and remove the driveshaft outboard joint from the front wheel hub using a plastic hammer.

Left driveshaft with intermediate shaft: A

16-4

BACK

Driveshafts Disassembly Double Loop Type

Special Tools Required • Threaded adapter, 24 x 1.5 mm 07XAe-001020A • Slide hammer, commercially available • Boot band pincer, commercially available

D

Inboard Joint Side: 1. Remove the set ring (A) from the inboard joint.

E Low Profile Type

2. Remove the boot bands. Take care not to damage the boot and dynamic damper. • If the boot band is welded type (A), cut the boot band (B). • If the boot band is a double loop type (e), lift up the band bend (D), and push it into the clip (E). • If the boot band is a low profile type (F), pinch and remove the boot band with a commercially available boot band pincer (G).

Welded Type

3. Make a mark (A) on each roller (B) and inboard joint (e) to identify the locations of rollers and grooves in the inboard joint. Then remove the inboard joint on the shop towel (D). Be careful not to drop the rollers when separating them from the inboard jOint.

c

(cont'd)

BACK

16-5

Driveline/Axle Driveshafts Disassembly (co nt'd) 4. Make a mark (A) on the rollers (B or C) and spider (0) to identify the locations of rollers on the spider, them remove the rollers.

8. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot and dynamic damper (for left drives haft on A/T models and all right driveshafts).

NOTE:

• Roller (B) is used on '98-00 A/T models and all '01-02 models. • Roller (C) is used on '98-00 MfT models.

(Left driveshaft on A/T models and all right driveshafts)

9. Remove the inboard boot and dynamic damper. Take care not to damage the boot and dynamic damper. 5. Remove the circlip (E).

10. Remove the vinyl tape.

6. Mark the spider (0) and driveshaft (F) to identify the position of the spider on the shaft. 7. Remove the spider.

16-6

BACK

Outboard Joint Side:

Ear Clamp Type

1. Remove the boot bands. Take care not to damage the boot and dynami'c damper. • If the boot band is a welded type (A), cut the boot band (8). • If the boot band is a double loop type (e), lift up the band bend (0), and push it into the clip (E). • If the boot band is an ear clamp type (F), lift up the three tabs (G) with a screwdriver. • If the boot band is the locki ng tabs type, pry up the tabs with a screwdriver, and lift up the end of the band. Welded Type 2. Slide the outboard boot (A) to the inboard joint side. Take care not to damage the boot. A

A

/ !J

!

Double Loop Type D

E

(cont'd)

BACK

16-7

Drivelinel Axle Driveshafts Disassembly (cont'd) 3. Wipe off the grease to expose the driveshaft and the outboard joint inner race.

8. Remove the stop ring from the driveshaft.

4. Make a mark (A) on the driveshaft (B) at the same position of the outboard joint end (C).

5. Carefully clamp the driveshaft in a vise.

6. Remove the outboard joint (A) using the special tool and a commercially available 5/8" x 18 slide hammer (B). 7. Remove the driveshaft from the vise.

16-8

BACK

Driveshafts Reassembly Exploded View '98-00 models INBOARD JOINT

/

..

~CUP / .~2-------'FdIT-'

(

j

.~

(~"Ii;r~ ~f(5~ .()~

~...., ..../

ROLLER

/

(For A/T modelsl

~~~~-~7-'." 7~~p~:c~~LOOPBAND

SET RING Replace.

/

Pack cavity with grease.

,',..,

SPIDER (For A/T modelsl

/

~

.~CiA

Cf'

~

/ .

---~

.

INBOARD BOOT

~~()~ DYNAMIC DAMPER (Left driveshaft for A/T modelsl

/DRNESHAFT /

/ DOUBLE LOOP BAND Replace. DOUBLE LOOP BAND Replace. ,,.. ..(, .

(Rubber typel

~

(TPEt~~.,

~


I

/

~ ~'-ia

("

, .. ,

/STOPRING Replace.

-

c~

OUTBOARD BOOT ?«RUBBERI

., .,

,.,.

_

~ DOUBLE LOOP BAND ~ Replace.

rrfl ,~ ~DU1BDARDJOM

/r""""~~" '~1A"""" ~

.

'.

A ieJ ~""~

/

.I

~ ~~

\1

'0

•

1

r

EAR~ ~ ('><,~~: ~

Replace.

OUTBOARD BOOT (TPEI

, .., ' ..,../

EAR CLAMP BAND Replace.

(cont'd)

BACK

16-9

Drivelinel Axle Driveshafts Reassembly (cont'd) Exploded View '01-02 models

I

ROLLE

()

1

j';"DER

-v

~

III

-


V

I

~

DYNAMIC DAMPER (Both driveshafts for AfT models and right driveshaftfor MIT models)

~

~/

~

,

.~ Pack cavity with grease.

EAR CLAMP BANDS Replace.

16-10

.-fiiift P"koavitywhh .,.....

DRIVESHAFT

OUTBOA\RDBOOT (TPEI

~eJ,.

______ INBOARD BOOT

~~

DYNAMIC DAMPER BAND (Both driveshafts for AIT models and right driveshaft for MIT models)

~

U

~f/!) LOW PROFILE BAND Replace.

~

DOUBLE LOOP BAND Replace. (Replacement parts only)

R

BACK

/STOPRING Replace.

#"

WOC

~

Special Tools Required o Boot band tool, KO-3191 or equivalent commercially available o Boot band pincers, Kent-Moore J-35910 or equivalent commercially available o Boot band pincer, commercially available

3. Install the spider (A) onto the driveshaft by aligning the marks (B) on the spider and the end of the driveshaft.


Inboard Joint Side: 1. Wrep the splines with vinyl tape (A) to prevent damage to the inboard boot and dynamic damper (for left driveshaft on AfT models and all right driveshafts).

4. Fit the circlip (C) into the driveshaft groove. Always rotate the circlip in its groove to be sure it is fully seated. 5. Fit the rollers (A or B) onto the spider (C) with their high shoulders facing outward, and note these items: o

(Left driveshaft on AfT models and all right driveshaftsl

o

2. Install the dynamiC damper and inboard boot to the driveshaft, then remove the vinyl tape.Take care not to damage the inboard boot and dynamic damper.

o

o

Reinstall the rollers in their original positions on the spider by aligning the marks (0). Hold the driveshaft pointed up to prevent the rollers from falling off. Roller (A) is used on '98-00 AfT models and all '01-02 models. Roller (B) is used on '98-00 MIT models.

(cont'd)

BACK

16-11

Drivelinel Axle Driveshafts Reassembly (cont'd) 8. Adjust the length of the driveshafts to the figure below, then adjust the boots to halfway between full compression and full extension. Make sure the ends of the boots seat in the grooves of the driveshaft and joint.

6. Pack the inboard joint with the joint grease included in the new driveshaft set. Grease quantity Inboard joint: 120-130 g (4.2-4.6 oz) ('98-00 models) 150-160 g (5.3-5.6 oz) ('01-02 models)

Left drives haft: MIT: 531- 536 mm (20.9-21.1 in.) A/T: 883 - 888 mm (34.8 - 35.0 in.) Right driveshaft: 511-516 mm (20.1-20.3 in.)

7. Fit the inboard joint onto the driveshaft, and note these items:

9. Position the dynamic damper as shown below.

• Reinstall the inboard joint (A) onto the driveshaft by aligning the marks (B) on the inboard joint and the rollers. • Hold the driveshaft so the inboard joint points up to prevent it from falling off. • For MIT models, align the roller holders (e) with the grooves in the inboard joint ('98-00 models).

Left drives haft:

A/T: Right driveshaft:

539 - 543 mm (21.2 - 24.1 in.) 260-264 mm (10.2-10.4 in.)

10. Install the boot bands . • For the double loop type, go to step 13. (Boot band replacement only) • For the low profile type, go to step 11.

16-12

BACK

11. Install the new low profile band (A) onto the boot (8) and dynamic damper, then hook the tab (C) of the band.

13. Fit the boot ends onto the driveshaft and the inboard joint, then install the band (A) onto the boot (8).

B

I c

12. Close the hook portion of the band with a commercially available boot band pincers (A), then hook the tabs (8) of the band.

14. Pull up the slack in the band by hand. 15. Mark a position (A) on the band 10-14 mm (0.40.6 in.) from the clip (8).

A

B

(cont'd)

BACK

16-13

Drivelinel Axle Driveshafts Reassembly (cont'd) 16. Thread the free end ofthe band through the nose section of the commercially available boot band tool KD-3191 or equvialent (A), and into the slot on the winding mandrel (B).

19. Unwind the boot band tool, and cut off the excess free end ofthe band to leave a 5-10 mm (0.2-0.4 in.) tail protruding from the clip.

20. Bend the band end (A) by tapping it down with a hammer.

17. Place a wrench on the winding mandrel of the boot band tool, and tighten the band until the marked spot (C) on the band meets the edge of the clip. 18. Lift up the boot band tool to bend the free end of the band 90 degrees to the clip. Center-punch the clip, then fold over the remaining tail onto the clip.

16-14

BACK

NOTE: • Make sure the band and clip do not interfere with anything and the band does not move . • Remove any grease remaining on the surrounding surfaces

21. Install the new set ring.

Outboard Joint Side: 1. Wrap the splines with vinyl tape (A) to prevent damage to the outboard boot.

Rubber Type

TPEType

2. Install the new boot bands (B) (ear clamp type). 3. Install the outboard boot. Take care not to damage the outboard boot. 4. Remove the vinyl tape.

(cont'd)

BACK

16-15

Drivelinel Axle Driveshafts Reassembly (cont'd) 5. Install the new stop ring (A) into the driveshaft groove (B).

7. To completely seat the outboard joint, pick up the driveshaft and joint, and drop them from about 10 cm (4 in.) onto a hard surface. Do not use a hammer as excessive force may damage the driveshaft.

A

~

6. Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is close on the joint.

10cm in.)

(4

8. Check the alignment of the paint mark (A) with the outboard joint end (B).

16-16

BACK

9. Pack the outboard joint with the joint grease included in the new joint boot set.

12. Set the new double loop band (A) onto the boot.

Grease quantity Outboard joint (Rubber): 130-140 9 (4.6-4.9 oz) Outboard joint (TPE): 140-150 9 (4.9-5.3 oz)

13. Pull up the slack in the band by hand. 14. Mark a position (A) on the band 10--14 mm (0.40.6 in.) from the clip (8). B

10. Install the outboard boot and boot bands . • For TPE type boot, go to step 20 . • For rubber type boot, go to step 11. 11. Fit the boot (A) ends onto the driveshaft (8) and outboard joint (e). A

B

(cont'd)

BACK

16-17

Drivelinel Axle Driveshafts Reassembly (cont'd) 15. Thread the free end of the band through the nose section of a commercially available boot band tool KD-3191 or equivalent (A), and into the slot on the winding mandrel (B).


c

19. Bend the band end (A) by tapping it down with a hammer. NOTE:

16. Place a wrench on the winding mandrel of the boot band tool, and tighten the band until the marked spot (C) on the band meets the edge ofthe clip. 17. Lift up the boot band tool to bend the free end of the band 90° to the clip. Center-punch the clip, then fold over the remaining tail onto the clip.

16-18

BACK

• Make sure the band and clip do not interfere with anything, and the band does not move. • Remove any grease remaining on the surrounding surfaces. A

20. Fit the boot (A) ends onto the driveshaft (B) and outboard joint (C).

22. Check the clearance between the closed ear portion of the band. If the clearance is not within the standard, close the ear portion of the band further. 6.0mm

(0.24 in.) MAX

---

----- ---.3.0 mm (0.12 in.) MAX

21. Close the ear portion (A) of the band with a commercially available boot band pincers (B).

BACK

16-19

Drivelinel Axle Driveshafts Installation 1. Apply 0.3 -1.0 g (0.01- 0.04 oz) of specified grease to the whole splined surface (A) of the left driveshaft (for vehicles with intermediate shaft). After applying grease, remove the grease from the splined grooves at intervals of 2 - 3 splines and from the set ring groove (B) so that air can bleed from the intermediate shaft.

/

r-r-

(

(

\I \ L-r-

r

A

e-

\

4. Install the outboard joint (A) into the front hub (B).

B

B

I

IL~

A

2. Install a new set ring onto the set ring groove of the driveshaft.

5. Install the knuckle (A) onto the lower arm (B). Be careful not to damage the ball joint boot (C). Wipe off the grease before tightening the nut at the ball joint. Torque the castle nut (D) to the lower torque specification, then tighten it only far enough to align the slot with the pin hole. Do not align the nut by loosening.

3. Clean the areas where the driveshaft contacts the differential thoroughly with solvent or carburetor cleaner, and dry with compressed air. Insert the inboard end (A) of the driveshaft into the differential (B) or intermediate shaft (C) unitl the set ring (D) locks in the groove (E).

~_~E

A

c

/ B

12x 1.25 mm 49-59N·m

15.0-6.0 kgf·m, 36-43 Ibf·ttl

6. Install the new cotter pin (E) into the pin hole, and bend the cotter pin as shown.

16-20

BACK

Intermediate Shaft Removal 7. Install the damper fork (A) over the driveshaft and onto the lower arm. Install the damper in the damper fork so the aligning tab (8) is aligned with the slot in the damper fork. Loosely install the flange bolt (C).

1. Drain the MTF (see page 13-3) or ATF (see page 14113). 2. Remove the left driveshaft (see page 16-3).

A

3. Remove the flange bolt (A) and two dowel bolts (8).

/Ap~.

B

\;) :. , . "-.--.:.Pr:J

10 x 1.25 mm 43 N·m (4.4 kgf·m. 32 Ibf·ft)

-.

12 x 1.25 mm 64 N.m (6.5 kgf.m. 47 Ibf.ft)

8. Loosely install the flange bolt (D) and a new selflocking nut (E). 9. Install a new spindle nut (A). then tighten the nut. After tightening, use a drift to stake the spindle nut shoulder (8) against the driveshaft.

4. Remove the intermediate shaft (A) from the differential. Hold the intermediate shaft horizontal until it is clear of the differential to prevent damage to the differential oil seal (8). A

10. Clean the mating surfaces of the brake disc and the front wheel, then install the front wheel with the wheel nuts.

B

11. Tighten the flange bolts and the self-locking nut with the vehicles weight on the damper. 12. Refill the transmission with recommended MTF (see page 13-3) or ATF (see page 14-113). 13. Check the front wheel alignment and adjust if necessary (see page 18-5).

BACK

16-21

Drivelinel Axle Intermediate Shaft Disassembly Special Tools Required

3. Press the intermediate shaft (A) out of the intermediate shaft bearing (B) using the special tools and a press. Be careful not to damage the metal rings (e) on the intermediate shaft during disassembly.

• Driver, 07749-0010000 • Driver attachment, 07947-6340500 • Support base attachment, 07LAF-SM40300 • Support base, 07965-SD90100 • Attachment, 42 x 47 mm, 07746-0010300 1. Remove the intermediate shaft outer seal (A) from the bearing support (B).

~

07749-0010000

~~

B

2. Remove the external snap ring (e).

A~ 4. Remove the internal snap ring.

16-22

BACK

c

5. Press the intermediate shaft bearing (A) out of the bearing support (B) using the special tools and a press.

BACK

16-23

DrivelinelAxle Intermediate Shaft Reassembly Exploded View

INTERMEDIATE SHAFT BEARING

Replace.

BEARING SUPPORT

//EXTERNALSNAPRING

OUTERSEAL /

Replace.

BEARING SUPPORT RING

Pack the interior of the outer seal.

3.0-4.0 9 (0.11-0.14 oz)

16-24

BACK

Special Tools Required • Driver 077 49-0010000 • Support base attachment 07LAF-SM40300 • Support base 07965-S090100 • Oil seal driver attachment 07947-S090101 • Fork seal driver, 39.2 x 49.5 x 15 mm 07947-4630100

4. Press the intermediate shaft into the shaft bearing using the special tool and a press.

NOTE: Refer to the Exploded View as needed during this procedure. 1. Clean the disassembled parts with solvent, and dry them with compressed air. Do not wash the rubber parts with solvent. 2. Press the intermediate shaft bearing (A) into the bearing support (B) using the special tools and a press.

•

/07749-0010000

------- 07947 ·4630100

5. Seat the external snap ring (A) into the groove of the intermediate shaft (B).

07947·8090101

3. Seat the internal snap ring in the groove of the bearing support.

(cont'd)

BACK

16-25

Drivelinel Axle Intermediate Shaft Reassembly (cont'd)

Intermediate Shaft Installation

6. Pack the interior of the outer seal (A). Install the outer seal into the bearing support (B) using the special tools and a press. A

1. Clean the areas where the intermediate shaft (A) contacts the transmission (differential) thoroughly with solvent or carburetor cleaner, and dry with compressed air. Insert the intermediate shaft assembly into the differential. Hold the intermediate shaft horizontal to prevent damage to the differential oil seal (B).

07749-0010000

.7947-S111101.~ ~

07LAF-SM40300

...

r:=!!M~1l

/

A

07965-S0901oo

B

2. Install the flange bolt (A) and two dowel bolts (B). A

10x 1.25mm 39 N·m (4.0 kgf·m,

29 Ibf·ft)

16-26

BACK

"

B 10x1.25mm 39 N·m (4.0 kgf·m, 29lbf.ft)

Steering Power Steering Special Tools ................................................................. Component Location Index ......................................... Symptom Troubleshooting Index ............................... Symptom Troubleshooting ......................................... Steering Wheel Rotational Play Check ....................... Power Assist Check ...................................................... Steering Linkage and Gearbox Inspection ................. Pump Pressure Test-with T/N 07406-0010001 ........... Pump Pressure Test-with T/N 07406-001000A .......... Fluid Leakage Inspection ............................................. Pump Belt Inspection and Adjustment ....................... Fluid Replacement ........................................................ Hoses and Lines Replacement .................................... Pump Replacement ...................................................... Pump Overhaul ............................................................. Steering Wheel Removal ............................................. Steering Wheel Disassembly and Reassembly ......... Steering Wheel Installation ......................................... Steering Column Removal/Installation ...................... Steering Column Inspection ........................................ Steering Column Tilt Lever Inspection/ Adjustment .................................................................. Steering Lock Replacement ......................................... Rack Guide Adjustment ............................................... Steering Gearbox Removal ......................................... Steering Gearbox Overhaul ......................................... Steering Gearbox Installation ..................................... Tie-Rod Ball Joint Boot Replacement .........................

17-2 17-3 17-4 17-6 17-7 17-7 17-8 17-9 17-10 17-11 17-12 17-14 17-15 17-16 17-17 17-22 17-23 17-24 17-25 17-27 17-28 17-28 17-29 17-30 17-32 17-47 17-50

Power Steering Special Tools Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Tool Number Descrmtion 07GAF-PH70100 Pilot Collar 07HAG-SF10100 Piston Seal Ring Guide Piston Seal Ring Sizing Tool 07HAG-SF1020A or 07HAG-SF10200 07JGG-001010A Belt Tension Gauge Ball Joint Remover, 28 mm 07MAC-SL00200 ® 07NAD-SR3020A Cylinder End Seal Remover Attachment ® 07NAG-SR3090A Valve Seal Ring Sizing Tool ill 07RAK-S040110 PIS Joint Adaptor (Pump) ® 07RAK-S040121 PIS Joint Adaptor (Hose) ® @) 07406-0010001 or 07406-001000A PIS Pressure Gauge @ 07725-0030000 Universal Holder @ 07746-0010100 Attachment, 32x35 mm @ 077 49-0010000 Driver @ 07916-SA50001 Locknut Wrench, 40 mm @ 07965-SA50500 Front Hub Dis/Assembly Tool @ 07974-SA5020A or 07974-SA50200 Sleeve Seal Ring Sizing Tool @ 07974-SA50800 Ball Joint Boot Clip Guide * Included," the Belt TensIon Gauge Set, 07TGG-001000A. Ref.No.

CD ® ®

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Component Location Index STEERING WHEEL Removal, page 17-22 Disassembly and Reassembly, page 17-23 Installation, page 17-24

POWER STEERING PUMP Pressure Test (-with TIN 07406-0010001), page 17-9 Pressure Test (-with TIN 07406-001000A), page 17-10 Belt Adjustment, page 17-12 Replacement, page 17-16 Overhaul, page 17-17

DRIVER'S AIRBAG ASSEMBLY Removal/Installation, page 23-278

STEERING COLUMN Steering Column Removal and Installation, page 17-25 Steering Column Inspection, page 17-27 Steering Lock Replacement, page 17-28

POWER STEERING GEARBOX Rack Guide Adjustment, page 17-29 Steering Gearbox Removal, page 17-30 Steering Gearbox Overhaul, step 1 on page 17-33 Steering Gearbox Installation, page 17-47 TIe Rod Ball Joint Boot Replacement, page 17-50 POWER STEERING FLUID RESERVOIR Fluid Replacement, page 17-14 Hoses and Lines Replacement, page 17-15 Fluid Leakage Inspection, page 17-11

BACK

17-3

Power Steering Symptom Troubleshooting Index Find the symptom in the chart below, and do the related procedures in the order listed until you find the cause. Procedure(sl

Symptom

Also check for:

Hard steering

Troubleshoot the system (see page 17-6)

• Modified suspension • Tire sizes, tire varieties, and air pressure • Power steering pump belt adjustment

Assist (excessively light steering at high speedl

Check the rack guide adjustment (see page 17-29).

Front wheel alignment (see page 18-5).

Shock or vibration when the wheel is turned to full lock

1. Check the rack guide adjustment (see page 17-291. 2. Check the power steering pump belt for slippage and adjust as necessary (see page 17-121. 3. Replace the steering gearbox (see page 17-30).

Steering wheel will not return smoothly

1. Check cylinder lines A and B for deformation. 2. Check wheel alignment (see page 18-5). 3. Replace the steering gearbox (see page 17-30).

Uneven or rough steering

1. 2. 3. 4. 5. 6.

Check the rack guide adjustment (see page 17-29). Check the power steering pump belt adjustment (see page 17-12). Check for low or erratic engine idle speed (see page 11-110). Check for air in the power steering system due to low fluid level. Check for low fluid level in the power steering reservoir due to possible leaks in system. Replace the steering gearbox (see page 17-301.

Steering wheel kicks back during wide turns

1. 2.

Check the power steering pump belt adjustment (see page 17-121. Check the power steering pump fluid pressure with TIN 07406-0010001 (see page 17-91, with TIN 07406-001000A (see page 17-101.

Humming

1.

Check when the noise occurs. • Ifthe noise happens 2-3 minutes after starting the engine in cold weather, this is normal. o If the noise happens when the wheel is turn with the vehicle stopped, this is normal due to the fluid pulsation. Check for the high-pressure hose touching the sub-frame or body. Check for automatic transmission convertor noise. Remove the power steering belt, and recheck.

2. 3. Rattle or chattering

17-4

1. Check for loose steering components (tie-rod and ball jointsl. Tighten or replace as necessary. 2. Check the steering column shaft for wobbling. If the steering columns wobbles, replace the steering column assembly (see page 17-25). 3. Check the rack guide adjustment (see page 17-29). 4. Check the power steering pump pulley. o Ifthe pulley is loose, tighten it (see step 32 on page 17-211. o If the pump shaft is loose, replace the pump (see page 17-161.

BACK

Hissing

• Check the fluid level. If low, fill the reservoir to the proper level and check for leaks. • Check the reservoir for leaks. • Check for crushed inlet hose or loose hose clamp allowing air into the suction side of the system. • Check the power steering pump shaft oil seal for leaks.

Pump noise

• Compare the pump noise at normal operating temperature to another vehicle, (pump noise up to 2-3 minutes after starting the engine in cold weather is normal). • Remove and inspect the pump for wear and damage (see page 17-18).

Squeaking

Check the power steering belt tension and adjust as necessary (see page 17-

12). Fluid leaks from the steering gearbox

• Fluid leaks from the top of the valve body unit: Replace the valve oil seal on top of the valve housing. • Fluid leaks from the left tie-rod boot: Replace the valve oil seal on the pinion shaft. Replace the cylinder end seal on the gearbox side. • Fluid leaks from the right tie-rod boot: Replace the cylinder end seal. • Fluid leaks from pinion shaft near the lower steering joint bolt: Replace the valve body unit.

Fluid leaks from lines

• Fluid leaks from the cylinder line A or B connections (flare nuts): Tighten the connection and retest. If it still leaks, replace the line. • Fluid leaks from a damaged cylinder line A or B: Replace the cylinder line. • Fluid leaks from the pump outlet hose or return line fitting on the valve body unit (flair nuts): Tighten the fitting and retest. If it still leaks, replace the hose, the line, or valve body unit as necessary.

Fluid leaks from pump

• Fluid leaks from the front oil seal: Replace the front oil seal. • Fluid leaks from the power steering pump housing: Replace the leaking O-rings or seals (see page 17-17), and if necessary replace the power steering pump (see page 17-16).

Fluid leaks from reservoir

• Fluid leaks from around the reservoir cap: Fluid level is too high: drain the reservoir to the proper level. • Fluid leaks from reservoir: Check for the reservoir for cracks and replace as necessary. Aerated fluid: check for an air leak on the inlet side of pump.

Fluid leaks from pump outlet hose (highpressure)

• Check the fitting for loose bolts. If the bolts are tight, replace the fitting 0ring. • Fluid leaks at the swagged joint: Replace the outlet hose.

Fluid leaks from pump inlet hose (Iowpressure)

Check the hose for damage, deterioration, or improper assembly. Replace or repair as necessary.

BACK

17-5

Power Steering Symptom Troubleshooting Hard Steering

6. Adjust the rack guide (see page 17-29), and retest.

1. Check the power assist (see page 17-7).

Is the steering OK?

Is the power assist more than 29 N (3.0 kgf, 6.6 Ibf)?

YES-Repair is completed .• NO-Faulty gearbox.•

YES - Go to step 2. 7. Check for the supply and return lines between the pump and the gearbox for clogging and deformation.

NO-Power assist is OK.• 2. Measure steady-state fluid pressure from the pump at idle with TIN 07406-0010001 (see page 179), with TIN 07406-001000A (see page 17-10).

Are the lines clogged or deformed? YES- Repair or replace the lines.•

Is the pressure 1,500 kPa (15 kgflcrrr, 213 psi) or less?

NO-Faulty valve body unit.•

YES- Go to step 3.

8. Check the flow control valve (see step 10 on page 17-18) for smooth movement and leaks.

NO-Goto step 7.

Is the flow control valve OK? 3. Measure the pump relief pressure at idle with TIN 07406-0010001 (see page 17-9), with TIN 07406001000A (see page 17-10).

YES-Faulty pump assembly.•

NO - Faulty flow control valve .• Is the pressure 7,200- 7,800 kPa (73- 80 kgflcrrr, 1,040- 1,140 psi) or less?

9. Check the cylinder lines A and B for deformation (see page 17-8).

YES- Go to step 4.

Are the A or B lines deformed?

NO - Go to step 8. YES - Replace the lines •• 4. With a spring scale,measure the power assist in both directions, to the left and to the right.

Are the two measurements within 5.0 N (0.51 kgf, 1. 121bf) of each other?

NO- Go to step 10. 10. Check for a bent rack shaft or misadjusted rack guide (to tight).

YES- Go to step 5.

Is the rack shaft bent or the rack guide adjusted too tight?

NO- Go to step 9. 5. Measure the fluid pressure with TIN 07406-0010001 (see page 17-9), with TIN 07406-001000A (see page 17-10) with both pressure gauge valves open (if so equipped), while turning the steering wheel fully to the left and fully to the right.

Is the pressure 7,200- 7,800 kPa (73- 80 kgflcrrt, 1,040-1,140 psi) or less? YES-Go to step 6. NO-Faulty gearbox.•

17-6

BACK

YES - Replace the rack shaft or readjust the rack guide.•

NO - Faulty valve body unit.•

Steering Wheel Rotational Play Check

Power Assist Check

1. Turn the front wheels to the straight ahead position. 2. Measure how far you can turn the steering wheel left and light without moving the front wheels.

1. Check the power steering fluid level (see page 1714) and pump belt tension (see page 17-12). 2. Start the engine, let it idle, and turn the steering wheel from lock-to-Iock several times to warm up the fluid .

• If the play is within the limit, the gearbox and linkage are OK. • If the play exceeds the limit, adjust the rack guide (see page 17-29). If the play is still excessive after rack guide adjustment, inspect the steering linkage and gearbox (see page 17-8).

3. Attach a commercially available spring scale to the steering wheel. With the engine idling and the vehicle on a clean, dry floor, pull the scale as shown and read it as soon as the tires begin to turn. • If the scale reads no more than 30 N (3.1 kgf, 6.8 Ibf) the gearbox and pump are OK . • If the scale reads more than 30 N (3.1 kgf, 6.8 Ibf) check the gearbox and pump.

ROTATIONAL PLAY: 0-10 mm (0-0.39 in.)

BACK

17-7

Power Steering Steering Linkage and Gearbox Inspection

BOOT Inspect for damage and deterioration.

STEERING JOINTS Check for loose joint bolts.

DUST SEAL Inspect for damage and deterioration.

LOCKNUT Check for loose locknut.

STEERING GEARBOX Inspect loose mounting bolts. GEARBOX MOUNTING CUSHIONS Inspect for deterioration.

17-8

END BALL JOINT Inspect for faulty movement and damage.

....rlc ..' "...

BALL JOINT BOOT Inspect for damage and deterioration.

BACK

Pump Pressure Test with TIN 07406-0010001 Special Tools Required • PIS joint adapter (pump), 07RAK-S040110 • PIS joint adapter (hose), 07RAK-S040121 • PIS pressure gauge, 07406-0010001

5. Fully open the shut-off valve (A).

Check the fluid pressure as follows to determine whether the trouble is in the pump or gearbox. 1. Check the power steering fluid level (see page 1714) and pump belt tension (see page 17-12). B

2. Disconnect the pump outlet hose (A) from the pump outlet with care so as not to spill the power steering fluid on the frame and other parts, then install the PIS joint adapter (pump) on the pump outlet (8). 07RAK-S040121

6. Fully open the pressure control valve (8). 7. Start the engine and let it idle.

8. Turn the steering wheel from lock-to-Iock several times to warm the fluid to operating temperature.

6x 1.0mm 11 N·m (1.1 kgf·m, 8Ibf·ft)

9. Measure steady-state fluid pressure while the engine is idling. If the pump is in good condition, the gauge should read less than 1,500 kPa (15 kgfl cm 2, 213 psi). If it reads high, check for: • Clogged or deformed feed or return line between the pump and gearbox • Clogged valve body unit 10. Close the pressure control valve, then close the shut-off valve gradually until the pressure gauge needle is stable. Read the pressure.

07RAK-S040110

INOTICE I 3. Connect the PIS joint adapter (hose) to the PIS pressure gauge, then connect the pump outlet hose (A) to the PIS joint adapter (hose). 4. Install the PIS pressure gauge to the PIS joint adapter (pump).

Do not keep the pressure control valve closed more than 5 seconds or the pump could be damaged by over-heating. 11. Immediatery open the pressure control valve fully. Ifthe pump is in good condition, the gauge should read at least 7,200-7,800 kPa (73-80 kgf/cm2, 1,040-1,140 psi). A low reading means pump output is too low for full assist. Repair or replace the pump.

BACK

17-9

Power Steering Pump Pressure Test with TIN 07406·001000A 5. Open the pressure control valve (A) fully.

Special Tools Required • PIS joint adapter (pump), 07RAK-S040110 • PIS joint adapter (hose), 07RAK-S040121 • PIS pressure gauge, 07406-001000A Check the fluid pressure as follows to determine whether the trouble is in the pump or gearbox. 1. Check the power steering fluid level (see page 1714) and pump belttension (see page 17-12). 2. Disconnect the pump outlet hose (A) from the pump outlet with care so as not to spill the power steering fluid on the frame and other parts, then install the PIS joint adapter (pump) on the pump outlet (B). 07RAK-S040121

6. Start the engine and let it idle. 7. Turn the steering wheel from lock-to-Iock several times to warm the fluid to operating temperature.

07406-001000A

~

8. Measure steady-state fluid pressure while the engine is idling. If the pump is in good condition, the gauge should read less than 1,500 kPa (15 kgfl cm 2, 213 psi). If it reads high, check for: • Clogged or deformed feed or return line between the pump and gearbox • Clogged valve body unit 9. Close the pressure control valve gradually and read the pressure.

INOTICEI Do not keep the pressure control valve closed more than 5 seconds or the pump could be damaged by over-heating. 3. Connect the PIS joint adapter (hose) to the PIS pressure gauge, then connect the pump outlet hose (A) to the PIS joint adapter (hose). 4. Install the PIS pressure gauge to the PIS joint adapter (pump).

17-10

10. Immediately open the pressure control valve fully. If the pump is in good condition, the gauge should read at least 7,200-7,800 kPa (73-80 kgf/cm2, 1,040-1,140 psi). A low reading means pump output is too low for full assist. Repair or replace the pump.

BACK

Fluid Leakage Inspection

PUMP ASSEMBLY Check for leaks at the pump seal, inlet and outlet fittings.

GEARBOX and VALVE BODY UNIT Check for leaks at the mating surface and flare nut connections.

HOSES and LINES Inspect hoses for damage, leaks, interference and twisting. Inspect fluid lines for damage, rusting and leakage. Check for leaks at hose and line joints and connections.

BACK

17-11

Power Steering Pump Belt Inspection and Adjustment Special Tools Required • Belttension gauge set, 07JGG-001000A • Belttension gauge, 07JGG-001010A

Adjustment 4. Loosen the power steering pump mounting bolt (A) and pump lock bolt (B). A

Belt Tension Gauge Method

22 N·m 12.2 kgf·m, 161bf.ftl

Inspection 1. Remove the PIS reservoir from the bracket, and set it aside. 2. Attach the belt tension gauge to the belt with the gauge face toward the engine, and measure the tension ofthe belt. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. NOTE: Remove the belt tension gauge carefully to avoid hitting the gauge reset lever. Tension: Used Belt: New Belt:

390-540 N (40-55 kgf, 88-121Ibf) 740-880 N (75-90 kgf, 165-198Ibf)

07JGG-001000A or 07JGG-001010A

B 22 N·m 12.2 kgf·m, 16lbf.ftl

5. Adjust the belt tension by moving the power steering pump with a 1/2" drive breaker bar to obtain the proper belt tension, then retighten the mounting bolt and lock bolt. 6. Start the engine and turn the steering wheel from lock-to-Iock several times, then stop the engine and recheck the tension of the belt.

3. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification.

17-12

BACK

Deflection Method

Adjustment 3. Loosen the power steering pump mounting bolt (A) and pump lock bolt (B).

Inspection

A

1. Apply a force of 98 N (10 kgf, 221bf) and measure the deflection between the power steering pump pulley (A) and the crankshaft pulley (B). Ifthe belt is worn or damaged, replace it.

22 N·m (2.2 kgf·m, 161bf·ftl

Deflection:

Used Belt: New Belt:

13.0 -16.0 mm (0.51 - 0.63 in.) 11.0 -12.5 mm (0.43 - 0.49 in.)

B 22 N·m (2.2 kgf·m, 16Ibf·ft) B

4. Adjust the belt tension by moving the power steering pump with a 1/2" drive breaker bar to obtain the proper belt tension, then retighten the mounting bolt and lock bolt. 5. Start the engine and turn the steering wheel from lock-to-Iock several times, then stop the engine and recheck the tension of the belt.

2. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification.

BACK

17-13

Power Steering Fluid Replacement Check the reservoir (AI at regular intervals, and add the recommended fluid as necessary. Always use Honda Power Steering Fluid-V or S. Using any other type of power steering fluid or automatic transmission fluid can cause increased wear and poor steering in cold weather.

1. Raise the reservoir, then disconnect the return hose (AI to drain the reservoir. Take care not to spill the fluid on the body and parts. Wipe off any spilled fluid at once.

SYSTEM CAPACITY: 1.1 A(1.16 US. qt, 0.97Imp.qt) at disassembly RESERVOIR CAPACITY: 0.4 A(0.42 US. qt, 0.35 Imp.qt) A

2. Connect a hose (B) of suitable diameter to the disconnected return hose, and put the hose end in a suitable container. 3. Start the engine, let it run at idle, and turn the steering wheel from lock-to-Iock several times. When fluid stops running out of the hose, shut off the engine. Discard the fluid. 4. Reinstall the return hose on the reservoir. 5. Fill the reservoir to the upper level line. 6. Start the engine and run it at fast idle, then turn the steering from lock-to-Iock several times to bleed air from the system. 7. Recheck the fluid level and add more if necessary. Do not fill the reservoir beyond the upper level line.

17-14

BACK

Hoses and Lines Replacement Note these items during installation: • Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. • Check all clamps for deterioration or deformation; replace with the clamps new ones if necessary. • Add the recommended power steering fluid to the specified level on the reservoir and check for leaks. HOSE CLAMP IB)

ADJUSTABLE HOSE CLAMP IA}

2.S-S.Smm (0.01-0.22 in. I

CYLINDER LINE 26 N·m (2.7 kgf·m, 20 Ibf·ttl

2.S-S.Smm (0.01-0.22 in. I

2.0-4.0mm (0.08-0.16 in. I

CYLINDER LINE 17 N·m (1.7 kgf·m, 12lbf·ttl

FEED HOSE 14 x 1.S mm 37 N·m (3.8 kgf·m, 27 Ibf·ttl

6x 1.0mm 11 N·m (1.1 kgf·m,8Ibf·ttl

RETURN LINE 16 x 1.5 mm 28 N·m (2.9 kgf·m, 21 Ibf·ttl

POWER STEERING PRESSURE SWITCH 10x 1.25 mm 12 N·m (1.2 kgf·m, 8.7Ibf·ttl

BACK

17-15

Power Steering Pump Replacement 1. Place a suitable container under the vehicle.

7. Connect the pump inlet hose and pump outlet hose. Tighten the pump fittings securely.

2. Drain the power steering fluid from the reservoir. 8. loosely install the pump in the pump bracket with the mounting bolt and lock bolt.

3. Remove the belt (A) by loosening the pump mounting bolt (B) and pump lock bolt (C).

9. Install the pump belt. Note these item during belt installation: • Make sure that the power steering belt (A) is properly positioned on the pulleys (B). • Do not get power steering fluid or grease on the power steering belt or pulley faces. Clean off any fluid or grease before installation.

A~

10. Adjustthe pump belt adjustment (see page 17-12). 11. Fill the reservoir to the upper level line (see page 17-14). C 22 N·m 12.2 kgf·m. 16 Ibf·ft)

4. Cover the Ale compressor with several shop towels to protect it from spilled power steering fluid. Disconnect the pump inlet hose (D) and pump outlet hose (E) from the pump (F). and plug them. Take care not to spill the fluid on the body or parts. Wipe off any spilled fluid at once. 5. Remove the pump mounting bolt and pump lock bolt. then remove the pump. Do not turn the steering wheel with the pump removed. 6. Cover the opening of the pump with a piece of tape to prevent foreign material from entering the pump.

17-16

BACK

Pump Overhaul Exploded View Replace the pump as an assembly if the parts indicated with asterisk (*) are worn or damaged. FLANGE BOLTS 20 N·m (2.0 kgf·m, 14 Ibf·ft)

4.5mm ROLLER

~ *PUMP COVER

~

"

5mmROllER

SNAP RING

~O

PUMP SEAL SPACER DRIVE SHAFT BAll BEARING mmSNAPRING

0--- 15.2 x 2.4 mm O·RING

~

Replace.

/

FLOW CONTROL VALVE CAP 49 N·m (5.0 kgf·m, 36 Ibf·ft)

PULLEVNUT 64 N·m (6.5 kgf·m, 47 Ibf·ft)

(cont'd)

BACK

17-17

Power Steering Pump Overhaul (cont'd) Special Tools Required Universal holder, 07725-0030000

Inspection

10. Check the flow control valve for wear, burrs, and other damage to the edges of the grooves in the valve.

Disassembly

NOTE: Refer to the Exploded View as needed during the following procedure. r-'r--

1. Remove the power steering pump (see page 17-16).

r--

~

=

D

0

2. Drain the fluid from the pump.

-

3. Hold the steering pump (A) in a vise with soft jaws, hold the pulley (B) with the special tool, and remove the pulley nut (C) and pulley. Be careful not to damage the pump housing with the jaws of the vise.

r---'--''-'

r-

-

=

'-

11. Inspect the bore of the flow control valve on the pump housing for scratches or wear. 12. Slip the flow control valve back in the pump housing, and check that it moves in and out smoothly. If OK, go to step 13; if not, replace the pump as an assembly. The flow control valve is not available separately.

4. Loosen the flow control valve cap with a hex wrench, then remove it, and the a-ring, flow control valve, and spring. 5. Remove the pump cover and pump cover seal. 6. Remove the outer side plate, pump cam ring, pump rotor, pump vanes, side plate and a-rings. 7. Remove the snap ring, then remove the sub-valve from the pump housing. 8. Remove the circlip, then remove the pump drive shaft by tapping the shaft end with a plastic hammer. 9. Remove the pump seal spacer and pump seal.

17-18

BACK

13. Attach a hose (A) to the end of the flow control valve (B) as shown. Then submerge the flow control valve (B) in a container of power steering fluid or solvent (C), and blow in the hose. o

o

Reassembly

16. Clean the disassembled parts with solvent, and dry them with compressed air. Do not dip rubber parts in solvent.

If air bubbles leak through the valve at less than 98 kPa (1.0 kgf/cm2, 14.2 psi), replace the pump as an assembly. The flow control valve is not available separately. If the flow control valve tests OK, set it aside for reassembly later.

17. Align the pin (A) ofthe sub-valve (B) with the oil passage (C) in the pump housing, and push the sub-valve into place. Then install the snap ring (D).

A

18. Install the new pump seal (A) (with its grooved side facing in) into the pump housing by hand, then install the pump seal spacer (B).

B

O---F

14. Inspect the ball bearing by rotating the outer race slowly. If you feel any play (axial or radial) or roughness, remove the faulty ball bearing (A), and install a new one (B).

,

__-c

B

, A

19. Position the pump drive shaft (C) in the pump housing (D), then drive it in using a 29 mm socket (E).

20. Install the 40 mm snap ring (F) with its radiused side facing out.

15. Inspect each part shown with an asterisk in the Exploded View; if any of them are worn or damaged, replace the pump as an assembly.

(cont'd)

BACK

17-19

Power Steering Pump Overhaul (cont'd) 24. Assemble pump rotor (A) to the pump cover (B). A

21. Coat the new pump cover seal (A) with power steering fluid, and install it into the groove in the pump cover (B).

c

jo ~ [)

B

~e/

25. Set the 10 vanes (C) in the grooves in the rotor. Make sure that the round ends (0) of the vanes are in contact with the sliding surface of the cam ring. 22. Install the outer side plate (C) over the two rollers (0).

26. Coat the new O-ring (A) with power steering fluid, and install it into the groove in the side plate (B).

23. Set the pump cam ring (A) over the two rollers with its "." mark (B) facing up.

~A

/B

B

Hl"'-----E

c 27. Install the side plate on the cam ring (C) by aligning the roller set holes (0) in the side plate with the rollers (E).

17-20

BACK

28. Coat the new O-ring (A) with power steering fluid, and position it in the bottom of the pump housing (B).

,

32. Install the pulley (A), then loosely install the pulley nut (8). Hold the steering pump in a vise with soft jaws. Be careful not to damage the pump housing with the jaws of the vise.

8x 1.25 mm /20N.m (2.0 kgf·m, 14lbf.ftl

B 64 N·m (6.5 kgf·m, 47lbf·ftl

I

~~~A

29. Install the pump cover assembly (C) in the pump housing.

33. Hold the pulley (A) with the special tool, and tighten the pulley nut (8).

30. Coat the flow control valve (A) with power steering fluid, then install it and the spring (B) in the pump housing.

I

34. Check that the pump turns smoothly by turning the pulley by hand.

A

-4Ot(@)/c B

/

D 49 N·m (5.0 kgf.m, 36lbf·ftl

31. Coat the new O-ring (C) with power steering fluid, and install it on the flow control valve cap (D), then install the cap on the pump housing, and tighten it.

BACK --------

----

-

----

17-21

Power Steering Steering Wheel Removal SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-28).

3. Loosen the steering wheel bolt (A), then install a steering wheel puller (B) on the steering wheel and remove it.

1. Align the front wheels straight ahead, then remove the driver's airbag from the steering wheel (see page 23-278). 2. Disconnect the radio remote switches connector and cruise control switches connector if equipped.

17-22

BACK

Note these items when removing the steering wheel: • Do not tap on the steering wheel or the steering column shaft when removing the steering wheel. • If you thread the puller bolts (e) into the wheel hub more than five threads, the bolts will hit the cable reel and damage it. To prevent this, install a pair of jam nuts five threads up on each puller bolt.

Steering Wheel DisassemblyIReassembly

STEERING DYNAMIC DAMPER

HOOK PLATE

/~

&.

/~~

COVER

\

COVER

ACCESS PANEL CRUISE CONTROL SWITCH

BACK

17-23

Power Steering Steering Wheel Installation 1. Before installing the steering wheel, make sure the front wheels are aligned straight ahead, then center the cable reel (A). Do this by first rotating the cable reel clockwise until it stops. Then rotate it counterclockwise about 2 and halfturns. The arrow mark (8) on the cable reel label point should point straight up. A

3. Install the steering wheel bolt and tighten it to 39 N·m (4.0 kgf·m, 29 Ibf·ft). 4. Connect the radio remote switches connector and cruise control switches connector if equipped. 5. Install the driver's airbag, and confirm that the system is operating properly (see page 23-278). 6. Check the horn, radio remote switches, cruise control set/resume switch and turn signal cancelling for proper operation.

2. Position the two tabs (A) of the turn signal cancelling sleeve (8) as shown, and install the steering wheel on to the steering column shaft, making sure the steering wheel hub (C) engages the pins (0) of the cable reel and tabs of the canceling sleeve. Do not tap on the steering wheel or steering column shaft when installing the steering wheel.

D

17-24

BACK

Steering Column Removal and Installation SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-28).

Removal 1. Record the radio station presets, and disconnect the battery. 2. Remove the driver's airbag, steering wheel, and cable reel; '98-00 models (see page 23-289); '01-02 models (see page 23-292) 3. Remove the driver's dashboard lower cover (see page 20-84). 4. Remove the column covers (A). B

22 N·m 12.2 kgf·m, 16lbf·ftl


A~

\ D


5. Remove the combination switch assembly (S) from the steering column shaft by disconnecting the connectors. 6. Disconnect the ignition switch connectors. 7. Remove the steering joint cover (e). 8. Disconnect the steering joint (D), and remove it from the column shaft. 9. Remove the steering column (E) by removing the attaching nuts and bolts.

(cont'd)

BACK

17-25

Power Steering Steering Column Removal and Installation (cont'd) Installation 1. Install the steering column and make sure the wires are not caught or pinched by any parts. 2. Insert the upper end of the steering joint onto the steering shaft (A) (line up the bolt hole (B) with the flat portion (C) on the shaft). 22N·m

(2.2 k ·m, 16 Ibi·tt)

3. Slip the lower end of the steering joint onto the pinion shaft (E) (line up the bolt hole (F) with the groove (G) around the shaft), and loosely install the lower joint bolt. Be sure that the lower joint bolt is securely in the groove in the pinion shaft. 4. Pull on the steering joint to make sure that the steering joint is fully seated. Then install the upper joint bolt and tighten it. 5. Finish the installation, and note these items: • Make sure the wire harness is routed and fastened properly. • Make sure the connectors are properly connected. • Reinstall the steering wheel (see page 17-24). • Reconnect the battery and reset the radio presets. • Verify cruise control, horn, radio remote, and turn signal switch operation. • Check wheel alignment (see page 18-5).

17-26

BACK

Steering Column/Tilt Lever Inspection/Adjustment • Check the steering column ball bearing (A) and the steering joint bearings (8) for play and proper movement. If any bearing is noisy or has is excessive play, replace the steering column as an assembly. • Check the retaining collar (C) for damage. If it is damaged, replace the steering column as an assembly. • Check the absorbing plates (D) for distortion or breakage. If there is distortion breakage replace the steering column as an assembly.

(cont'd)

BACK

17-27

Power Steering Steering Column/Tilt Lever Inspection/Adjustment (cont'd)

Steering Lock Replacement 1. Remove the steering column (see page 17-25).

1. Move the tilt lever (A) from the loose position to the lock position 3 to 5 times; then measure the tilt lever preload 10 mm (0.4 in) from the end of the tilt lever.

2. Center punch each of the two shear bolts, and drill their heads off with a 5 mm (3/16 in.) drill bit. Be careful not to damage the switch body when removing the shear bolts.

Preload: 70-90 N (7-9 kgf, 15-20 Ibf)

o

2. If the measurement is out of the specification, adjust the preload using the following procedures. 3. Remove the shear bolts from the switch body. o

o

o

o

Loosen the tilt lever, and set the steering column in the neutral position. Remove the 6 mm lock bolt (B), and remove the stop (C). Be careful not to loosen the tilt lever when installing the stop or tightening the 6 mm lock bolt. Adjust the preload by turning the tilt lock bolt (0) left or right. Pull up the tilt lever to the uppermost position, and install the stop. Check the preload again. If the measurement is still out of specification, repeat the above procedures to adjust.

4. Install the switch body without the key inserted. 5. Loosely tighten the new shear bolts. 6. Insert the ignition key, and check for proper operation of the steering wheel lock and that the ignition key turns freely. 7. Tighten the shear bolts (A) until the hex heads (B) twist off.

1

~W)\\\\\\\m !

B

17-28

BACK

Rack Guide Adjustment 7. Check for unusual steering effort through the complete turning travel.


Locknut wrench, 40 mm, 07916-SA50001

8. Check the steering wheel rotational play and the power assist (see page 17-7).

1. Set the wheels in the straight ahead position. 2. Loosen the rack guide screw locknut (A) with the special tool, then remove the rack guide screw (8). A

f

07916-SA50001

3. Remove the old sealant from rack guide screw, and apply new sealant all around the threads (C). Loosely install the rack guide screw on the steering gearbox.

4. Tighten the rack guide screw to 25 N·m (2.5 kgf·m, 18 Ibf·ft) , then loosen it. 5. Retighten the rack guide screw to 3.9 N·m (0.4 kgf· m, 2.9 Ibf·ft) then back it off to specified angle. Specified Return Angle:

20°

6. Tighten the locknut while holding the rack guide screw.

BACK

17-29

Power Steering Steering Gearbox Removal Special Tools Required

7. Remove the steering joint bolts (A), disconnect the steering joint by moving the steering joint (B) toward the column.

Ball joint remover, 28 mm, 07MAC-SL00200 Note these items during removal: o

o

B

Using solvent and a brush, wash any oil and dirt off of the valve body unit its lines, and the end if the gearbox. Blow dry with compressed air. Be sure to remove the steering wheel before disconnecting the steering joint. Damage to the cable reel can occur. 1. Drain the power steering fluid (see page 17-14). 2. Raise the vehicle, and make sure it is securely supported. 3. Remove the front wheels. A

4. Remove the driver's airbag (see page 23-278). 8. Remove the cotter pin (A) from the 10 mm nut (B), and loosen the nut.

5. Remove the steering wheel (see page 17-22). 6. Remove the steering joint cover.

07MAC-SL00200

9. Separate the tie-rod ball joint and knuckle using the special tool (see page 18-9).

17-30

BACK

10. Loosen the 14 mm flare nut (A), and disconnect the pump outlet hose (8). C

16. Remove the stiffener plates (A), then remove the right mounting brackets (8).

D

A A

B

17. Pull the steering gearbox (A) all the way down to clear the pinion shaft (8) from the bulkhead, and remove the pinion shaft grommet from the top of the valve body unit.

11. Loosen the 17 mm flare nut (e), and remove the return line (D). 12. After disconnecting the hoses and lines, plug or seal them with a piece of tape or equivalent to prevent foreign materials from entering. NOTE: Do not loosen the cylinder line A and 8 between the valve body unit and cylinder. 13. Grasp the right tie-rod and pull the rack all the way to the right, then remove the right and left tie-rod ends (A), and locknut (8).

A

B

18. Move the steering gearbox to the right so the left rack end clears the rear beam, then place the left rack end below the rear beam. 19. Move the steering gearbox to the left, and tilt the left side down to remove it.

14. Remove the 3 way catalytic converter (see page 95). 15. Disconnect the MfT shift cable (see page 13-4) or AfT shift cable (see page 14-114) from the transmission.

BACK

17-31

Power Steering Steering Gearbox Overhaul Exploded View FLANGE BOLTS

20 N·m (2.0 kgf·m. 14lbf·ftl VALVE OIL SEAL Replace.

f~ ' i VALVE _ HOUSING

~~

BUSHING

~~~

~ Replace.

SNAPRING

V II1/ ...

FLARE NUTS

17 N·m 11.7 kgf·m.12Ibf·ftl

SLEEVE

/SlHVE SEAL .WGS Replace.

VALVE

~

~ Replace.

~...

O-RING Replace.

~

/

CYLINDER END SEAL Replace.

~~VALVEOILSEAL \

" " Replace.

CYLINDER LINE B '-

/({o@

woo ~ /

CYLINDER END

69 N·m (7.0 kgf.m. 51lbf·ftl

/

/()()

SEAL RING

WAVE WASHER

"'-

PINION SHAFT

/O-RING Replace.

a

~~~

O-RING Replace. RACK GUIDE SCREW

GEARBOX HOUSING

SPRING RACK GUIDE

PISTON SEAL RING Replace.

STEERING RACK

"

/@() CYLINDER END SEAL Replace.

17-32

BACK

/BACKUP RING Replace.

I·!·· 3. Unbend the lock washer.

Special Tools Required • Cylinder end seal remover attachment, 07NAD-SR3020A • Pilot collar, 07GAF-PH70100 • Valve seal ring sizing tool, 07NAG-SR3090A • Ball joint boot clip guide, 07974-SA50800 • Piston seal ring sizing tool, 07974-SA5020A or 07974-SA50200 • Attachment, 32 x 35 mm, 07746-0010100 • Driver, 07749-0010000 • Piston seal ring guide, 07HAG-SF10100 • Piston seal ring sizing tool, 07HAG-SF1020A or 07HAG-SF10200 • Pincers, Oetiker 1098, or equivalent, commercially available

4. Hold the flat surface sections (A) of the right side steering rack (B) with a wrench, and unscrew the both rack ends (C) with a wrench. Be careful not to damage the rack surface with the wrench. Remove the lock washer (D) and stop washer (E).

NOTE: Refer to the Exploded View as needed during this procedure. Disassembly

1. Remove the steering gearbox (see page 17-30). 2. Remove the boot bands (A) and tie-rod clips (B). Pull the boots away from the ends of the gearbox.

5. Loosen the locknut (A), then remove the rack guide screw (B).

6. Remove the spring (C) and the rack guide (D) from the gearbox. (cont'd)

BACK

17-33

Power Steering Steering Gearbox Overhaul (cont'd) 10. Drill a 3 mm (0.12 in.) diameter hole approximately 2.5-3.0 mm (0.10-0.12 in.) in depth in the staked point (A) on the cylinder. Do not allow metal shavings to enter the cylinder housing. After removing the cylinder end (B), remove any burrs at the staked point.

7. Remove the cylinder lines from the gearbox.

8. Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth. 9. Remove the two flange bolts, then remove the valve body unit (A) from the gearbox (B).

/

17-34

B

11. Attach the yoke of a universal puller (A) to the steering gearbox mounts with bolts. Clamp the yoke in a vise with soft jaws as shown, then loosen and remove the cylinder end (B). Do not clamp the cylinder housing or gearbox housing in the vise.

BACK

I·!·' 12. Install the bearing separator (Alan the gearbox housing as shown.

16. Insert a 24" long, 3/8" drive extension (AI and the special tool into the cylinder from the left side. Make sure that the special tool is securely positioned on the backup ring edges. Be careful not to damage the inner surface of the cylinder with the special tool.

c

13. Place a appropriate size deep socket wrench (B) on the steering rack (C). 14. Set the steering gearbox in a press so the left side points upward, then press the cylinder end seal (DI and steering rack out of the gearbox. Hold the steering rack to keep it from falling when pressed clear. Be careful not to damage the inner surface of the cylinder housing with the tool. 15. Remove the cylinder end seal from the steering rack.

(cont'd)

BACK

17-35

Power Steering Steering Gearbox Overhaul (cont'd) 17. Setthe gearbox in a press, then press outthe cylinder end seal (A) and backup ring (B) from the gearbox.

18. Carefully pry the piston seal ring (A) and O-ring (B) off the rack piston. Be careful not to damage the inside of the seal ring groove and piston edges when removing the seal ring.

Note these items when pressing the cylinder end seal: • Keep the tool straight to avoid damaging the cylinder wall. Check the tool angle, and correct it if necessary, when removing the cylinder end seal. • Use a press to remove the cylinder end seal. Do not try to remove the seal by striking the tool. It will break the backup ring, and the cylinder end seal will remain in the gearbox.

19. Before removing the valve housing (A), apply vinyl tape (B) to the splines on the pinion shaft (C).

~ _~B

...______c

B

A

20. Separate the valve housing from the pinion shaft! valve using a press.

17-36

BACK

21. With your finger check the inner wall of the valve housing where the seal ring slides. If there is a step in the wall, the housing is worn. Replace it.

23. Remove the snap ring (A) and sleeve (8) from the pinion shaft.

NOTE: There may be sliding marks from the seal ring on the wall of the valve housing. Replace the valve housi ng only if the wall is stepped.

/

/ 24. Using a cutter or an equivalent tool, cut and remove the four seal rings from the sleeve. 8e careful not to damage the edges of the sleeve grooves and outer surface when removing the seal rings.

22. Check for wear, burrs and other damage to the edges ofthe grooves in the sleeve. NOTE: The pinion shaft and sleeve are a precision matched set. If either the pinion shaft or sleeve must be replaced, replace both parts as a set.

(cont'd)

BACK

17-37

Power Steering Steering Gearbox Overhaul (cont'd) 25. Using a cutter or an equivalent tool, cut the valve seal ring (AI and O-ring (BI at the cutting groove position (CI in the pinion shaft. Remove the valve seal ring and O-ring. Be careful not to damage the edges of the pinion shaft groove and outer surface when removing the valve seal ring and O-ring.

26. Remove the valve oil seal (AI and wave washer (BI from the pinion shaft.

27. Press the valve oil seal (AI and bushing (BI out of the valve housing using a hydraulic press and special tool. A

28. Clean the disassembled parts with solvent, and dry them with compressed air. Do not dip rubber parts in the solvent.

Note these items during disassembly: • Inspect the ball bearing (CI by rotating the outer race slowly.lfthere is any excessive play or wear, replace the pinion shaft and sleeve as an assembly . • The pinion shaft and sleeve are a precise fit; do not intermix old and new pinion shafts and sleeves.

I

·

Od 17-38

BACK

34. Remove the tape, and apply power steering fluid to the surface of the valve seal ring (A).

Reassembly 29. Apply vinyl tape (A) to the stepped portion of the pinion shaft, and coat the surface of the vinyl tape with the power steering fluid.

07NAG·SR3090A A

/

30. Install the wave washer (8). 31. eoatthe inside surface of the new valve oil seal (e) with power steering fluid, and install the seal with its grooved side facing opposite the bearing, then slide it over the pinion shaft, being careful not to damage its sealing lip (D). 32. Apply vinyl tape (A) to the splines and stepped portion of the shaft, and coat the surface of the vinyl tape with the power steering fluid.

A

35. Apply power steering fluid to the inside of the special tool. Set the larger diameter end of the special tool over the valve seal ring, and move the special tool up and down several times to make the valve seal ring fit in the pinion shaft groove. 36. Remove the special tool, turn it over, slide the smaller diameter end over the valve seal ring. Move it up and down several times to make the valve seal ring fit snugly in the pinion shaft groove.

33. Fit the new a-ring (8) in the groove of the pinion shaft. Then slide the new valve seal ring (e) over the shaft and in the groove on the pinion shaft.

(cont'd)

BACK

17-39

Power Steering Steering Gearbox Overhaul (cont'd) 37. Apply power steering fluid to the surface of the special tool. Slip 2 new seal rings (A) over the special tool from the smaller diameter end, and expand them. Install only 2 rings at a time from each end ofthe pinion shaft sleeve (B).

41. Apply power steering fluid to the surface ofthe pinion shaft (A). Slide the sleeve (B) onto the pinion shaft by aligning the locating pin (C) on the inside ofthe sleeve with the cutout (D) in the shaft. Then install the new snap ring (E) securely in the pinion shaft groove.

Note these items when installing the seal ring: • Do not over-expand the seal ring. Install the resin seal rings with care so as not to damage them. After installation, be sure to contract the seal rings using the special tool (sizing tool) . • There are two types of sleeve seal rings: black and brown. Do not mix the different types of rings as they are not compatible.

A

Note these items during reassembly: • Be careful not to damage the valve seal ring when inserting the sleeve . • Install the snap ring with its radiused side toward the sleeve.

\

ii

38. Align the special tool with each groove in the sleeve, and slide a sleeve seal ring into each groove. After installation, compress the seal rings with your fingers temporarily.

42. Apply power steering fluid to the seal ring lip of the new valve oil seal (A), then install the seal in the valve housing (B) using a hydraulic press and special tools. Install the seal with its grooved side facing the tool.

39. Apply power steering fluid to the seal rings on the sleeve, and to the entire inside surface of the special tool, then slowly insert the sleeve into the special tool.

40. Move the sleeve back and forth several times to make the seal rings snugly fit in the sleeve. Be sure thatthe seal rings are not twisted.

17-40

BACK

07746-0010100

I-g·' 43. Press the bushing (A) into the valve housing with a hydraulic press and special tool. 07749-0010000

~,

47. Press the pinion shaft/sleeve into the valve housing with a hydraulic press. Check that the pinion shaft/ sleeve turns smoothly by hand after installing it.

07746-0010100

~v

44. Apply vinyl tape (A) to the pinion shaft, then coat the vinyl tape with power steering fluid. 48. Coat the special tool with power steering fluid, then slide it onto the rack, big end first. 49. Position the new D-ring (A) and new piston seal ring (B) on the special tool, then slide them down toward the big end of the tool. Note these items during reassembly: • Do not over expand the resin seal rings. Install the resin seal rings with care so as not to damage them. After installation, be sure to contract the seal ring using the special tool (sizing tool) . • Replace piston's D-ring and seal ring as a set.

45. Insert the pinion shaft into the valve housing (B). Be careful not to damage the valve seal rings (e). 46. Remove the vinyl tape from the pinion shaft, then remove any residue from the tape adhesive.

50. Pull the D-ring off into the piston groove, then pull the piston seal ring off into the piston groove on top of the O-ring.

(cont'd)

BACK

17-41

Power Steering Steering Gearbox Overhaul (cont'd) 51. Coat the piston seal ring (AI and the inside of the special tool with power steering fluid. then carefully slide the tool onto the rack and over the piston seal ring. 52. Move the special tool back and forth several times to make the piston seal ring fit snugly in the piston.

54. Coat the inside surface of the new cylinder end seal (AI with power steering fluid. then install it onto the steering rack with its grooved side toward the piston. When installing the cylinder end seal. be careful not damage the lip of the seal with the edges or teeth of the steering rack.

A

i 07HAG·SF1020A or 07HAG·SF10200

53. Wrap vinyl tape (AI around the rack teeth and rack end edges. then coat the surface of the tape with power steering fluid. Make sure that the vinyl tape is wrapped carefully so there is no stepped portion. 55. Remove the vinyl tape from the steering rack. then remove any adhesive residue. 56. Install the new backup ring (AI on the steering rack. then place the cylinder end seal (81 against the piston. A

A

17-42

BACK

57. Grease the steering rack teeth, then insert the steering rack into the gear box housing. Be careful not to damage to inner surface of the cylinder wall with the rack edges.

61. Wrap vinyl tape around the rack end edges, and coat the surface of the tape with the power steering fluid. Make sure that the vinyl tape is wrapped carefully so there is no stepped portion.

58. Insert an appropriate size deep socket wrench (A) onto the steering rack as shown.

62. Coat the inside surface of the new cylinder end seal with power steering fluid, then install the seal onto the steering rack with its grooved side toward the piston.

iii

A

I!I""--B

59. Install the cylinder end seal (B) into the bottom of the cylinder by pressing on the tool with a press. Do not push on the tool with excessive force as it may damage the cylinder end seal.

63. Push in the cylinder end seal with your finger.Be careful not to damage the face of the seal with the threads and burrs at the staked position of the cylinder housing.

60. Remove the tool, and center the steering rack.

64. Remove the vinyl tape from the steering rack, then remove any adhesive residue.

(cont'd)

BACK

17-43

Power Steering Steering Gearbox Overhaul (cont'd) 65. Attach the yoke of a universal puller (A) to the steering gearbox mounts with bolts, then clamp the yoke in a vise with soft jaws. Do not clamp the cylinder housing or gearbox housing in the vise.

68. Coat the new O-ring (A) with grease, and carefully fit it on the valve housing. D

20 N·m (2.0 kgf·m. 14Ibf·ft)

A

\

66. Coat the inside surface of the cylinder end (A) with power steering fluid, then install the cylinder end by screwing it into the cylinder (B).

69. Apply grease to the needle bearing (B) in the gearbox housing, then install the valve body unit (C) by engaging the gears. Note the valve body unit installation position (direction of the line connections). 70. TIghten the flange bolts (D) to the specified torque.

C 69 N·m (7.0 kgf·m, 51Ibf·ft)

67. Remove the yoke from the gearbox, then, after tightening the cylinder end (C), stake the point of the cylinder shown (opposite from where the stake was removed during disassembly).

17-44

BACK

71. Install the cylinder lines.

75. Install the stop washer (A), and screw each rack end (B) into the rack while holding the lock washer (C) so its tabs (0) are in the slots (E) in the end of the rack .

Note these items during reassembly: • Thoroughly clean the joints ofthe cylinder lines. The joints must be free of foreign material. • Install the cylinder lines by tightening the flare nuts by hand first, then tighten the flare nuts to the specified torque.

78N·m 18.0 kgf·m, 58 Ibf·ft)

'~ 11.7 ...·m. 12Ibf·ft(

76. Hold the flat surface sections of the right side steering rack with a wrench, and tighten the both rack ends. Be careful not to damage the rack surface with the wrench. 72. Grease the sliding surface of the rack guide (A), and install it onto the gearbox housing.

77. Bend the lock washer back against the flat spots on the rack end joint housing.

73. Apply sealant all around the threads on the rack guide screw (B), then install the spring (C), rack guide screw and locknut (0). 74. Adjustthe rack guide screw (see page 17-29). After adjusting, check that the rack moves smoothly by sliding it right and left.

(cont'd)

BACK

17-45

Power Steering Steering Gearbox Overhaul (cont'd) 78. Apply multipurpose grease (A) to the circumference of the rack end joint housing.

~

(PIN 08798-9013)

81. Install the new boot bands by aligning the tabs (A) with holes (B) of the band.

\~

\ B

82. Close the ear portion (A) of the band with commercially available pincers Oetiker 1098 or equivalent (B).

79. Apply a light coat of silicone grease to the boot grooves (B) on the rack ends. 80. Center the steering rack within its stroke. Install the boots on the rack ends with the tie-rod clips. After installing the boots, wipe the grease off the threaded section (A) of the rack end.

83. Slide the rack right and left to be certain that the boots are not deformed or twisted.

17-46

BACK

Steering Gearbox Installation 1. Before installing the gearbox, slide the rack all the way to right.

5. Install the mounting cushion (A) on the steering gearbox.

2. Pass the right side of the steering gearbox (A) above and through the right side ofthe rear beam. Be careful not to bend or damage the two power steering lines and cylinder lines when installing the gearbox.

C, G: 38 N·m (3.9 kgf·m, 28 Ibf·ttl F: 43 N·m (4.4 kgf·m, 32 Ibf·ttl 6. Install the mounting brackets (B) over the mounting cushion, then install the two gearbox mounting bolts (C). Position the split portion (0) of the mounting cushion as shown. 3. Raise the left side ofthe steering gearbox above and through the left side of the rear beam. Then insert the pinion shaft (B) up through the bulkhead. 4. Install the pinion shaft grommet (A). Align the slot (B) in the pinion shaft grommet with the lug portion on the valve housing.

7. Install the stiffener plates (E) with the two gearbox mounting bolts (F) and six stiffener plate attaching bolts (G). Install the bolts loosely first, then tighten them securely. 8. Center the steering rack within its stroke.

B

(cont'd)

BACK

17-47

Power Steering Steering Gearbox Installation (cont'd) 9. Install the steering joint (A), and reconnect the steering shaft (B) and pinion shaft (C). Make sure the steering joint is connected as follows: o

o

o

11. Install the steering joint cover (A) with the clamps (B) and clips (C).

Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole (D) with the flat portion (E) on the shaft). Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole (F) with the groove around the shaft), and loosely install the lower joint bolt. Be sure that the lower joint bolt is securely in the groove in the pinion shaft. Pull on the steering joint to make sure that the steering joint is fully seated. Then install the upper joint bolt and tighten it.

22N·m 12.2 kgf·m, 16Ibf·ft)

12. Connect the return line (A) and feed line (B) to the valve body unit (C). After connecting the fluid lines, make sure that there is no interference between the lines and other parts. 16x 1.5 mm 28 N·m 129 kgf·m, 21 Ibf·ft)

B

E D

F

10. Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (about 2 turns) until the arrow mark on the label points straight up. Reinstall the steering wheel (see page 17-24).

17-48

c

BACK

14x 1.5 mm 37 N·m 13.8 kgf·m, 27 Ibf.ft)

B

13. Thread the right and left tie-rod ends (A) and locknut (B) onto the rack an equal number of turns.

A

B

16. Connect the Mrr shift linkage (see step 26 on page 13-15) or AfT shift cable (see step 13 on page 14-120) from the transmission. 17. Install the three way catalytic converter (see page 9-5). 18. Install the front wheels. 19. Fill the system with power steering fluid. and bleed air from the system (see page 17-14). 20. After installation. perform the following checks.

14. Wipe off any grease contamination from the ball joint tapered section and threads then reconnect tie-rod ends (A) to the steering knuckles. Install the 10 mm nut (B) and tighten it.

• Start the engine, allow it to idle. and turn the steering wheel from lock-to-Iock several times to warm up the fluid. Check the gearbox for leaks (see page 17-11). • Adjustthe fronttoe (see page 18-5). • Check the steering wheel spoke angle. Adjust by turning the right and left tie-rods equally. if necessary.

B 43N·m (4.4 kgf·m. 32 Ibf.ft)

15. Install the new cotter pin (C) and bend it as shown.

BACK

17-49

Power Steering Tie-rod Ball Joint Boot Replacement Special Tools Required Front hub dis/assembly tool, 07965-SA50500

1. Remove the boot from the tie-rod end, and wipe the old grease off the ball pin. 2. Pack the lower area of the ball pin (A) with fresh multipurpose grease.

O .

;C

..

.

B

~

.' \ ..... 0

.......

A-

--$jjjjiiffi

3. Pack the interior of the new boot (8) and lip (e) with fresh multipurpose grease. Note these items when installing new grease: • Keep grease off the boot installation section (D) and the tapered section (E) if the ball pin . • Do not allow dust, dirt, or other foreign materials to enter the boot. 4. Install the new boot (A) using the special tool. The boot must not have a gap at the boot installation sections (8). After installing the boot, check the ball pin tapered section for grease contamination, and wipe it if necessary.

17-50

BACK

Suspension Front and Rear Suspension Special Tools ................................................................. Component location Index ......................................... Wheel Alignment .......................................................... Wheel Bearing End Play Inspection ............................ Wheel Runout Inspection ............................................ Ball Joint Removal .......................................................

18-2 18-3 18-5 18-8 18-8 18-9

Front Suspension Knuckle/Hub Replacement .......................................... Ball Joint Boot Replacement ....................................... Upper Arm Replacement ............................................. lower Arm Replacement ............................................. Damper/Spring Replacement ......................................

18-10 18-15 18-16 18-17 18-18

Rear Suspension Hub/Bearing Replacement-Disc Brake ....................... Hub/Bearing Replacement-Drum Brake ..................... Knuckle Replacement ................................................... Upper Arm Replacement ............................................. Trailing Arm Replacement ........................................... leading Arm Replacement .......................................... lower Arm Replacement ............................................. Control Arm Replacement ........................................... Damper/Spring Replacement ......................................

18-22 18-24 18-25 18-27 18-28 18-28 18-29 18-29 18-30

Front and Rear Suspension Special Tools Ref. No.

CD ® ® CD

® @

®

18-2

Tool Number 07GAF-SE00100 07GAG-SD40700 07MAC-SL00200 07965-SA00600 07749-0010000 07947 -6340201 07965-SD90100

Qty 1 1 1 1 1 1 1

Description Hub Dis/Assembly Tool Ball Joint Boot Clip Guide Ball Joint Remover, 28 mm Bearing Driver Attachment Driver Attachment, 58 x 72 mm Sum>ort Base

CD

®

G),@

®

BACK

®

Component Location Index Front Suspension

FRONT DAMPER Removal, step 1 on page 18-19 Disassembly/Inspection, step 1 on page 18-19 Reassembly, step 1 on page 18-20 Installation, step 1 on page 18-21

____ UPPER ARM ~


KNUCKLE/HUB Replacement, page 18-10

BACK

18-3

Front and Rear Suspension Component Location Index (cont'd) Rear Suspension

REAR DAMPER Removal, step 1 on page 18-31 Disassembly/Inspection, step 1 on page 18-31 Reassembly, step 1 on page 18-32 Installation, step 1 on page 18-33

LEADING ARM Replacement, page 18-28

HUB (includes bearing) Replacement, page 18-22

18-4

BACK

Wheel Alignment Caster Inspection

Caster Adjustment

For proper inspection/adjustment of the wheel alignment, check and adjust the following before checking the alignment:

Caster angle can be adjusted by increasing/decreasing the number of the adjusting shims. Remove and install the radius rod each time the caster angle is adjusted.

• • • •

Check that the suspension is not modified. Check the tire size and tire pressure. Check the runout of the wheels and tires. Check the suspension ball joints. (Hold a wheel with your hands and move it up and down and right and left to check for wobbling).

1. Raise the front of the vehicle, and make sure it is securely supported. 2. Remove the self-locking nut (A) on the end of the radius rod (8).

/

A 54 N·m (5.5 kgf·m, 40 Ibf·ft)

Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and/or turning angle). Follow the equipment manufacturer's instructions.

B

3. Remove the flange bolts at the radius rod (8) on the lower arm, and remove the radius rod (see page 18-17). 4. Adjust the caster angle by increasing/decreasing the adjusting shims (C). Note these items during adjustment:

1. Check the caster angle. Caster angle: 2°48'

\

± 1°

• Do not use more than two adjusting shims. • One adjusting shim changes the caster angle by 35' and the caster angle can be adjusted by 1°10' maximum. • One adjusting shim is 3.2 mm (0.13 in.) in thickness.

2. If out of specification, record the caster reading, then adjust the caster.

5. After the adjustment, install the radius rod onto the lower arm, and tighten the flange bolts (see page 18-17). 6. Tighten the new self-locking nut to the specified torque.

(cont'd)

BACK

18-5

Front and Rear Suspension Wheel Alignment (cont'd) Camber Inspection

Front Toe Inspection/Adjustment


Use commercially-available computerized 4 wheel alignment equipment to measure wheel alignment (caster, camber, toe, and/or turning angle). Follow the equipment manufacturer's instructions.

1. Check the camber angle.

1. Check the tire pressure.

Camber angle: Front: 0°00' ± 1° Rear: - 0°30' ± 1°

2. Center the steering wheel spokes. 3. Check the toe with the wheels pointed straight ahead.

2. If out of specification, check for bent or damaged suspension components.

Front toe: 0

± 2 mm (0 ±

1/16 in.)

• If adjustment is required, go on to step 4. • If no adjustment is required, remove alignment equipment. 4. Loosen the tie-rod locknuts (A), and turn both tierods (B) in the same direction until the front wheels are pointing straight ahead.

A 14x 1.5 mm 44 N·m (4.5 kgf·m, 33 Ibf·ft)

5. Turn both tie-rods equally until the toe reading on the turning radius gauge is correct. 6. After adjusting, tighten the tie-rod locknuts. Reposition the tie-rod boot if it is twisted or displaced.

18-6

BACK

1.11 Rear Toe Inspection/ Adjustment

Turning Angle Inspection



1. Release the parking brake to avoid an incorrect measurement.

1. Turn the wheel right and left while applying the brake, and measure the turning angle of both wheels.

2. Check the toe. Turning angle: Inward wheel: 38°32' ± 1° Outward wheel: 31 °03' (Reference)

Rear toe-in: 2±2 mm (1/16± 1/16 in.) • If adjustment is required, go to step 3 . • If no adjustment is required, remove alignment equipment. 3. Hold the adjusting bolt (A) on the rear control arm, and loosen the self-locking nut (B).

B 10x 1.25mm 54 N·m (5.5 kgf·m, 40 Ibf·ftl

2. If the turning angle is not within the specifications, check for bent or damaged suspension components.

4. Adjust the rear toe by turning the adjusting bolt until the toe is correct. 5. Install the self-locking nut, and tighten it while holding the adjusting bolt.

BACK

18-7

Front and Rear Suspension Wheel Bearing End Play Inspection

Wheel Runout Inspection

1. Raise the vehicle, and make sure it is securely supported.


2. Remove the wheels, then reinstall the wheel nuts.

2. Check for bent or deformed wheels.

3. Attach the dial gauge. On the front, place the dial gauge against the hub flange. On the rear, place the dial gauge against the center of the hub cap.

3. Set up the dial gauge as shown, and measure axial runout by turning the wheel.

Front:

Front and Rear Wheel Axial Runout: Standard: Steel Wheel: 0-1.0 mm (0-0.04 in.' Aluminum Wheel: 0-0.7 mm (0-0.03 in.' Service Limit: 2.0 mm (0.08 in.'

Rear:

4. Readjust the dial gauge to the position shown, and measure radial runout.

Front/Rear: Standard: 0-0.05 mm (0-0.002 in.'

Front and Rear Wheel Radial Runout: Standard: Steel Wheel: 0-1.0 mm (0-0.04 in.' Aluminum Wheel: 0-0.7 mm (0-0.03 in.' Service Limit: 1.5 mm (0.06 in.'

4. Measure the bearing end play moving the brake disc inward or outward. 5. If the bearing end play measurement is more than the standard, replace the wheel bearing. 5. If the wheel runout is more than the service limit, replace the wheel.

18-8

BACK

Ball Joint Removal Special Tools Required Ball Joint Remover. 28 mm 07MAC-SL00200

1. Install a hex nut onto the threads of the ball joint. Make sure the nut is flush with the ball joint pin end to prevent damage to the threads end of the ball joint.

4. Once the special tool is in place. turn the adjusting bolt (A) as necessary to make the jaws parallel. Then hand-tighten the pressure bolt (B). and recheck the jaws to make sure they are still parallel.

2. Apply grease (A) to the special tool on the areas shown. This will ease installation of the tool and prevent damage to the pressure bolt (B) threads. A

.,,

,

.-'

I

,

--

5. After making the adjustment to the adjusting bolt. make sure the head of the adjusting bolt is in this position (A) to allow the jaw (C) to pivot.

3. Install the special tool as shown. Insert the jaws carefully. making sure you do not damage the ball joint boot. Adjust the jaw spacing by turning the pressure bolt.

6. With a wrench. tighten the pressure bolt (B) until the ball joint pin pops loose from the steering/ suspension arm. If necessary. apply penetrating type lubricant to loosen the ball joint. 7. Remove the tool. then remove the nut from the end of the ball joint. and pull the ball joint out of the steering/suspension arm. Inspect the ball joint boot. and replace it if damaged.

07MAC-SL00200

BACK

18-9

Front Suspension Knuckle/Hub Replacement Exploded View CASTLE NUT

/

7-

/10x1.25mm 39-47 N·m (4.0-4.8 kgf·m. 29-35 Ibf·ftl -COTTER PIN

Replace.

WHEEL BEARING

Replace. / SNAP RING

o 0/

SET RING

~

q -

~~

\'!!P

/~

WASHER-SCREW

BALL JOINT BOOT

/

Check for deterioration and damage.

6x 14mm 9.3N·m (0.95 kgf·m. 6.9 Ibf·ftl

- - - - COTTER PIN

Replace.

CASTLE NUT

12 x 1.25 mm 49-59 N·m (5.0-6.0 kgf·m. 36-43 Ibf·ftl

6 mm BRAKE DISC RETAINING SCREW 9.3 N·m (0.95 kgf·m. 6.9 Ibf·ftl / FRONT HUB Check for damage and cracks.

BRAKE DISC Check for wear and rust.

WHEELNUT /

SPINDLE NUT

24x 1.5 mm 245 N·m (25.0 kgf·m. 181 Ibf.ftl Replace.

18-10

BACK

12x 1.5mm 108N·m (11.0 kgf·m. 80lbf·ftl

7. Remove the wheel sensor (A) from the knuckle (B) (for vehicles with ABS). Do not disconnect the wheel sensor connector.

Special Tools Required • Ball Joint Remover, 26 mm 07MAC-SL00200 • Hub Dis/Assembly Tool 07GAF-SE00100 • Attachment, 58 x 72 mm 07947-6340201 • Bearing Driver Attachment 07965-SA00600 • Driver 077 49-0010000 • Support Base 07965-SD90100 1. Loosen the wheel nuts slightly. 2. Raise the front of the vehicle, and make sure it is securely supported. 3. Remove the wheel nuts and front wheel.

C 9.3N·m 10.95 kgf·m. 6.9 Ibf·ft)

4. Raise the locking tab on the spindle nut (A), then remove the nut.

8. Remove the 6 mm brake disc retaining screws (A).

108N·m 111.0 kgf.m,

r

oftl

A 245 N·m 125.0 kgf·m, 181Ibf·ft)

5. Remove the brake hose mounting bolts (A). 9. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the disc excessively.

~:.3N.m

10.95 kgf·m, 6.9Ibf·ft)

10. Remove the brake disc from the knuckle. 11. Check the front hub for damage and cracks.

B 108N·m 111.0 kgf.m. 80 Ibf·ft)

6. Remove the caliper mounting bolts (B), and hang the caliper assembly (C) to one side. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper from the undercarriage. (cont'd)

BACK

18-11

Front Suspension Knuckle/Hub Replacement (cont'd) 12. Remove the cotter pin (A) from the tie-rod end ball joint, then loosen the nut (8).

16. Remove the cotter pin (A) from the upper ball joint castle nut (8), and remove the nut. 07MAC-SL00200

A

B 10 x 1.25 mm 43N·m

07MAC-SL00200

(4.4kgf·m, 32Ibf·ft)

B 10x 1.25 mm 39-47 N·m 14.0-4.8 kgf·m, 29-35 Ibf·ft)

13. Remove the tie-rod ball joint from the knuckle using the special tool (see page 18-9). 14. Remove the cotter pin (A) from the lower arm ball joint castle nut (8), and remove the nut. 07MAC-SL00200

17. Remove the upper ball joint from the knuckle using the special tool (see page 18-9). 18. Pull the knuckle outward, and remove the driveshaft outboard joint (8) from the knuckle (A) by tapping the driveshaft end (e) with a plastic hammer, then remove the knuckle.

C

15. Remove the lower ball joint from the knuckle using the special tool (see page 18-9).

B

18-12

BACK

C

19. Separate the hub (A) from the·knuckle (BI using the special tool, and a hydraulic press. Take care not to distort the splash guard. Hold onto the hub to keep it from falling when pressed clear.

21. Press the wheel bearing (AI out of the knuckle (B) using the special tools and a press.

Press

!~

/

B

B

20. Remove the snap ring (AI and the splash guard (BI from the knuckle (C).

\

A

22. Press the wheel bearing inner race (A) from the hub (BI using the special tool, a commercially available bearing separator (C), and a press.

Press

r7:=-..=tf..2

23. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly.

(cont'd)

BACK

18-13

Front Suspension Knuckle/Hub Replacement (cont'd) 24. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press. Place the wheel bearing on the knuckle with the pack seal side facing (metal color) toward the inside. Be careful not to damage the sleeve of the pack seal.

27. Install the hub (A) on the knuckle (B) using the special tools shown and a hydraulic press. Be careful not to distort the splash guard (C). Press

...

~.19""SA"'"

D

\ A~~

/01749-0010000

BLACK COLOR

~~

.-----C

~07965-5D90100

/

07965-5D90100

28. Install the knuckle in the reverse order of removal, and pay particular attention to the following items: B

o

o

25. Install the snap ring (A) securely in the knuckle (B). o

D

9.3 N·m (0.95 kgf.m, 6.9 Ibf.ft)

o

o

o

o

o

26. Install the splash guard (C), and tighten the screws (D).

18-14

BACK

o

Be careful not to damage the ball joint boots when installing the knuckle. Torque all mounting hardware to the specified torque values. Torque the castle nuts to the lower torque specifications, then tighten them only far enough to align the slot with the pin hole. Do not align the castle nut by loosening. Install new cotter pins on the castle nuts after torquing. Raise the locking tab on the spindle nut (C), then remove the nut. Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. Check the front wheel alignment, and adjust it if necessary (see page 18-5).

Ball Joint Boot Replacement 5. For a lower ball joint. adjust the special tool with the adjusting bolt (B) until its base is just above the groove around the bottom of the boot. Then slide the clip over the tool and into position on the boot.


Ball Joint Boot Clip Guide 07GAG-SD40700 1. Remove the boot clip and the boot. 2. Pack the interior of the boot and lip (A) with grease. Do not contaminate the lower collar of the boot (B) with grease. A

B

c

6. For an upper ball joint. just hold the tool over the joint. then slide the clip over the tool and into position on the boot.

B

3. Wipe the grease off the tapered portion of the shaft and pack fresh grease into the base. Do not let dirt. or other foreign materials get into the boot.

7. After installing a boot. wipe any grease off the exposed portion of the ball joint shaft.

4. Install the boot on the ball joint. then squeeze it gently to force out any air.

BACK

18-15

Front Suspension Upper Arm Replacement 1. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheel.

6. Remove the flange bolts (A) from the upper arm (B). B

2. Remove the front damper (see step 1 on page 1819). 3. Remove the wheel sensor bracket nut (A) from the upper arm (B). B

A 10x 1.25 mm 64N·m (6.5 kgf.m, 47 Ibf·ttl

7. Install the upper arm in the reverse order of removal, and note these items: • Be careful not to damage the ball joint boot when connecting the upper arm to the knuckle. • Tighten all mounting hardware to the specified torque values.Tighten the castle nut to the lower torque value, then tighten it only far enough to align the slot with the hole in the stud. Do not align the castle nut by loosening it. • Use a new cotter pin on the castle nut. • Before installing the wheel, clean the mating surface on the brake disc and the inside of the wheel. • Check the front wheel alignment, and adjust it if necessary (see page 18-5).

A 9.3 N'm (0.95 kgf·m, 6.9 Ibf·ttl

4. Remove the cotter pin from the upper ball joint castle nut, and remove the nut. 07MAC-SL00200

\:

10 x 1.25 mm 39-47N·m (4.0-4.8 kgf·m, 29-35 Ibf·ttl

5. Remove the upper ball joint from the knuckle using the special tool (see page 18-9).

18-16

BACK

Lower Arm Replacement 1. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheel. 2. Remove the damper fork. -1 Remove the damper pinch bolt (A). -2 Remove the lower bolt and self-locking nut (B) from the damper fork. -3 Remove the damper fork (C) from the damper.

5. Remove the lower arm. -1 Remove the self-locking nut from the stabilizer link (A). -2 Remove the radius rod bolts (B). -3 Remove the lower arm mounting bolt (C). -4 Remove the lower arm (D) from the rear beam.

C

~/

./

Ci

~

II B



3. Remove the cotter pin from the lower ball joint castle nut, and remove the nut.

6. Install the lower arm in the reverse order of removal, and note these items:

07MAC-SL00200

o

o

o

o o

o

Be careful not to damage the ball joint boot when connecting the lower arm to the knuckle. Tighten all mounting hardware to the specified torque values. Tighten the castle nut to the lower torque value, then tighten it only far enough to align the slot with the hole in the stud. Do not align the castle nut by loosening it. Use a new cotter pin on the castle nut. Before installing the wheel, clean the mating surfaces on the brake disc and the inside of the wheel. Check the front wheel alignment, and adjust it if necessary (see page 18-5).

12x 1.25 mm 49-59N·m 15.0-6.0 kgf·m, 36-43 Ibf·ftl

4. Remove the lower ball joint from the knuckle using the special tool (see page 18-9).

BACK

18-17

Front Suspension DamperISpring Replacement Exploded View SELF· LOCKING NUT 10x 1.25mm 29 N·m (3.0 kgf·m, 22 Ibf·tt) Replace.

/

r

_____ WASHER

,!.,_______ _______ RUBBER BUSHING _____ Check for deterioration ~

@3

0-

and damage. COLLAR

~_------- MOUNT BASE ~ .. " .... __-------RUBBER BUSHING

'81'


~ ._o--_____ .. .SPRING CUSHION


~s

DUSTCOV~R PLATE

~~,

.""""=~A

DUST COVER Check for bending and damage.

' - -~

11~

D~UMPSTOPPLATE BUMP STOP Check for weakness and damage.

DAMPER SPRING Check for weakened compression and damage.

18-18

BACK

DisassemblyIinspection


Strut Spring Compressor, Branick MST-580A or Model 7200, or equivalent, commercially available

Removal 1. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheel.

1. Compress the damper spring with a commercially available strut spring compressor (A) according to the manufacturer's instructions, then remove the self-locking nut (B). Do not compress the spring more than necessary to remove the nut.

2. Remove the damper fork. -1 Remove the damper pinch bolt (A). -2 Remove the lower bolt (B) and self-locking nut (C) from the damper fork. -3 Remove the damper fork (D) from the damper. D

2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. A

c

B

3. Reassemble all parts, exceptthe spring.

3. Remove the damper by removing the five flange nuts. NOTE: Damper springs are different, left and right. Mark the springs Land R before you continue.

4. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should move smoothly. If it does not (no compression or no extension), the gas is leaking, and the damper should be replaced. 5. Check for oil leaks, abnormal noises, or binding during these tests.

(cont'd)

BACK

18-19

Front Suspension Damper/Spring Replacement (cont'd) Reassembly

5. Install the rubber bushing, washer (AI, and a new 10 mm self-locking nut (8).

1. Install the damper unit on a commercially available strut spring compressor (A).

A

B 10x 1.25mm 29 N·m 13.0 kgf.m, 22 Ibf·tt)

6. Hold the damper shaft, and tighten the 10 mm selflocking nut. 2. Assemble the damper in the reverse order of removal except for the washer and self-locking nut. Align the bottom of the damper spring and the spring lower seat (8). 3. Position the mount base (AI on the damper unit.

V A

4. Compress the damper spring with the spring compressor.

18-20

BACK

Installation

5. Raise the knuckle with a floor jack until the vehicle just lifts off the safety stand.

1. Loosely install the damper (A) on the frame with the aligning tab (B) facing inside, then loosely install the five flange nuts (e).

6. Tighten damper pinch bolt.

__--c

7. Tighten the flange bolt and the self-locking nut.

10x 1.25 mm 50 N·m (5.1 kgf·m, 37Ibf·ft)

8. Tighten the flange nuts on the top of the damper to the specified torque. 9. Install the front wheel.

C 8x1.25mm 17N·m (1.7 kgf·m, 12Ibf·ft)

B

2. Install the damper fork (D) over the driveshaft and onto the lower arm. Install the front damper in the damper fork so the aligning tab (B) is aligned with the slot in the damper fork.

E

/

~?

~

/1 F

12 x 1.25 mm 64 N·m (6.5 kgf·m. 47 Ibf·ft)

10 x 1.25 mm 43 N·m (4.4 kgf·m, 32 Ibf·ft)

3. Loosely install the damper pinch bolt (E) into the damper fork. 4. Loosely install a new self-locking nut (F) with the flange bolt (G).

BACK

18-21

Rea.r Suspension Hub/Bearing Replacement - Disc Brake Exploded View

SPLASH GUARD

//S mm BOLT 9.3 N·m (0.95 kgf·m, S.9 Ibf·ft)

~

BRAKE DISC

9.8 N·m (1.0 kgf·m, 7 Ibf·ft)

/

HUB (includes bearing)

SPINDLE NUT 22 x 1.5 mm 181 N·m (18.5 kgf·m, 139Ibf·ft) Replace.

WHEEL NUT 12 x 1.5 mm 108N·m (11.0 kgf·m, 80 Ibf·ft)

18-22

BACK

1. Raise the rear of the vehicle, and make sure it is securely supported.

9. Remove the 6 mm brake disc retaining screws (A). A 9.8N·m 11.0 kgf·m, 7 Ibf·ft)

2. Remove the wheel nuts and rear wheel. 3. Pull the parking brake lever up. 4. Remove the hub cap (A). A

B

10. Screw two 8 x 1.25 mm bolts (B) into the disc (C) to push it away from the hub. Turn each bolt 2 turns at a time to prevent cocking the disc excessively. 11. Remove the hub bearing unit from the knuckle.

B 22x 1.5 mm 181 N·m 118.5 kgf.m, 139Ibf·ft) Replace.

12x1.5mm 108N·m 111.0 kgf·m, 80 Ibf·ft)

5. Raise the locking tab on the spindle nut (B), then remove the nut. 6. Release the parking brake lever. 7. Remove the brake hose mounting bolt (A).

12. Install the hub/bearing unit in the reverse order of removal, and pay particular attention to the following items: o

o

o

A 8x1.25mm 22 N·m 12.2 kgf·m, 16 Ib'.ttl

o

Before installing the brake disc, clean the mating surfaces ofthe rear hub and brake disc. Wash the bearing and spindle thoroughly in high flash point solvent before reassembly. To prevent damage to the caliper or brake hose, use a short piece of wire to hang the caliper from the undercarriage. After tightening, use a drift to stake the spindle nut shoulder against the spindle.

8. Remove the caliper bracket mounting bolts (B), and hang the caliper (C) to one side. To prevent damage to the caliper or brake hose, use a short piece of wire to hang the caliper from the undercarriage.

BACK

18-23

Rear Suspension Hub/Bearing Replacement - Drum Brake Exploded View

SPINDLE NUT 22 x 1.5 mm 181 N·m (18.5 kgf·m, 134 Ibf.tt) Replace.

jR'PI'' .

HUBCAP

((@ HUB (includes bearing)

BRAKE DRUM

WHEEL NUT 12 x 1.5 mm 108 N·m (11.0 kgf.m, 80 Ibf·ttl

18-24

BACK

Knuckle Replacement Special Tools Required

1. Raise the rear ofthe vehicle, and make sure it is securely supported.

Ball joint remover, 28 mm 07MAC-SL00200

2. Remove the wheel nuts and rear wheel.

1. Raise the rear of the vehicle, and make sure it is securely supported, then remove the rear wheel.

3. Pull the parking brake lever up. 2. Remove the rear brake caliper, the caliper mounting bracket, and the brake hose mounting bolt from the rear knuckle (disc brake model) (see step 7 on page 18-23).

4. Remove the hub cap (A).

3. Remove the rear brake disc and hub/bearing unit (disc brake model) (see step 9 on page 18-23) or brake drum and hub/bearing unit (drum brake model) (see left column). 4. Remove the cotter pin from the upper ball joint castle nut, and remove the nut. 07MAC-SL0020

~~=t_~=.

B 22x 1.5 mm 181 N·m (18.5 kgf·m, 134Ibf.tt)

12x1.Smm 108 N·m (11.0 kgf.m, 80 Ibf·tt)

I~~~\

5. Raise the locking tab on the spindle nut (B), then remove the nut.

\

6. Release the parking brake lever.

/

c:=J~ 12 x 1.25 mm 49-58N·m (5.0-6.0 kgf.m.

7. Remove the brake drum and the hub/bearing unit.

36-43 Ibf· ftl

5. Separate the upper ball joint from the knuckle using the special tool (see page 18-9). 6. Remove the ABS sensor from the splash guard (disc brake model) (see page 19-71). 7. Remove the flange nut (A) from the stabilizer link. A 10 x 1.25 mm 39 N·m (4.0 kgf·m.

29lbf·ftl

'7 I,

8. Install the hub/bearing unit in the reverse order of removal, and pay particular attention to the following items: • Wash the bearing and spindle thoroughly in high flash point solvent before reassembly . • After tightening, use a drift to stake the spindle nut shoulder against the spindle.

C

8. Remove the damper lower mount bolt (B), and the stabilizer link mounting bracket (C). (cont'd)

BACK

18-25

Rear Suspension Knuckle Replacement (cont'd) 9. Remove the control arm mounting nut from the rear knuckle.

12. Remove the parking brake cable mounting bolt (A) from the trailing arm, then remove the trailing arm mounting bolt (B) from the rear knuckle.

22 N·m /2.2 kgf·m, 16Ibf·ft)

10. Remove the leading arm mounting bolt from the rear knuckle.

B-----

12x25mm 59 N·m (6.0 kgf·m, 43lbf·ft)

13. Remove the lower arm mounting bolt (A) and nut (B), then remove the knuckle.

12 x 1.25 mm 55 N·m (6.0 kgf·m, 43 Ibf·ft)

11. Remove the splash guard mounting bolts and the splash guard (A) (on disc brake model), or the backing plate mounting bolts and the backing plate (B) (on drum brake model).

14. Install the knuckle in the reverse order of removal, and pay particular attention to the fOllowing items: o

o

o

o o

o

18-26

BACK

Be careful not to damage the ball joint boot when connecting the upper arm to the knuckle. Tighten all mounting hardware to the specified torque values. Tighten the castle nut to the lower torque specifications, then tighten it only far enough to align the slot with the hole in the ball joint pin. Do not align the castle nut by loosening it. Use a new cotter pin in the castle nut. Before installing the wheel, clean the mating surfaces on the brake disc or drum and inside of the wheel. Check the rear wheel alignment, and adjust it if necessary (see page 18-5).

Upper Arm Replacement 1. Raise the rear of the vehicle, and make sure it is securely supported, then remove the rear wheel.

6. Remove the upper arm bolt (A). Remove the upper arm (B) from the vehicle. B

2. Remove the cotter pin from the upper ball joint castle nut, and remove the nut. 07MAC-SL00200

A

12x 1.25 mm 59 N·m (6.0 kgf·m, 43 Ibf·tt)

7. Install the upper arm in the reverse order of removal, and note these items: o

3. Remove the upper ball joint from the knuckle using the special tool (see page 18-9).

o

4. Remove the brake hose mounting bolts (A).

o

A B 9.3 N·m (0.95 kgf·m, 6.9 Ibf·tt) 9.3 N·m (0.95 kgf·m,

6.'~

o o

o

Be careful not to damage the ball joint boot when connecting the upper arm to the knuckle. Tighten all mounting hardware to the specified torque values. Tighten the castle nut to the lower torque specifications, then tighten it only far enough to align the slot with the hole in the stud. Do not align the castle nut by loosening it. Use a new cotter pin in the castle nut. Before installing the wheel, clean the mating surfaces on the brake disc and the inside of the wheel. Check the rear wheel alignment, and adjust it if necessary (see page 18-5).

5. Remove the wheel sensor mounting bolt (B) (for vehicles with ABS).

BACK

18-27

Rear Suspension Leading Arm Replacement

Trailing Arm Replacement 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheel.

1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheel.

2. Remove the parking brake cable mounting bolt (A) from the trailing arm (B).

2. Remove the leading arm mounting bolts (A), and remove the leading arm (B) from the vehicle. B

3. Remove the trailing arm mounting bolts (C). 4. Remove the trailing arm (B) from the vehicle. C 12x 1.25 mm 59 N·m (6.0 kgf·m, 43 Ibf·ft)

A

12x 1.25 mm 59 N·m (6.0 kgf·m, 43 Ibf·ft)

3. Install the leading arm in the reverse order of removal, and note these items: B

A 22 N·m (2.2 kgf·m, 16Ibf·ft)

5. Install the trailing arm in the reverse order of removal, and note these items: • Tighten all mounting hardware to the specified torque values. • Before installing the wheel, clean the mating surfaces on the brake disc and the inside of the wheel. • Check the rear wheel alignment, and adjust it if necessary (see page 18-5).

18-28

BACK

• Tighten all mounting hardware to the specified torque values. • Before installing the wheel, clean the mating surfaces on the brake disc and the inside ofthe wheel. • Check the rear wheel alignment, and adjust it if necessary (see page 18-5).

Lower Arm Replacement

Control Arm Replacement



2. Remove the lower arm mounting bolt (A).

2. Remove the control arms from the vehicle. -1 Remove the self-locking nut (A) from the knuckle bolt. -2 Remove the self-locking nut (B) from the rear suspension subframe. -3 Remove the control arms (C) from the vehicle.

3. Remove the lower arm mounting nut (B) and mounting bolt (C). 4. Remove the lower arm (0) from the vehicle. A 12x 1.25mm 59 N·m (6.0 kgf·m, 43 Ibf·ft)

B 10x 1.25mm 54 N·m (5.5 kgf·m, 40 Ibf·ft)

~

D

~~

5. Install the lower arm in the reverse order of removal, and note these items:

c

• Tighten all mounting hardware to the specified torque values. • Before installing the wheel, clean the mating surfaces on the brake disc and the inside of the wheel. • Check the rear wheel alignment, and adjust it if necessary (see page 18-5).

3. Install the control arm in the reverse order of removal, and note these items:

BACK

• Tighten all mounting hardware to the specified torque values. • Before installing the wheel, clean the mating surfaces on the brake disc and the inside of the wheel. • Check the rear wheel alignment, and adjust it if necessary (see page 18-5).

18-29

Rear Suspension DamperISpring Replacement Exploded View SELFOLOCKING NUT 10 x 1.25 mm 29 N·m 13.0 kgf.m. 22 Ibf·ft) Replace.

/ (

_____ WASHER Check for weakness.

I@ _______

@>

@..

RUBBER BUSHING

~----0----___ @

~ , __I_~-------- -.J

MOUNT BASE

-COLLAR

-----------RUBBER BUSHING

SPRING MOUNT CUSHION Check for deterioration and damage.

DAMPER SPRING

------------

--------RUBBER

---//

®~------SPRING SEAT CUSHION Check for deterioration

~

~

and damage.

~ BUMPSTOPPLATE BUMP STOP Check for weakness and damage.

DUST COVER Check for bending and damage.

DAMPER UNIT

18-30

BACK

Special Tools Required Strut Spring Compressor, 8ranick MST-580A or Model 7200, or equivalent, commercially available.

Removal 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheel.

DisassemblyIinspection 1. Compress the damper spring with a commercially available strut spring compressor (A) according to the manufacturer's instructions, then remove the self-locking nut (8). Do not compress the spring more than necessary to remove the self-locking nut.

2. Remove the rear bulkhead cover (see page 20-76). 3. Remove the two flange nuts (A).

B

A

2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. 4. Remove the flange bolt (A) from the knuckle. A 10x 1.25 mm 59 N·m 16.0 kgf·m,

43lbf·ft)

3. Reassemble all parts, except the spring.

B 10x 1.25 mm 39 N·m 14.0 kgf.m,

4. Compress the damper by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should move smoothly. If it does not, replace it.

29Ibf·ft)

\

5. Check for oil leaks, abnormal noises, and binding during these tests.

c

5. Remove the flange nut (8) from the stabilizer link. 6. Lower the rear suspension, and remove the damper (C) from the vehicle. NOTE: Damper springs are different, left and right. Mark the springs Land R before you continue. (cont'd)

BACK

18-31

Rear Suspension Damper/Spring Replacement (cont'd) Reassembly 1. Install the damper unit on a commercially available strut spring compressor (A).

5. Install the washer(A), and loosely install a new selflocking nut (8). B 10x 1.25 mm 29 N·m (3.0 kgf·m. 22 Ibf·tt)

2. Assemble the damper in the reverse order of disassembly, except for the washer and selflocking nut. Align the bottom of the damper spring and the spring lower seat (8). A

6. Hold the damper shaft with a hex wrench, and tighten the self-locking nut.

B

3. Position the damper mounting base on the damper unit. 4. Compress the damper spring with the spring compressor.

18-32

BACK

Installation

3. Raise the rear suspension with a floor jack until the vehicle just lifts off the safety stand.

1. Lower the rear suspension, position the damper(A), and loosely install the two flange nuts(B). B 10x 1.25 mm 50 N·m (5.1 kgf·m,37 Ibf·ft)

4. Tighten the flange bolt and nut on the bottom ofthe damper to the specified torque. 5. Tighten the two flange nuts on top of the damper to the specified torque.

~(\

6. Install the rear bulkhead cover (see page 20-76).

~

7. Install the rear wheels. A

8. Check the rear wheel alignment, and adjust it if necessary (see page 18-5).

2. Loosely install the flange bolt(A)and nut(B). A 10x 125 mm

....m.43"."

"N~

B 10x 1.25mm 39 N·m (4.0 kgf.m, 29Ibf·ft)

BACK

18-33

BACK

Brakes Conventional Brake Components Special Tools ................................................................. Component Location Index ........................................ . Brake System Operation and Leakage Check ............................................................ Brake Pedal and Brake Pedal Position Switch Adjustment ..................................................... Parking Brake Check and Adjustment .................................................................. Brake System Bleeding .............................................. .. Brake System Indicator Circuit Diagram ....................................................................... Parking Brake Switch Test .......................................... . Brake Fluid Level Switch Test ..................................... . Front Brake Pads Inspection/ Replacement .............................................................. . Front Brake Disc Inspection ......................................... Front Brake Caliper Overhaul ..................................... . Master Cylinder Replacement .................................... . Master Cylinder Inspection ......................................... . Master Cylinder Push rod Clearance Adjustment .................................................................. Brake Booster Test ....................................................... Brake Booster Replacement ....................................... . Rear Brake Pads Inspection/ Replacement ............................................................... Rear Brake Disc Inspection ......................................... . Rear Brake Caliper Overhaul ...................................... . Rear Drum Brake Inspection ....................................... . Rear Brake Shoes Replacement .................................. Rear Wheel Cylinder Replacement ............................ . Brake Hoses and Lines Inspection ............................. . Brake Hose Replacement ........................................... .. Parking Brake Cable Replacement ..............................

19-2 19-3 19-4 19-5 19-6 19-7 19-8 19-9 19-9 19-10 19-12 19-13 19-14 19-15 19-15 19-17 19-18 19-19 19-21 19-22 19-25 19-27 19-29 19-30 19-31 19-32

ABS (Anti-lock Brake System) Components .............................................. . 19-35

m

Conventional Brake Components Special Tools Tool Number 07JAG-SD40100

CD

19-2

BACK


INDICATOR Brake System Indicator Circuit Diagram, page 19-8 Parking Brake Switch Test, page 19-9 Brake Fluid Level Switch Test, page 19-9

BRAKE BOOSTER Brake Booster Test, page 19-17 Brake Booster Replacement, page 19-18

PARKING BRAKE CABLE Parking Brake Cable Replacement, page 19-32

REAR BRAKES REAR DRUM BRAKE:

FRONT BRAKES Front Brake Pads, Inspection and Replacement, page 19-10 Front Brake Disc Inspection, page 19-12 Front Brake Caliper Overhaul, page 19-13

PARKING BRAKE LEVER Parking Brake Check and Adjustment, page 19-6

BRAKE PEDAL Brake Pedal and Brake Pedal Position Switch Adjustment, page 19-5

BRAKE HOSES/LINES Brake Hoses and Lines Inspection, page 19-30 Brake Hoses Replacement, page 19-31

Rear Drum Brake Inspection, page 19-25 Rear Brake Shoes Replacement, page 19-27 Rear Wheel Cylinder Replacement, page 19-29

REAR BRAKES REAR DISC BRAKE: Rear Brake Pads Inspection and Replacement, page 19-19 Rear Brake Disc Inspection, page 19-21 Rear Brake Caliper Overhaul, page 19-22

MASTER CYLINDER Master Cylinder Replacement, page 19-14 Master Cylinder Inspection, page 19-15 Master Cylinder Push rod Clearance Adjustment, page 19-15 Brake System Bleeding, page 19-7

BACK

19-3

Conventional Brake Components Brake System Operation and Leakage Check Ch eckal l0f teo h f l l oWing Items: Component Procedure Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes do not work properly, check the brake booster. Replace the brake booster as an assembly if it does not work properly or if there are signs of leakage . Piston Cup and • Check brake operation by applying the brakes. Look for damage or signs of fluid Pressure Cup leakage. Replace the master cylinder as an assembly if the pedal does not work Inspection (B) properly or if there is damage or signs of fluid leakage. • Check for a difference in brake pedal stroke between quick and slow brake applications. Replace the master cylinder if there is a difference in pedal stroke. Brake Hoses (C) Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it is damaged or leaking. Caliper Piston Seal and Check brake operation by applying the brakes. Piston Boots (0) Look for damage or signs of fluid leakage. If the pedal does not work properly, the brakes drag, or there is damage or signs offluid leakage, disassemble and inspectthe brake caliper. Replace the boots and seals with new ones whenever the brake caliper is disassembled. Wheel Cylinder Piston Check brake operation by applying the brakes. Cup and Oust Cover (E) Look for damage or signs of fluid leakage. If the pedal does not work properly, the brakes drag, or there is damage or signs of fluid leakage, replace the wheel cylinder.

19-4

BACK

Brake Pedal and Brake Pedal Position Switch Adjustment Pedal Height 1. Disconnect the brake pedal position switch connector, loosen the brake pedal position switch locknut (A), and back off the brake pedal position switch (B) until it is no longer touching the brake pedal.

2. Lift up the carpet. At the insulator cutout, measure the pedal height (C) from the middle ofthe left side of the pedal pad (D).

4. Screw in the brake pedal position switch until its plunger is fully pressed (threaded end (A) touching the pad (B) on the pedal arm). Then back off the switch 3/4 of a turn to make 0.9 mm (0.04 in.) of clearance between the threaded end and the pad. Tighten the locknut firmly. Connect the brake pedal position switch connector. Make sure the brake lights go off when the pedal is released.

Standard Pedal Height (with carpet removed): MIT: 165 mm (68/16 in.) A/T: 169 mm (610/16 in.)

5. Check the brake pedal free playas described below.

Pedal Free Play 1. With the engine off, check the pedal free play (A) on the pedal pad (B) by pushing the pedal by hand. Free Play: 1-5 mm (1/16-3/16 in.) 3. Loosen the push rod locknut (A), and screw the push rod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the push rod pressed.

2. If the pedal free play is out of specification, adjust the brake pedal position switch (C). If the pedal free play is insufficient, it may result in brake drag.

BACK

19-5

Conventional Brake Components Parking Brake Check and Adjustment Check

3. Pull the parking brake lever up one click.

1. Pull the parking brake lever (A) with 196 N (20 kgf, 44 Ibf) force to fully apply the parking brake. The parking brake lever should be locked within the specified number of clicks (B).

~~y~

~7--

Lever Locked Clicks: Vehicle With Rear Disc Brakes: 9 -11 Vehicle With Rear Drum Brakes: 9-11

Pulled up with 196 N (20 kgf, 44 Ibtl

A

~

:-r B

.... _._________________

....

5. Tighten the adjusting nut (A) until the parking brakes drag slightly when the rear wheels are turned.

I

)

4. Remove the rear console lid (see page 20-83).

~

_.- .... _.-----_ ... _---- .. :

,~"

2. Adjust the parking brake if the lever clicks are out of specification.

Adjustment NOTE: After rear brake caliper servicing, loosen the parking brake adjusting nut, start the engine, and press the brake pedal several times to set the self-adjusting brake before adjusting the parking brake. 1. Block the front wheels, then raise the rear of the vehicle, and make sure it is securely supported. 2. Make sure the parking brake arm (A) on the rear brake caliper contacts the brake caliper pin (B).

6. Release the parking brake lever fully, and check that the parking brakes do not drag when the rear wheels are turned. Readjust if necessary. 7. Make sure the parking brakes are fully applied when the parking brake lever is pulled up fully. 8. Reinstall the rear console lid.

19-6

BACK

Brake System Bleeding NOTE:

FRONT DISC BRAKE:

• Do not reuse the drained fluid. • Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system. • Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. • Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. • The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as required.

9 N·m (0.9 kgf·m, 6.5 Ibf·ttl

1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A).

REAR DISC BRAKE: 9 N·m (0.9 kgf·m, 6.5 Ibf·ttl

(

\

2. Have someone slowly pump the brake pedal several times, then apply steady pressure. 3. Loosen the left-front brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely.

REAR DRUM BRAKE:

4. Repeat the procedure for each wheel in the sequence shown below until air bubbles no longer appear in the fluid.

7 N'm (0.7 kgf·m, 5lbf·ttl

5. Refill the master cylinder reservoir to the MAX (upper) level line. BLEEDING SEQUENCE:

® Front Right

~c:
@RB.rRight

:]

® Rear Left

BACK

19-7

Conventional Brake Components Brake System Indicator Circuit Diagram

BATTERY UNDER·HooD FUSE/ RELAY BOX

UNDER·DASH DRIVER'S FUSE/RELAY BOX

IGNmON SWITCH

I

~~'f.r.5AI

I

L-~r"\,.P---<>--WHT ~ BLK/VEL ~---YEL-;:==4_~~A~~~~~EB~LY~ BRAKE SYSTEM INDICATOR

GRN/7~'_-"-_-~-';--N-~~--;;;-'-'_-"-_-'-I-..-=t·.-.-"-"'-,--GRN/RED ----~l~---GRN/RED

!i

DAYTIME RUNNING UGHTS CONTROL UNIT

,

! :

I !:

GRN/RED

GRN/WHT!

i.... .. _ •. _ .. _J._ .. ....£~!'·lI'!i_..

GRN/RED

!

.....Y~~ PARKING BRAKE SWITCH CLOSED: Laver up OPEN: Lev.. down

~ I

BLK

ToABS CONTROL UNIT (PARK'

.A. G302

19-8

BACK

BRAKE FLUID LEVEL SWITCH CLOSED: Float down OPEN: Float up

-----'

Parking Brake Switch Test

Brake Fluid Level Switch Test

1. Remove the rear console, and disconnect the connector (A) from the switch (B).

1. Remove the reservoi r cap (A). Check that the float (B) moves up and down freely; if it doesn't, replace the reservoir cap assembly.

B

2. Check for continuity between the positive terminal and body ground: • With the brake lever up, there should be continuity. • With the brake lever down, there should be no continuity.

2. Check for continuity between the terminals with the float in the down position (C) and the up position (0):

• With the float up, there should be no continuity . • With the float down, there should be continuity.

NOTE (Canada): If the parking brake switch is OK, but the brake system indicator does not function, do the input test for the daytime running lights control unit (see page 22-96).

BACK

19-9

Conventional Brake Components Front Brake Pads Inspection and Replacement ~CAUTION Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. • Avoid breathing dust particles. • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

5. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include pad backing plate (A) thickness. Brake Pad Thickness: Standard: 10.5-11.5 mm (0.41-0.45 in.' Service Limit: 1.6 mm (0.06 in.'

1. Loosen the front wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels. 2. Remove the brake hose mounting bolts (A) from the knuckle.

A

6. If the brake pad thickness is less than the service limit, replace the front pads as a set. 7. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. 8. Check the brake disc for damage and cracks.

c

9. Install the pad retainers (A). 3. Remove pin A (B) and pivot the caliper (C) up out of the way. Check the hoses and pin boots for damage and deterioration. 4. Remove the pad shims (A), pad retainers (B), and pads (C).

A

I

o 19-10

BACK

10. Apply Molykote M77 grease to both sides of the pad shims (A) and the back ofthe pads (B). Wipe excess grease off the shim. Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads. A

C

~

12. Push in the piston (A) so the caliper will fit over the pads. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down. 13. Pivot the caliper down into position. Being careful not to damage the pin boot, install the caliper bolt (B) and torque it to proper specification. B / 7 4 N·m 17.5 kgf·m, 54Ibf·ft)

A A

(t o

0,.:

.-. '-'

B

11. Install the brake pads and pad shims correctly. Install the pad with the wear indicator (C) on the inside. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.

14. Install the brake hose onto the knuckle. 15. Press the brake pedal several times to make sure the brakes work, then test-drive. NOTE: Engagement of the brake may require 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. 16. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.

BACK

19-11

Conventional Brake Components Front Brake Disc Inspection Thickness and Parallelism

Runout 1. Loosen the front wheel nuts slightly, then raise the vehicle, and make sure it is securely supported. Remove the front wheels.

1. Loosen the front wheel nuts slightly, then raise the vehicle, and make sure it is securely supported. Remove the front wheels.

2. Remove the brake pads (see page 19-10).

2. Remove the brake pads (see page 19-10).

3. Inspect the disc surface for damage and cracks. Clean the disc thoroughly, and remove all rust.

3. Using a micrometer, measure disc thickness at eight points, approximately 45° apart and 10 mm (0.4 in.) in from the outer edge of the disc. Replace the brake disc if the smallest measurement is less than the max. refinishing limit.

4. Use wheel nuts and suitable flat washers (A) to hold the disc securely against the hub, then mount a dial indicator as shown, and measure the runout at 10 mm (0.4 in.) from the outer edge ofthe disc.

Brake Disc Thickness: Standard: 22.9-23.1 mm (0.90-0.91 in.' Max. Refinishing Limit: 21.0 mm (0.83 in.' Brake Disc Parallelism: 0.015 mm (0.0006 in.' max.

Brake Disc Runout: Service limit: 0.10 mm (0.004 in.'

NOTE: This is the maximum allowable difference between the thickness measurements.

108N·m (11 kgf.m, 80 Ib'·ftl

5. Ifthe disc is beyond the service limit, refinish the brake disc with an on-car brake lathe. The KwikLathe produced by Kwik-way Manufacturing Co. and the "Front Brake Disc Lathe" offered by Snapon Tools Co. are approved for this operation.

Max. Refinish limit: 21.0 mm (0.83 in.' NOTE: • If the brake disc is beyond the service limit for refinishing, replace it (see page 18-10). • A new disc should be refinished if its runout is greater than 0.10 mm (0.004 in.).

19-12

4. If the disc is beyond the service limit for parallelism, refinish the brake disc with an on-car brake lathe. The Kwik-Lathe produced by Kwik-way Manufacturing Co. and the "Front Brake Disc Lathe" offered by Snap-on Tools Co. are approved for this operation .

BACK

NOTE: If the brake disc is beyond the service limit for refinishing, replace it (see page 18-10).

Front Brake Caliper Overhaul ~CAUTION Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. o Avoid breathing dust particles. o Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Remove, disassemble, inspect, reassemble, and install the caliper and note these items: o

o o o o

o o o

o o

o o o

Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. To prevent dripping, cover disconnected hose joints with rags or shop towels. Clean all parts in brake fluid and air dry; blowout all passages with compressed air. Before reassembling, check that all parts are free of dirt and other foreign particles. Replace parts with new ones as specified in the illustration. Make sure no dirt or other foreign matter gets into the brake fluid. Make sure no grease or oil gets on the brake discs or pads. When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. Do not reuse drained brake fluid. Always use Genuine Honda DOT 3 Brake Fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. Coat the piston, piston seal groove, and caliper bore with clean brake fluid. Replace all rubber parts with new ones. After installing the caliper,check the brake hose and line for leaks, interference, and twisting.

~ : Rubber grease

_-'iiiiiiiI ,..............

~=;~"~;.~~:;::'

INNER SHIM A

.

INNER SHIM B

V

-~CALIPER BRACKET

/

OUTER PAD SHIM

~ \0

74 N·m 11.""·m. "Ibf·ft'

~

BRAKE HOSE

~

Replace.

k ... m , 80 Ibf·ft)

~N~ itslear indicator upward.

BANJO BOLT 34N·m (3.5kgf·m, 25Ibf·ft)

PIN BOOT

FLANGE BOLTS 12 x 1.25 mm

\

BRAKE PADS

/PISTON SEAL

/

Replace.

CALIPER BRACKET

.f))~

~~ _ _ _ _ PISTON BOOT

BLEED SCREW 9 N·m (0.9 kgf·m, 6.5Ibt·ft)

PIN A

- -fijijffi

\

~

CALIPER BODY

:e

p ;;.

PISTON

BACK

19-13

Conventional Brake Components Master Cylinder Replacement

INOTiCe I Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

5. Disconnect the brake lines (A) from the master cylinder. To prevent spills, cover the hose joints with rags or shop towels.

1. Remove the 8 mm flange nuts (AI. A 8x 1.25 mm 22 N·m 12.2 kgf·m, 16Ibf.ft)

B

2. Remove the strut brace (B). B 8x1.25mm 15 N·m 11.5 kgf·m,11Ibf·ft)

6. Remove the master cylinder mounting nuts (B) and washers. 7. Remove the master cylinder (C) from the brake booster (D). Be careful not to bend or damage the brake lines when removing the master cylinder. 8. Remove the rod seal (E) from the brake booster. 9. Install the master cylinder in the reverse order of removal, and note these items: • Replace all rubber parts with new ones whenever removed. • Coat the lip of the new rod seal with recommended seal grease in the master cylinder set. • Install the rod seal onto the brake booster with its grooved side toward the master cylinder.

4. Remove the brake fluid from the master cylinder reservoir (C) with a syringe.

19-14

BACK

Master Cylinder Inspection

Master Cylinder Pushrod Clearance Adjustment

NOTE: • Before reassembling, check that all parts are free of dust and other foreign particles. • Do not try to disassemble the master cylinder assembly. Replace the master cylinder assembly with a new part if necessary. • Do not allow dirt or foreign matter to contaminate the brake fluid.

...-.=~

_

=.

/

Special Tools Required Pushrod Adjustment Gauge 07JAG-SD40100 NOTE: Master cylinder pushrod-to-piston clearance must be checked and adjustments made, if necessary, before installing the master cylinder. 1. Set the special tool (A) on the master cylinder body (B), push in the center shaft (C) until the top of it contacts the end ofthe secondary piston (D) by turning the adjusting nut (E) .

RESERVOIR CAP Check for blockage of vent holes .

. ' /RESERVOIR SEAL Check for damage and deterioration.

'"

RESERVOIR

2. Without disturbing the center shaft's position, install the special tool (A) backwards on the booster. B 15 N·m 11.5 kgf·m. 11lbf·ftl

MASTER CYLINDER Check for leaks, rust and damage.

C 0-101 kPa 10-760 mmHg. 30 in.Hgl

A 07JAG-SD40100

3. Install the master cylinder nuts (B), and tighten to the specified torque. 4. Connect the booster in-line with a vacuum gauge (C) 0-101 kPa (0-760 mmHg, 30 in.Hg) to the booster's engine vacuum supply. and maintain an engine speed that will deliver 66 kPa (500 mmHg, 20 in.Hg) of vacuum. (cont'd)

BACK

19-15

Conventional Brake Components Master Cylinder Pushrod Clearance Adjustment (cont'd) 5. With a feeler gauge (A), measure the clearance between the gauge body and the adjusting nut (B) as shown. If the clearance between the gauge body and adjusting nut is 0.4 mm (0.02 in.), the pushrod-topiston clearance is 0 mm. However, if the clearance between the gauge body and adjusting nut is 0 mm, the pushrod-to-piston clearance is 0.4 mm (0.02 in.) or more. Therefore it must be adjusted and rechecked.

Clearance:

9. Check the push rod length (A) as shown if the booster is removed. If the length is incorrect, loosen the pushrod locknut (B), and turn the clevis (C) in or out to adjust. A 116 mm (4.6 in.)

0-0.4 mm (0-0.02 in.'

10. Install the master cylinder (see page 19-14).

6. If the clearance is incorrect, loosen the star locknut (A) and turn the adjuster (B) in or out to adjust. • Adjust the clearance while the specified vacuum is applied to the booster. • Hold the clevis (C) while adjusting. A 22N·m (2.2 kgf·m, 16 Ibf·ft)

7. Tighten the star locknut securely. 8. Remove the special tool (0).

19-16

BACK

Brake Booster Test Functional Test

Booster Check Valve Test

1. With the engine stopped, press the brake pedal several times to deplete the vacuum reservoir, then press the pedal hard and hold it for 15 seconds. If the pedal sinks, either the master cylinder is bypassing internally, or the brake system (master cylinder, lines, modulator, proportioning valve, or caliper) is leaking.

1. Disconnect the brake booster vacuum hose (check valve built-in) (A) at the booster (B). A

2. Start the engine with the pedal pressed. If the pedal sinks slightly, the vacuum booster is operating normally. If the pedal height does not vary, the booster or check valve is faulty. 3. With the engine running, press the brake pedal lightly. Apply just enough pressure to hold back automatic transmission creep. Ifthe brake pedal sinks more than 10 mm (3/8 in.) in 3 minutes, the master cylinder is faulty. A slight change in pedal height when the AlC compressor cycles on and off is normal. (The AlC compressor load changes the vacuum available to the booster.)

Leak Test

2. Start the engine, and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not working properly. Replace the brake booster vacuum hose and check valve, and retest.

1. Press the brake pedal with the engine running, then stop the engine. If the pedal height does not vary while pressed for 30 seconds, the vacuum booster is OK. If the pedal rises, the booster is faulty. 2. With the engine stopped, press the brake pedal several times using normal pressure. When the pedal is first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. If the pedal position does not vary, check the booster check valve.

BACK

19-17

Conventional Brake Components Brake Booster Replacement 1. Remove the master cylinder (see page 19-14).

5. Remove the cotter pin (A) and joint pin (B). B

2. Disconnect the vacuum hose (A) from the brake booster (B), then remove the vacuum hose bracket (C).

c

C 8x 1.25 mm 13 N·m 11.3 kgf·m, 9.4Ibf·ft)

6. Remove the four booster mounting nuts (C).

A

3. For MIT model only, remove the clutch reservoir (D) and reservoir bracket. Do not disconnect the clutch hose from the reservoir.

7. Pull the brake booster (A) forward, then turn it to the right until the clevis (B) is clear of the bulkhead (C).

4. Remove the IAT sensor. 18 N·m 11.8 kgf·m, 13 Ibf·ft)

8. Remove the brake booster from the engine compartment. 9. Install the brake booster in the reverse order of removal, and note these items: • Adjust the pushrod length before installing the brake booster. • After installation, adjust brake pedal height and brake pedal free play (see page 19-5). • Replace the IAT sensor O-ring and the booster clevis cotter pin.

19-18

BACK

Rear Brake Pads Inspection and Replacement 5. Remove the pad shim (A) and brake pads (8).

ACAUTION Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health . • Avoid breathing dust particles . • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheel. 2. Release the parking brake. 3. Remove the brake hose (A) from the suspension arm by removing the mounting bolt (8). Thoroughly clean the outside of the caliper to prevent dust and dirt from entering inside. Support the caliper with a piece of wire so that it does not hang from the brake hose. A

B

6. Using vernier calipers, measure the thickness of each brake pad lining. Measurement does not include pad backing plate (A) thickness.

Brake Pad Thickness: Standard: 8.5-9.5 mm (0.33-0.37 in.) Service Limit: 1.6 mm (0.06 in.)

4. Remove the two caliper bolts (e) and caliper (D) from the bracket.

(cont'd)

BACK

19-19

Conventional Brake Components Rear Brake Pads Inspection and Replacement (cont'd) 7. Remove the pad retainers.

13. Rotate the caliper piston (A) clockwise into the cylinder, then align the cutout (B) in the piston with the tab (C) on the inner pad by turning the piston back. Lubricate the boot with rubber grease to avoid twisting the piston boot. Ifthe piston boot is twisted, back it out so it is positioned properly. F

8. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. 9. Check the brake disc for damage and cracks. 10. Install the pad retainers. 11. Apply Molykote M77 grease to the pad side of the shim (A). Wipe excess grease off the shim. Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads. E

8x1.0mm 25N·m (2.5 kgf·m, 18 Ibf·tt)

c

B

14. Install the brake caliper (0). 15. Install and torque the caliper bolts (E) to proper specification.

t~c

16. Install the brake hose (F) onto the suspension arm with the mounting bolt (G). 17. After installation, check for leaks at hose and line joints and connections, and retighten if necessary.

B

12. Install the brake pads (B) and pad shim on the caliper bracket. Install the inner pad with its wear indicator (C) facing downward.

18. Press the brake pedal several times to make sure the brakes work, then test-drive.

If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.

19-20

BACK

NOTE: Engagement of the brake may require 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.

Rear Brake Disc Inspection Thickness and Parallelism

Runout 1. Raise the rear of the vehicle, and make sure it is securely supported.

1. Loosen the rear wheel nuts slightly, then raise the vehicle, and make sure it is securely supported. Remove the rear wheels.

2. Remove the brake pads (see page 19-19). 2. Remove the brake pads (see page 19-19). 3. Inspect the disc surface for damage and cracks. Clean the disc thoroughly, and remove all rust. 4. Use wheel nuts and suitable flat washers (A) to hold the disc securely against the hub, then mount a dial indicator (B) as shown, and measure the runout at 10 mm (0.4 in.) from the outer edge of the disc.

3. Using a micrometer (A), measure disc thickness at eight points, approximately 45° apart and 10 mm (0.4 in.) in from the outer edge of the disc. Replace the brake disc ifthe smallest measurement is less than the max. refinishing limit. Brake Disc Thickness: Standard: 8.9 - 9.1 mm (0.350 - 0.358 in.) Max. Refinishing Limit: 8.0 mm (0.31 in.) Brake Disc Parallelism: 0.015 mm (0.0006 in.) max.

Brake Disc Runout: Service Limit: 0.10 mm (0.004 in.) B

This is the maximum allowable difference between the thickness measurements.

A

5. If the disc is beyond the service limit, refinish the brake disc. Max. Refinishing Limit:

4. If the disc is beyond the service limit for parallelism, refinish the brake disc.

8.0 mm (0.31 in.)

NOTE: A new disc should be refinished if its runout is greater than 0.10 mm (0.004 in.).

BACK

NOTE: If the brake disc is beyond the service limit for refinishing, replace it (see page 18-22).

19-21

Conventional Brake Components Rear Brake Caliper Overhaul ~CAUTION Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health . • Avoid breathing dust particles . • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

Remove, disassemble, inspect, reassemble, and install the caliper and note these items: • Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. • Clean all parts in brake fluid and air dry; blowout all passages with compressed air. • Before reassembling, check that all parts are free of dirt and other foreign particles. • Replace parts with new ones as specified in the illustration. • Make sure no dirt or other foreign matter gets into the brake fluid. • Make sure no grease or oil gets on the brake discs or pads. • When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. • Do not reuse drained brake fluid. • Always use Honda DOT 3 Brake Fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. • Coat the piston, piston seal groove, and caliper bore with clean brake fluid. • Replace all rubber parts with new ones. • After installing the caliper, check the brake hose and line for leaks, interference, and twisting.

19-22

BACK

Sedan:

-

_ _ _ : Silicone grease

~: Rubber grease ::~~~ (~~LJgf.m, 25 Ibf.ttl

10 x 1.25 mm 3 9 N·m

SEALING WASHERS Replace.

f ttl

~

BRAKE HOSE

ARM~ ~

~ .N,m (0.' "",·m•.

,

.

CAUPE" BODY .

Y' ~~. ~ 0

PISTON SEAL Replace.

-

/SLEEVE

/

SPftING

~

CAM BOOT Replace.

PISTON ASSEMBLY

~ / PARKING LEVERI CAM ASSEMBLY

Replace.

~.

~

(?&)

SPRING CASE

CONNECTOR Replace. PAD SPRING

~

CALIPER BOLTS

RETAINER RING

~5 ~::!.~ kgf·m, 19 Ibf·ttl

Jj r\ ~~P1NA/':!'p=," I -",vf) ____ ~ ~

~/

~

BOOT CLIP Replace.

'~~~RETAINER ~

BRAKE PADS

OUTER PAD SHIM

0/1 \

PISTON BOOT Replace.

~

PIN B

PIN BOOTS

~

~

CALIPER BRACKET

CALIPER BRACKET PIN

(cant'd)

BACK

19-23

Conventional Brake Components Rear Brake Caliper Overhaul (cont'd) Coupe:

~ : Silicone grease ~ : Rubber grease ..

BRAKE H O % E 34 BANJO BOLT N·m (3.5 kgf.m. 25 Ib'·ftl

10 mm FLANGE BOLTS 34 N·m (3.5 kgf·m. 25 Ib'·ftl

Ii

{£ fI1~

SEALING WASHERS Replace. _______ BLEED SCREW 9 N·m (0.9 kgf·m. 6.5Ib'·ftl

~

fig

_______

CALIPER BODY

~~SlEEVEPISTON

~'

-----::=;-~

~:;a~~OT~VER

/PIN

~OG2 ~~

O-RING

~e. ~

SPRING WASHER

~

~

PARKING NUT 27 N.m (2.8 kgf.m. 20 Ib'.ftl

Jj.

~

~ADJusnNGBOlT

Li

CUP

"

()

;,;a$4

~~~

" / -~f1

~

/PISTONBOOT Replace.

.

O~ ~ \~

I

~(l(j ~~

I~

&z,

PIN A

~>

~

~

\

0

~

PIN BOOT

-~

BACK

~


-~

RETAINER

.::~

~U~RMA~

10 mm FLANGE BOLTS 38 N·m (3.9 kgf·m. 281b'·ftl

19-24

CIRCLIP //PISTONASSEMBlV

ADJUSnNG / SPRING B BEARING A SPRING COVER PAD SPRING PINB Il':!l. PIN BOOTS ~~ I Replace. GREASE

BRAKE PADS _ _ _ _ _

OUTER PAD SHIM CALIPER BOLTS 23 N·m (2.3 kgf·m. 17 Ibf·ftl

/SPACER

Rear Drum Brake Inspection

ACAUTION Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health . • Avoid breathing dust particles • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. NOTE: • Contaminated brake linings or drums reduce stopping ability . • Block the front wheels before jacking up the rear of the vehicle. 1. Raise the rear of the vehicle, and make sure it is securely supported.

2. Release the parking brake, and remove the rear brake drum (see page 19-271 . • N·m (o~m. 6......ft)

BACKING PLATE Marked left and right. /

7 N·m (0.7 kgf·m, 5Ibf·ft)

ADJUSTER BOLT Check ratchet teeth for wear and damage.

~Q

PARKING BRAKE LEVER Marked left and right. UPPER RETURN SPRING Check for weakness and damage. WAVE WASHER

II

U-CLIP Replace.

tl~

WHEEL CYLINDER Inspect for leakage.

BRAKE SHOE

If brake shoes are to be reused, mark and reassemble in same position.

SELF-ADJUSTER LEVER

(cont'dl

BACK

19-25

Conventional Brake Components Rear Drum Brake Inspection (cont'd) 3. Check the wheel cylinder (A) for leakage.

8. Measure the inside diameter of the brake drum with inside vernier calipers.

A

Drum Inside Diameter: 219.9-220.0 mm (8.657-8.661 in.' Standard: Service Limit: 221.0 mm (8.700 in.'

B

4. Check the brake linings (B) for cracking, glazing, wear, and contamination. 5. Measure the brake lining thickness (e). Measurement does not include brake shoe thickness.

9. If the inside diameter of the brake drum is more than the service limit, replace the brake drum. 10. Check the brake drum for scoring, grooves, and cracks .

. Brake Lining Thickness: Standard: 4.5 mm (0.18 in.) Service Limit: 2.0 mm (0.08 in.' 6. If the brake lining thickness is less than the service limit, replace the brake shoes as a set. 7. Check the bearings in the hub unit for smooth operation. If it requires servicing, replace it (see step 1 on page 18-23).

19-26

BACK

Rear Brake Shoes Replacement 5. Remove the brake shoe assembly.

ACAUTION Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. • Avoid breathing dust particles . • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

6. Remove the upper return spring (e), self-adjuster lever (D), and self-adjuster spring (E), and separate the brake shoes . 7. Remove the wave washer (A), parking brake lever (8), and pivot pin (e) from the brake shoe (D) by removing the U-c1ip (E).

E~

1. Disengage the upper return spring (A) with the tool (8).

/A

o

((§J~

A

c

B

o 2. Remove the tension pins (e) by pushing the retainer spring (D) and turning them.

8. Apply brake cylinder grease (PIN: 08733-80202) or equivalent rubber grease to the sliding surface of the pivot pin (A), and insert the pin into the brake shoe.

3. Lower the brake shoe assembly (A), and remove the lower return spring (8). Make sure not to damage the dust cover on the wheel cylinder.

E

4. Disconnect the parking brake cable from the parking brake lever.

(cont'd)

BACK

19-27

Conventional Brake Components Rear Brake Shoes Replacement (cont'd) 9. Install the parking brake lever (B) and wave washer (C) on the pivot pin, and secure with a new U-clip (D). o

o

Install the wave washer with its convex side facing out. Pinch the U-clip securely to prevent the pivot pin from coming out from the brake shoe.

15. Apply brake cylinder grease (PIN: 08733-B020E) or equivalent rubber grease to the sliding surfaces shown. Wipe off any excess. Don't get grease on the brake linings. . . . Sliding surface

10. Connect the parking brake cable to the parking brake lever. 11. Clean the threaded portions of clevises A and B. Coat the threads of the clevises with grease. To shorten the clevises, turn the adjuster bolt (C). E

16. Apply Molykote 44MA to the brake shoe ends and opposite edges of the shoes shown. Wipe off any excess. Don't get grease on the brake linings.. . . . . Opposite edge of the shoe

t::::>o Brake shoe ends

(Shoe side ends and backing

/~p./~_~te contact surface)

o

12. Hook the self-adjuster spring (D) to the adjuster lever first, then to the brake shoe. 13. Install the clevises and upper return spring (E), noting the installation direction. Be careful not to damage the wheel cylinder dust covers. 14. Install the lower return spring (F).

19-28

BACK

'<"

Rear Wheel Cylinder Replacement NOTE: • Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. • To prevent spills, cover the hose joints with rags or shop towels. • Use only a genuine Honda wheel cylinder special bolt.

17. Install the brake shoes (A) onto the backing plate. Be careful not to damage the wheel cylinder dust covers. D

1. Remove the brake shoes (see page 19-27). 2. Disconnect the brake line (A) from the wheel cylinder (B).

E 7 N·m (0.7 kgf·m, Slbf·ftl

c 18. Install the tension pins (B) and the retainer springs (C).

19. Hook the upper return spring (D) with the tool (E). C 9 N·m (0.9 kgf·m, 6.S Ibf·ftl

20. Install the brake drum. 21. If the wheel cylinder has been removed, bleed the brake system (see page 19-7). 22. Press the brake pedal several times to set the selfadjusting brake.

3. Remove the bolt (C) and the wheel cylinder from the backing plate. 4. Apply sealant (E) between the wheel cylinder (B) and backing plate (D), and install the wheel cylinder.

23. Adjust the parking brake (see page 19-5). 5. Install the removed parts in the reverse order of removal. 6. Fill the brake reservoir up, and bleed the brake system (see page 19-7). 7. After installation, check for a leak at the line joint, and retighten if necessary.

BACK

19-29

Conventional Brake Components Brake Hoses and Lines Inspection 1. Inspect the brake hoses, for damage, deterioration, leaks, interference, and twisting. 2. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines. 3. Check for leaks at hose and line joints or connections, and retighten if necessary. 4. Check the master cylinder and ABS modulator unit for damage and leakage. NOTE: Replace the brake hose clip whenever the brake hose is serviced.

BRAKE LlNE-to-BRAKE HOSE

15 N·m 11.5 kgf·m,11Ibf.ft) BRAKE HOSE-to-CALIPER (BANJO BOLT)

DISC BRAKE: BRAKE HOSE-to-CALIPER (BANJO BOLT)

34 N·m (3.5 kgf·m, 25 Ibf.ft) BLEED SCREW 9 N·m (0.9 kgf·m, 6.5 Ibf·ft) DRUM BRAKE: BRAKE LlNE-to-WHEEL CYLINDER

34 N·m (3.5 kgf·m, 25 Ibf·ft)

15 N·m (1.5 kgf·m, 11Ibf·ft) BLEED SCREW

7

(0.7 kgf·m, 5lbf·ftl

BRAKE LlNE-to-BRAKE HOSE

15 N·m (1.5 kgf·m, 11Ibf·ft)

PROPORTIONING CONTROL VALVE-toBRAKE LINE

15 N·m (1.5 kgf·m, 11lbf·ft) MASTER CYLINDER-to-BRAKE LINE

15 N·m (1.5 kgf·m, 11Ibf·ft)

WithABS: ABS MODULATOR UNIT-to-BRAKE LINE


ABS MODULATOR UNIT

19-30

BACK

Brake Hose Replacement NOTE: • Before reassembling, check that all parts are free of dust and other foreign particles. • Replace parts with new ones whenever specified to do so. • Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water.

6. Install the brake hose (A) on the knuckle with 2 6 mm flange bolts (B) first, then connect the brake hose to the caliper with the banjo bolt (C) and new sealing washers (D).

A

1. Replace the brake hose (A) if the hose is twisted, cracked, or if it leaks. B

1,,-

C

(

"---

34N·m (3.5 kgf·m, 25 Ibf·ft)

\

---

7. Install the brake hose (A) on the upper brake hose bracket (B) with a new brake hose clip (C). 2. Disconnect the brake hose from the brake line (B) using a 10 mm flare-nut wrench (C).

C

D

\ ,'5 NO"m,,: ':omo ",

Wl~V~-~·

3. Remove and discard the brake hose clip (A) from the brake hose (B).

Ib,f.ft)

OOO\~
/~A 8. Connect the brake line (D) to the brake hose. 9. After installing the brake hose, bleed the brake system (see page 19-7). 10. Do the following checks: • Check the brake hose and line joint for leaks, and tighten if necessary . • Check the brake hoses for interference and twisting.

4. Remove the banjo bolt (C), and disconnect the brake hose from the caliper. 5. Remove the brake hose from the knuckle.

BACK

19-31

Conventional Brake Components Parking Brake Cable Replacement Exploded View PARKING BRAKE CABLE Check for faulty movement. (Drum brake)

PARKING BRAKE CABLE Check for faulty movement.

';--... ".

./'

«

""

~ ..> BRAKE HOSE CLIP . , .. ./.. Replace.

......,-.,. / " ' /

lijf

ax1.2Smm 22 N·m (2.2 kgf·m, 16lbf·ftl

PARKING BRAKE CABLE Check for faulty movement. (Disc brake)

.'

~ ~'"~~Nrn \

EQUALIZER

PARKING BRAKE LEVER Check for smooth operation.

19-32

BACK

,

...-....

Ii ./. ./"'/ "'. <·~··.>

I

"

""" .. ' /

.,./'

6x1.0mm 9.a N·m (1.0 kgf·m, 7.2Ibf·ftl

ax1.2Smm 22 N·m (2.2 kgf·m, 16lbf·ftl

(Sliding surfacel

./

Rear Drum Brake: (OX and LX Type)

NOTE: • The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature failure. • Refer to the Exploded View as needed during this procedure.

1. Remove the brake shoe assembly (see page 19-27). 2. Remove the parking brake cable mounting bolts from the backing plate.

Rear Disc Brake: (EX Type)

3. Remove the parking brake cable (A) from the backing plate (8) using a 12 mm offset wrench (C).

1. Release the parking brake lever fully, and remove the brake hose clip (A) from the parking brake cable.

~, ~__

B

C

/)'---7>~'_~ J1-"

~~j

""~'\\.f?~L:

'"

c~ )~C\/~~)~(~ ~)

_ .

.

)

~) /",/(

J~

r

/

.'

J

,

/ \

~-----'/

iA

~

\

A

B

2. Disconnect the parking brake cable (8) from the lever (C).

BACK

19-33

19-34

BACK

Brakes Conventional Brake Components ..................... 19-1 ABS (Anti-lock Brake System) Components Component Location Index ......................................... General Troubleshooting Information ....................... DTC Troubleshooting Index ........................................ Sympton Troubleshooting Index ................................ System Description ...................................................... Circuit Diagram ............................................................. DTC Troubleshooting ................................................... ABS Indicator Circuit Troubleshooting ...................... Modulator Unit Removal and Installation ................................................................. ABS Control Unit Replacement ................................... Wheel Sensor Inspection ............................................. Wheel Sensor Replacement ........................................

19-36 19-37 19-40 19-41 19-42 19-50 19-52 19-67 19-69 19-70 19-70 19-71

ABS Components Component Location Index

UNDER-HOOD ABS RELAV BOX (PUMP MOTOR RELA V) Inspection, page 22-52

-REAR WHEEL SENSOR Inspection, page 19-70 Replacement, page 19-71

UNDER-HOOD ABS RELA V BOX (FAIL-SAFE RELAV) Inspection, page 22-52 UNDER-HOOD FUSE/RELAV BOX

LEFT-REAR WHEEL SENSOR Inspection, page 19-70 Replacement, page 19-71

DRIVER'S UNDER-DASH FUSE/RELAV BOX A LINK CONNECTOR (DLC) ABS CONTROL UNIT Replacement, page 19-70 RIGHT-FRONT WHEEL SENSOR Inspection, page 19-70 Replacement, page 19-71

LEFT-FRONT WHEEL SENSOR Inspection, page 19-70 Replacement, page 19-71

MODULATOR UNIT Removal and Installation, page 19-69

19-36

BACK

~

~ General Troubleshooting Information ABS Indicator

Self-diagnosis

• Ifthe system is OK, the ABS indicator goes off two seconds after turning the ignition switch ON (II) without starting the engine, and then comes on again and goes off 2 seconds after starting the engine. This occurs because the ABS control unit is turned on by the IG2 power source. • The ABS indicator comes on when the ABS control unit detects a problem in the system. However, even though the system is operating properly, the ABS indicator will come on, under the following conditions: - Only drive wheels rotate - One drive wheel is stuck - Vehicle spins - ABS continues to operate for a long time - Signal disturbance

• Self-diagnosis can be classified into 2 categories: - Initial diagnosis: Done right after the engine starts and until the ABS indicator goes off. - Regular diagnosis: Done right after the initial diagnosis until the ignition switch is turned OFF. • When a problem is detected by self-diagnosis, the system: - Turns the fail-safe relay OFF - Turns the solenoid valve OFF - Turns the pump motor OFF - Turns the ABS indicator ON

To determine the actual cause of the problem, question the customer about the problem, taking the above-listed conditions into consideration.

Kickback The motor operates when the ABS is functioning, and the fluid in the reservoir is forced out to the master cylinder, causing kickback at the brake pedal.

Pump Motor • When a problem is detected and the ABS indicator comes on, there are cases when the indicator stays on until the ignition switch is turned OFF, and cases when the indicator light goes off automatically when the system returns to normal. For OTCs 61 and 62, the indicator goes off automatically when the system returns to normal. For all other codes, the indicator stays on until the ignition switch is turned OFF. • For OTCs 12, 14, 16, 18,21,22,23,24,51,52 and 53, the ABS indicator goes off when the vehicle is driven again and the system is OK after the ignition switch is turned from OFF to ON (II). However, ifthe OTC is cleared, the CPU resets and the indicator goes off right after the engine is started if the system is OK.

• The pump motor operates when the ABS is functioning. • The ABS control unit checks the pump motor operation during initial diagnosis when the vehicle is started. You may hear the motor operate at this time, but it is normal.

Brake Fluid Replacement/Air Bleeding Brake fluid replacement and air bleeding procedures are the same as for vehicles without ABS. To ease bleeding, start with the front wheels.

Diagnostic Trouble Code (DTC) • If the CPU cannot be activated or the CPU fails, the ABS indicator comes on, but the OTC is not memorized. • The memory can hold any number of OTCs. However, when the same OTC is detected more than once, the later one is written over the old one. Therefore, when the same problem is detected repeatedly, it is memorized as one OTC. • The OTCs are indicated in the order of ascending number, not in the order they occur. • The OTCs are memorized in the EEPROM (nonvolatile memory). Therefore, the memorized OTCs cannot be canceled by disconnecting the battery. Do the specified procedures to clear the OTCs. (cont'd)

BACK

19-37

ABS Components General Troubleshooting Information (cont'd) How to Troubleshoot ABS DTCs

3. Turn the ignition switch ON (II) without the brake pedal pressed.

The troubleshooting flowchart procedures assume that the cause ofthe problem is still present and the ABS indicator is still on. Following the flowchart when the ABS indicator does not come on can result in incorrect diagnosis. The connector illustrations show the female terminal connectors with a single outline and the male terminal connectors with a double outline.

NOTE: If the brake pedal is pressed when turning the ignition switch ON (II), the system shifts to the MES mode. 4. The blinking frequency indicates the DTC. NOTE: If the DTC is not memorized, the ABS indicator will go off for 3.6 seconds, and then come back on.

1. Question the customer about the conditions when the problem occured, and try to reproduce the same conditions for troubleshooting. Find out when the ABS indicator came on, such as during initial diagnosis, during ABS control, after ABS control, when vehicle speed was at a certain speed, etc.

The system will not indicate the DTC unless these conditions are met: • Vehicle speed is 6 mph (10 km/h) or less. • SCS circuit is shorted to body ground before the ignition switch is turned ON (II). • The brake pedal is released.

2. When the ABS indicator does not come on during the test-drive, but troubleshooting is done based on the DTC, check for loose connectors, poor contact of the terminals, etc. before you start troubleshooting. 3. After troubleshooting, clear the DTC, and test-drive the vehicle. Make sure the ABS indicator does not come on.

How to Retrieve ABS DTCs

c

d

ON

OFF a

Ignition switch ON {III

1. Connectthe Honda PGM Tester (A) to the 16P Data Link Connector (B) located behind the driver's side kick panel with the ignition switch OFF.

First cycle a: 2 sec. b: 3.6 sec. Ii: 1.3 sec.

d: 0.4 sec. e: 0.5 sec. f: 0.3 sec.

Second cycle

5. Turn the ignition switch OFF. 6. Press "EXIT" on the Honda PGM Tester. 7. Disconnect the Honda PGM Testerfrom the 16P Data Link Connector.

B

2. Select "scs" on the display of the Honda PGM Tester, then push "YES" at the "SERVICE CHECK SIGNAL" mode.

19-38

BACK

~ ~ How to Clear ASS DTCs

7. After the ABS indicator goes off, release the brake pedal again.

1. Connect the Honda PGM Tester (A) to the 16P Data Link Connector (B) located behind of the driver's kick panel with the ignition switch OFF.

You cannot clear the DTC unless these conditions are met: o o

o

Vehicle speed is 6 mph (10 km/h) or less. SCS circuit is shorted to body ground before the ignition switch is turned ON (II). The brake pedal is pressed before the ignition switch is turned ON (II). d

~······5

ON ABS

indicator

a OFF

Depressed--+--'--T Brake pedal Released·

2. Select "SCS" on the display ofthe Honda PGM Tester, then push "YES" at the "SERVICE CHECK SIGNAL" mode.

Ignition switch ON (II) a: 2 sec. d: 0.3 sec. b: 4 sec. e: within 3 sec. c: 5 sec.

3. Press the brake pedal. 4. Turn the ignition switch ON (II) while keeping the brake pedal pressed. 5. After the ABS indicator goes off, release the brake pedal. 6. After the ABS indicator comes on, press the brake pedal again.

8. After a few seconds, the ABS indicator blinks twice and the DTC is cleared. Ifthe indicator does not blink twice, repeat steps 1 through 7. If the indicator stays on after the indicator blinks twice, check the DTC because a problem was detected during initial diagnosis before shifting to MES mode. 9. Turn the ignition switch OFF. 10. Press "EXIT' on the Honda PGM Tester. 11. Disconnect the Honda PGM Tester from the 16P Data Link Connector.

BACK

19-39

ABS Components DTC Troubleshooting Index DTC DTC:11 DTC:12 DTC:13 DTC:14 DTC:15 DTC:16 DTC:17 DTC:18 DTC:21 DTC:22 DTC:23 DTC:24 DTC:31 DTC:32 DTC:33 DTC:34 DTC:35 DTC:36 DTC:37 DTC:38 DTC:41 DTC:42 DTC:43 DTC:44 DTC:51 DTC:52 DTC:53 DTC:54 DTC:61 DTC:62 DTC:71 DTC:81

19-40

Detection Item Right-front wheel sensor (open/short to body ground/short to power) Right-front wheel sensor (electrical noise/intermittent interruption) Left-front wheel sensor (open/short to body ground/short to power) Left-front wheel sensor (electrical noise/intermittent interruption) Right-rear wheel sensor (open/short to body ground/short to power) Right-rear wheel sensor (electrical noise/intermittent interruption) Left-rear wheel sensor (open/short to body ground/short to power) Left-rear wheel sensor (electrical noise/intermittent interruption) Right-front pulser Left-front pulser Right-rear pulser Left-rear pulser Right-front inlet solenoid Right-front outlet solenoid Left-front inlet solenoid Left-front outlet solenoid Right-rear inlet solenoid Right-rear outlet solenoid Left-rear inlet solenoid Left-rear outlet solenoid Right-front wheel lock Left-front wheel lock Right-rear wheel lock Left-rear wheel lock Motor lock Motor stuck OFF Motor stuck ON Fail-safe relay Low ignition voltage High ignition voltage Different diameter tire Central Processing Unit (CPU) diagnosis, and ROM/RAM diagnosis

BACK

Note (see page 19-52) (see page 19-53) (see page 19-52) (see page 19-53) (see page 19-52) (see page 19-53) (see page 19-52) (see page 19-53) (see page 19-54) (see page 19-54) (see page 19-54) (see page 19-54) (see page 19-55) (see page 19-55) (see page 19-55) (see page 19-55) (see page 19-55) (see page 19-55) (see page 19-55) (see page 19-55) (see page 19-58) (see page 19-58) (see page 19-58) (see page 19-58) (see page 19-59) (see page 19-59) (see page 19-61) (see page 19-63) (see page 19-65) (see page 19-65) (see page 19-66) (see~age 19-66)

~

~ Symptom Troubleshooting Index Diagnostic~rocedure

Symptom

ABS indicator does not come on

ABS Indicator Circuit Troubleshooting (see page

ABS indicator does not go off and no DTC is stored

ABS Indicator Circuit Troubleshooting (see page

Also check for

19-67) 19-67)

BACK

19-41

ABS Components System Description ABS Control Unit Inputs and Outputs for Connector A (22P) ABS CONTROL UNIT CONNECTOR A (22PI

6 7 8 9 10 FLWH FLWC+) FRWH FRWC+) STOP 16 17 18 19 20 MCK RLWC+) RLWH RRWC+)RRWH

21 FSR

11 IG2 22 OLC


Terminal number

Wire color

Terminal sign (Terminal namel

1

BLK

4

GRN/ RED

GND3 (Ground 31 PARK (Parking)

6

BRN

7

GRN/ BLU

8

GRN

9

GRN/ BLK

10

WHT/ BLK

11

YEll BLK

FLW(-) (Front-left wheel negative) FLW(+) (Front-left wheel positive) FRW(-) (Front-right wheel negative) FRW(+) (Front-right wheel positive) STOP

IG2 (Ignition 21

Description Terminal

Measurement Conditions (Ignition switch ON (II))

Voltage

Ground

1-GND

--

Below 0.3 V

Detects parking brake switch signal

4-GND

Detects left-front wheel sensor signal

6-7

Detects right-front wheel sensor signal

8-9

Engine running, Parking brake Wheel

Pulled Release

Turn wheel at 1 turn/ second

Stopped

Detects brake switch signal

10-GND

Brake pedal

Power source for activating the system

11-GND

Ignition switch

Depressed Released ON (II) Start (III)

19-42

BACK

Below 0.3 V Battery Voltage AC: 0.053Vor above (Reference) Oscilloscope: 0.15 Vp-p or above

0.25 V1.15 V

Battery Voltage Below 0.3 V Battery Voltage Below 0.3 V

~

~

Terminal number

Wire color

Terminal sign (Terminal name)

12

BLK

14

BRN

GND4 (Ground 4) SCS (Service check signal)

16

GRN

17

LT BLU

18

GRY

19

GRN/ YEL

20

BLU/ YEL

21

YEll GRN

22

LT BLU

MCK (Motor check)

RLW (+) (Rear-left wheel positive) RLW(-) (Rear-left wheel positive) RRW(+) (Rear-right wheel positive) RRW(-) (Rear-right wheel negative) FSR (Fail-safe relay)

DLC (Data link connector)

Terminal

Measurement Conditions (Ignition switch ON (II))

Voltage

Ground

12-GND

--

BelowO.3V

Detects service check connector signal (DTC indication or DTC erasure) Detects pump motor drive signal

14-GND

SCS circuit

16-GND

Pump motor

Detects left-rear wheel sensor signal

17-18

OFF Remove MCK fuse Wheel Turn wheel at 1 turn/ second

Detects right-rear wheel sensor signal

19-20

Description

Drives fail-safe relay (Fail-safe relay is turned OFF to shut off the power source to the solenoid and pump motor relay when problem occurs.) Communicates with Honda PGM Tester

21-GND

22-GND

ABS (SCS circuit must be open)

Shorted Opened

Below 0.3 V Approx. 5 V

ON

Battery Voltage BelowO.3V Approx. 10 V AC: 0.053Vor above (Reference) Oscilloscope: 0.15 Vp-p or above

Stopped

0.25 V1.15 V

Warning Normal

Below 0.3 V Approx.11V

--

--

(cont'd)

BACK

19-43

ABS Components System Description (cont'd) ABS Control Unit Inputs and Outputs for Connector B (12P) ABS CONTROL UNIT CONNECTOR B (12P)

3 RR-

4 FL-

5 RL-

FR-

WALP

2 GND1

OUT

OUT

OUT

OUT

8 RR-

9 FL-

10

11

7

RL-

FR-

12

GND2

IN

IN

IN

IN

PMR

1

6


Terminal number

Wire color

1

BLU/ WHT

2

BLK

3

YEll WHT

4

YEll BLU

5

YEll GRN

6

YEll BLK

7

BLK

8

RED/ WHT

9

RED/ BLU

10

RED/ GRN

11

RED/ BLK

12

YEll RED

Terminal sign (Terminal name) WALP (Warning lamp)

GND1 (Ground 1) ' RR-OUT (Rear-right outlet) FL-OUT (Front-left outlet) RL-OUT (Rear-left outlet) FR-OUT (Front-right outlet) GND2 (Ground 2) RR-IN (Rear-right inlet) FL-IN (Front-left inlet) RL-IN (Rear-left inlet) FR-IN (Front-right inlet) PMR (Pump motor relay)

Description Terminal Drives ABS indicator light (Turns the indicator light drive transistor to ON, then turns off the indicator light) Ground

1-GND

Measurement Conditions (Ignition switch ON (II)) ABS ON OFF indicator

--

2-GND

Drives right-rear outlet solenoid valve

3-GND

Drives left-front outlet solenoid valve

4-GND

Drives left-rear outlet solenoid valve

5-GND

Drives right-front outlet solenoid valve

ABS indicator

4-6V BelowO.3V

Below 0.3 V OFF

Battery Voltage

Below 0.3 V

6-GND

ON (Disconnect connector A to turn light on)

Ground

7-GND

--

BelowO.3V

Drives right-rear inlet solenoid valve

8-GND

Drives left-front inlet solenoid valve

9-GND

Drives left-rear inlet solenoid valve

10-GND

Drives right-front inlet solenoid valve

11-GND

Drives pump motor relay

12-GND

OFF

Battery Voltage

ON (Disconnect connector A to turn light on)

BelowO.3V

ABS indicator

ABS indicator

OFF

Pump motor ON

19-44

Voltage

BACK

ON OFF

Below 1.0V Battery Voltage Below 0.3 V

~ ~ Features When the brake pedal is pressed during driving, the wheels can lock before the vehicle comes to a stop. In such an event, the maneuverability of the vehicle is reduced if the front wheels are locked, and the stability of the vehicle is reduced if the rear wheels are locked, creating an extremely unstable condition. The ASS precisely controls the slip rate of the wheels to ensure maximum grip force from the tires, and it thereby ensures maneuverability and stability of the vehicle. The ASS calculates the slip rate of the wheels based on the vehicle speed and the wheel speed, then it controls the brake fluid pressure to reach the target slip rate. Grip Force of Tire and Road Surface

Slip Rate BRAKING START POINT

COEFFICIENT OF FRICTION

RADIAL DIRECTION OF THE ROTATIONAL DIRECTION

C A: Distance without slip B: Slipped distance C: Actual distance B VEHICLE SPEED-WHEEL SPEED SLIP RATE= C= VEHICLE SPEED

SLIP RATE

NO: Normally Open NC: Normally Closed

(cont'd)

BACK

19-45

ABS Components System Description (cont'd) ABS Control Unit Main Control The ASS control unit detects the wheel speed based on the wheel sensor signal it received, then it calculates the vehicle speed based on the detected wheel speed. The control unit detects the vehicle speed during deceleration based on the rate of deceleration. The ASS control unit calculates the slip rate of each wheel, and it transmits the control signal to the modulator unit solenoid valve when the slip rate is high. The pressure reduction control has 3-modes: pressure reducing, pressure retaining, and pressure intensifying. ABS CONTROL UNIT

r'-'-'-'-'-'-'-'-'-'-'-'-'-'-'-'-'-'-'-'-'-'-I "

DETECTSPEED VEHICLE

i

19-46

"

I

BACK

~ ~ Self-diagnosis

1. The ABS control unit is equipped with a main CPU and a sub CPU, that check each other for problems. 2. The CPUs check the circuit of the system. 3. Self-diagnosis can be classifield into 2 categories: o o

Initial diagnosis: Done right after the engine starts and until the ABS indicator goes off. Regular diagnosis: Done right after the initial diagnosis until the ignition switch is turned OFF.

4. When a problem is detected by self-diagnosis, the system: o o o o

Turns the fail-safe relay OFF Turns the solenoid valve OFF Turn the pump motor OFF Turns the ABS indicator ON

Self-diagnosis Table Detection Timing

Detection hem

Diagnostic Trouble

Regular

Diagnosis

Diagnosis

CI

0

A

0

S. A and L. Sand L Aand L

Motor lock

0 0 0 0

Motor stuck OFF

(>

AandL

11.13. 15. 17

Wheel sensor (open/short to body ground/short to powerl

12.14.16. 18 21-24 31-38 41-44

Wheel sensor (electrical noise/intermittent interruption I

51 52 53 54 61 62 11 81

Fail-safe Mode

Initial

CodelDTCI

Pulser Solenoid (short to body ground/short to wirel

C)

Wheel lock

S AandL Sand L

Motor stuck ON

0

0

AandL

Fail-safe relay

0

(>

S

0 0

B

0 0

S

Low ignition voltage High ignition voltage Different diameter tire Central Processing Unit (CPUI diagnosis, and ROM/RAM diagnosis

0

B S

Operation Mode Table Description

Operation Mode

ABS Indicator

Regular operation

Operation in normal condition

Fail-safe mode-S

The ABS control unit turns the system off when the control unit detects a problem.

Comes ON when a problem is

Fail-safe mode-A

If the ABS control unit detects a malfunction during an emergency stop. it will turn off the


malfunctioning component. and continue to modulate the rest of the ASS system until the

detected.

OFF detected.

vehicle comes to a stop. At that. the entire system will be turned off until the problem goes away. Fail-safe mode-L

The ABS control unit stores a DTC in back-up memory when it detects a problem. If a

ON

problem is detected when the ignition switch is turned ON (III. the ASS control unit will turn the system off. If the problem goes away, the ABS control unit will turn the system on again. Fail-safe mode-B

The ABS control unit will turn the system off if ignition voltage drops. and will turn on again


when ignition voltage returns to normal.

detected.

On-board Diagnosis Function

The ABS control unit is connected to the 16P Data Link Connector. The ABS can be diagnosed with the Honda PGM Tester. The ALB Checker cannot be used with this system. For air bleeding, and checking wheel sensor signals, use the Honda PGM Tester. See the Honda PGM Tester user's manuals for specific operating instructions. (cont'd)

BACK

19-47

ABS Components System Description (cont'd) ABS Modulator The ABS modulator consists of the inlet solenoid valve, outlet solenoid valve, reservoir, pump, pump motor, and the damping chamber. The modulator reduces the caliper fluid pressure directly. It is a circulating-type modulator because the brake fluid circulates through the caliper, reservoir, and the master cylinder. The hydraulic control has three modes: pressure intensifying, pressure retaining, and pressure reducing. The hydraulic circuit is an independent four channel-type, one channel for each wheel.

SOLENOID VALVE

MASTER CYLINDER

MODULATOR UNIT 1-----------------

! !

"'""'\.:r...1.

I, I

iL__ _ RF

LR

RR

LF IN: INLET VALVE (NORMAllY OPEN) OUT: OunET VALVE (NORMAllY ClOSED)

Pressure intensifying mode:

Inlet valve open, outlet valve closed Master cylinder fluid is pumped out to the caliper.

Pressure retaining mode:

Inlet valve closed, outlet valve closed Caliper fluid is retained by the inlet valve and outlet valve.

Pressure reducing mode:

Inlet valve closed, outlet valve open Caliper fluid flows through the outlet valve to the reservoir.

Motor operation mode:

When starting the pressure reducing mode, the pump motor is ON. When stopping ABS operation, the pump motor is OFF. The reservoir fluid is pumped out by the pump, through the damping chamber, to the master cylinder.

19-48

BACK

~ ~ Wheel Sensor The wheel sensors are the magnetic contactless type. As the gear pulser teeth rotate past the wheel sensor's magnetic coil, AC current is generated. The AC frequency changes in accordance with the wheel speed. The ASS control unit detects the wheel sensor signal frequency and thereby detects the wheel speed.

.O I:~~ GEARPULSER

at HIGH SPEED

WHEEL SENSOR

Wheel Speed and Modulator Control SPEED

VEHICLE SPEED

---=:::...::

WHEEL SPEED

TIME PRESSURE

OUTLET VALVE ON OFF INLET VALVE ON

··. ··., , ,

·.

.., ..,

·. ,,

'

OFF MOTOR ON OFF

When the wheel speed drops sharply below the vehicle speed, the inlet valve closes to retain the caliper fluid pressure. When the wheel speed drops further, the outlet valve opens momentarily to reduce the caliper fluid pressure. The pump motor starts at this time. As the wheel speed is restored, the inlet valve opens momentarily to increase the caliper fluid pressure.

BACK

19-49

ABS Components Circuit Diagram BATTERY

+

UNDER-HOOD FUSEIRELAY BOX S~OP (lOAI

BRAKE SWITCH

Oosed: Brake pedal depressed

..----~---'cnJ>----_6-- WHTlYEl~WHT/lLK,-------------::":":=~==~-----WHT/llK----'r2~1-~ DRIVER'S UNDER-DASH FUSEIRELAY BOX

-:_"ulse..,,'rell

r-9---<1'\J>--f.i1---YEl--(ijJ~_+..L"'-"""(UI--~D--"1- - -_ _ ~~~ -~

IGNITION

~

\'p---¢--WHT

Gl

~ IG

ILKIYE (7_SAl l YEl--¢---1\JP---tliiloo

BRAKEFLUID

~

lEVEl SWITCH OGsed: Lowlluid

Ac MIRROR (7.5AI

G302

ABS F/S (lOAI

WHT/GRN

I

..--YEl/GRN-

UNDER-HOOD ABS RELAY BOX

It~~I

FAIL-SAFE RELAY

2

I

W

IRI lK

YEURED -

YEUBlK

I~

-'I-

T,

~

BlUlWHT'----

ABS INDICATOR CIRCUIT

I

BLK.2,.

-

Gsi"

YEUBlK:-----

-

YEUGRNI-----

G20l

YEIJRED-----

IR

ER-DASH

J 5

lK

GRNI-----

GRN MODULATOR UNIT LEFT-FRONT SOLENOID

-:Nil

FL-IN

4

'N

~OUT RIGHT-FRONT SOLENOID

':1m ~

RED/BLU-----

FL-OUT

8

,

YEUBLU-----

FR-IN

RED/BLK-----

FR-OUT

5

YEUBLK----

LEFT-REAR SDLENOID

~ .f'i'iI

RL-IN

2

I OUT

REDlGRNI-----

RL-OUT

6

YEUGRN----

RIGHT-REAR SOLENOID

.f'i'iI .f'iIII

UNDER-HOOD FUSEIRELAY BOX CONNECTORS lIP CONNECTOR 10 number)

[; IfuU" l2?3[1i'M171.2 ~

is;

~~7n~91 II 2D _ _ CONNECTORS

'IPCONNECTOR

18P CONNECTOR (0 numb.d 7

<0_1

I 2 3 • 567 I 9 10 " 121314 15 1617 18

B 9 10

YEUWHT-----

BLK~

-

18P CONNECTOR (0 number)

12 13 14

BRAKE SWITCH CONNECTOR 2P CONNECTOR 4P CONNECTOR

m (-1-)

22PCONNECTOR ( 0 . . - )

Wire side of lemate lerminats

19-50

2

•

UNDER-DASH DRIVER'S FUSEIRELAY BOX CONNECTORS

2DPCONNECTOR ( 0 _ 1

....M~

~~'mi~~t~~ENGER'S FUSE/RELAY 7P CONNECTOR (0 numberl

REDJWHT'----

RR-OUT

7

PUMP MOTOR

,

WHT/llU

RR-IN

3

IN

BACK

5 & 7 '4 15

PUMP MOTOR RELAY CONNECTOR

...IImI...

Q:J.IJ FAIL-sAFE RELAY

CONNECTOR

~

MOOULATOR UNIT CONNECTOR

(Onu_r)

4 3 2 1 17& 5 10 PUMP MOTOR CONNECTOR

(Onurn"")

dIb

~ ~

PCMISCS)

------WH1IBlX------;I;\~- WHT/BlX---"::=-7"""

~::t:rE

V

rD'fCl

'f

~

SCS

IRN

DATA LINK

T

.;~ONNE~ORI16P)

PCM IDlC)

12

LT BLU

1

Y

Y

WHT/GRH

~l IJU(

R2 DlfT BLU4-LT BLU

G10l G40l

-------------~~

--------------mw--~~D_~H WHEEL SENSOR ______

~lEFT.

~FRONT

~RIGHT.

I_ _ _ _ _ _ ~FRONT

~lEFT. ' _ _ _ _ _ _@REAR

m 2

------I,

G30'

ABS CONTROL UNIT CONNECTORS CONNECTOR A(22P)

DATA lINK

CONNECTOR (16P)

RIGHT.

-

REAR

G30S

WHEEl SENSOR CONNECTOR

~EAR

-

Terminaisiclo 01

CONNECTOR BI'2p)

.......

W.. sicIootl_ _

BACK

19-51

ABS Components DTC Troubleshooting DTC 11, 13,15,17: Wheel Sensor (Open/Short to Body Ground/Short to Power)

4. Check for continuity between the appropriate wheel sensor (+) circuit terminal and body ground (see table).

1. Disconnect the ASS control unit connector A (22P). DTC 11 (Rioht-front) 13 (Left-front) 15 (Right-rear) 17 (Left-rear)

2. Start the engine. 3. Measure the voltage between the appropriate wheel sensor (+) circuit terminal and body ground (see table). DTC 11 (Right-front) 13 (Left-front) 15 (Right-rear) 17 (Left-rear)

Appropriate Terminal A9: FRW(+) A7: FLW(+) A19: RRW(+) A17:RLW(+)

ABS CONTROL UNIT CONNECTOR A 122PI

Appropriate Terminal A9: FRW(+) A7:FLW(+) A19:RRW(+) A17: RLW(+)

FLW 1+1 IGRN/BLUI

FRW 1+1 IGRN/BLKI

ABS CONTROL UNIT CONNECTOR A I22PI FLW 1+1 IGRN/BLUI

FRW 1+1 IGRN/BLKI


Is there continuity? YES- Go to step 5. NO- Go to step 6. Wire side offemale terminals

Is there 2 V or more? YES- Repair short to power in the (+) circuit wire between the ASS control unit and the appropriate wheel sensor••

5. Disconnect the harness 2P connector from the appropriate wheel sensor, then check for continuity between the (+) and (-) terminals of the harness and body ground.

Is there continuity? NO - Go to step 4. YES - Repai r short to body ground in the (+ ) or (- ) circuit wire between the ASS control unit and the wheel sensor.• NO- Replace the wheel sensor.•

19-52

BACK

~ ~ OTC 12, 14, 16, 18: Wheel Sensor (Electrical

6. Check the resistance between the appropriate wheel sensor (+) and (-) circuit terminals (see table). DTC 11 (Right-front) 13 (Left-front) 15 (Right-rear) 17 (Left-rear)

Noise/Intermittent Interruption)

Appropriate Terminal 1-) Side 1+) Side A8:FRW(-) A9: FRW(+) A6:FLWI-) A7: FLWI+) A19: RRW 1+) A20: RRW(-) A17:RLW(+) A18:RLW(-)

NOTE: If the ABS indicator comes on for the reasons described below,the indicator goes off when you testdrive the vehicle at 19 mph (30 km/h). • Only the drive wheels rotated • The vehicle spun • Electrical noise 1. Visually check for appropriate wheel sensor and pulser installation (see table).

ASS CONTROL UNIT CONNECTOR A 122PI FRW I-I IGRNI

DTC 12 14 16 18

Appropriate Wheel Sensor Riaht-front Left-front Riaht-rear Left-rear

Are they installed correctly? YES-Go to step 2. RLW I-I IGRYI

RRW 1+1 IGRN/YEl)

NO - Reinstall or replace the appropriate wheel sensor or pulser..

Wire side of female terminals (s

the resistance 450- 2,000 Q ? 2. Disconnect the ABS control unit connector A (22P).

YES - Check for loose ABS control unit connectors. If necessary, substitute a known-good ABS control unit, and recheck.

3. Measure the resistance between the appropriate wheel sensor (+ ) and (- ) circuit terminals (see table).

NO-Goto step 7. DTC 7. Disconnect the harness 2P connector from the appropriate wheel sensor, and check the resistance between the (+) and (-) terminals of the wheel sensor.

11 (Right-front) 13 (Left-front) 15 (Right-rear) 17 (Left-rear)

Appropriate Terminal 1-) Side 1+) Side A8:FRW(-) A9: FRW(+) A7: FLW (+) A6: FLW (-) A19: RRW(+) A20: RRW(-) A17: RLW (+) A18: RLW(-)

Is the resistance 450- 2,000 Q ? (s

YES- Repair open in the (+) or (-) circuit wire, or short between the (+) circuit wire and the 1-) circuit wire between the ABS control unit and the wheel sensor..

there less than 450 Q ?

YES-Repair short to wire between the appropriate wheel sensor (+) and (-) circuits .• NO-Go to step 4.

NO - Replace the wheel sensor..

(cont'd)

BACK

19-53

ABS Components DTC Troubleshooting (cont'd) 4. Check for continuity between the appropriate wheel sensor (+) circuit terminal and other wheel sensor (+) circuit terminals (see table). DTC 12 14 16 18

Appropriate Terminal A9: FRW(+) A7: FLW(+) A19: RRW(+) A17: RLW{+)

Othere Terminal A7: FLW(+) A9: FRW{+) A9: FRW{+) A9: FRW (+)

A19: RRW{+) A19: RRW(+) A7: FLW(+) A7: FLW(+)

OTC 21, 22, 23, 24: Pulser 1. Clear the DTC. 2. Test-drive the vehicle at 19 mph (30 km/h) or more.

A17: RLW{+) A17: RLW(+) A17: RLW{+) A19: RRW(+)

Does the ABS indicator come on and are OTCs 21, 22, 23, or 24 indicated? YES - Go to step 3. NO - The system is OK at this time .• 3. Check the appropriate pulser gear for a chipped tooth (see table).

Is there continuity? YES - Repair short to wire between the appropriate wheel sensor and the other wheel sensor.• NO- Clear the DTC, and test-drive the vehicle. If the ABS indicator comes on and the same DTC is indicated, replace the ABS control unit.•

DTC 21 22 23 24

Appropriate Pulser Right-front Left-front Right-rear Left-rear

Is the pulser OK? YES-Check for loose ABS control unit connectors. If necessary, substitute a known-good ABS control unit, and recheck. • NO - Replace the driveshaft or the hub unit. (Chipped pulser gear).

19-54

BACK

~ ~ DTC 31, 32, 33, 34, 35, 36, 37, 38: Solenoid

5. Connect the modulator unit connector.

1. Verify the DTC.

6. Check for continuity between the appropriate A8S control unit connector 8 (12P) solenoid circuit terminal and body ground (see table).

Is Dre 54 indicated?

DTC 31: FR-IN 32: FR-OUT 33: FL-IN 34: FL-OUT 35: RR-IN 36: RR-OUT 37: RL-IN 38: RL-OUT

YES - Do the appropriate troubleshooting for DTC54.• NO-Go to step 2. 2. Turn the ignition switch OFF. 3. Disconnect the modulator unit connector and the A8S control unit connector 8 (12P). 4. Check for continuity between the appropriate A8S control unit connector 8 (12P) solenoid circuit terminal and body ground (see table).

31: 32: 33: 34: 35: 36: 37: 38:

DTC FR-IN FR-OUT FL-IN FL-OUT RR-IN RR-OUT RL-IN RL-OUT

ABS CONTROL UNIT CONNECTOR B (12PI FL-OUT IYEL/BLUI RL-OUT IYEL/GRNI RR-OUT IYEL/WHTI

Appropriate Terminal 811 86 89 84 88 83 810 85

= ABS CONTROL UNIT CONNECTOR B 112PI FL-OUT IYEL/BLUI RL-OUT IYEL/GRNI RR-OUT IYEL/WHTI

ApproP!iate Terminal 811 86 89 84 88 83 810 85

FR-OUT IYEL/BLKI


=


FR-OUT IYEL/BLKI

YES- Replace the modulator unit.• NO- Go to step 7. 7. Disconnect the modulator unit connector.


=

Is there continuity? YES - Repair short to body ground in the appropriate solenoid circuit wire between the A8S control and the modulator unit.• NO - Go to step 5.

(cont'd)

BACK

19-55

ABS Components DTC Troubleshooting (cont'd) 8. Connect the appropriate modulator unit connector solenoid circuit terminal to body ground with a jumper wire (see table).

DTC

9. Check for continuity between the appropriate A8S control unit connector 8 (12P) solenoid circuit terminal and body ground (see table).

Appropriate Terminal

31: FR-IN 32: FR-OUT 33: FL-IN 34: FL-OUT 35: RR-IN 36: RR-OUT 37: RL-IN 38: RL-OUT

DTC

No.1 No.5 No.4 No.8 No.3 No.7 No.2 No.6

31: FR-IN 32: FR-OUT 33: FL-IN 34: FL-OUT 35: RR-IN 36: RR-OUT 37: RL-IN 38: RL-OUT

MODULATOR UNIT CONNECTOR RR-IN (RED/WHT)

RL-IN (RED/GRN)

FL-IN (RED/BLU)

FR-IN (RED/BLK)

,

FL-OUT (VEL/BLU)

=

Appropriate Terminal 811 86 89 84 88 83 810 85

ABS CONTROL UNIT CONNECTOR B (12P) FL·OUT (VEL/BLU) RL-OUT (VEL/GRN) RR·OUT (YEL/WHT)

FR-OUT (YEL/BLK)

'1

4 312 1 FR-OUT (VEL/BLK) 8 716 5 10

RR-OUT (VEL/WHT)

IX /J RL-OUT (VEL/GRN)

JUMPER WIRE Terminal side of female terminals


Is there continuity? YES-Go to step 10. NO- Repair open in the appropriate solenoid circuit wire between the A8S control unit and the modulator unit.. 10. Remove the jumper wire from the modulator unit connector. 11. Connect the modulator unit connector.

19-56

BACK

~ ~ 12. Connect the fail-safe relay connector terminal No.2 to body ground with a jumper wire. NOTE: The wire colors of the fail-safe relay connector are WHT/GRN, BRN/BlK, BlK, YELlGRN. FAil-SAFE RELAY CONNECTOR

14. Disconnect the modulator unit connector, and remove the jumper wire from the fail-safe relay connector terminal. 15. Check for continuity between the appropriate A8S control unit connector 8 (12P) terminal and all other solenoid circuit terminals (see table).


DTC 31: 32: 33: 34: 35: 36: 37: 38:

SOlEN~ID (BRN/BlK) ~ JUMPER WIRE

4

3

=

811 B6 B9 B4 88 83 810 B5

FR-IN FR-OUT Fl-IN Fl-OUT RR-IN RR-OUT Rl-IN Rl-OUT

Terminal side of female terminals ABS CONTROL UNIT CONNECTOR B (12PI

13. Check the resistance between the appropriate ABS control unit connector B (12P) terminal and body ground (see table). IN: 8-10 Q (at 20°C, 68°F) OUT: 3 - 5 Q (at 20°C, 68°F)

DTC 31: FR-IN 32: FR-OUT 33: Fl-IN 34: Fl-OUT 35: RR-IN 36: RR-OUT 37: Rl-IN 38: Rl-OUT

8

Appropriate Terminal 7

811 B6 89 84 88 83 B10 B5

9 FL-IN (RED IBLU)

11

10

RL-IN (RED IGLN)

FR-IN (RED IBLK)

12

Is there continuity? YES- Repair the short in the appropriate wires between the A8S control unit and the modulator unit.•

FR-OUT (VEL/BLKI

Q

RR-IN (RED IWHn


ABS CONTROL UNIT CONNECTOR B (12P) FL-OUT (YEL/BWI RL-OUT (VEL/GRNI RR-OUT (YEL/WHTI

2

5 6 4 3 RR-OUT FL-OUT RL-OUT FR-OUT (YEL (YEL (YEL (YEL IBLU) IGLN) IBLK) IWHT)

NO- Go to step 16.

Q


=

Is there resistance OK? YES-Go to step 14. NO- Replace the modulator unit.• (cont'd)

BACK

19-57

ABS Components DTC Troubleshooting (cont'd) DTC 41, 42, 43, 44: Wheel Lock

16. Connect the modulator unit connector. 17. Check for continuity between the appropriate A8S control unit connector 8 (12P) terminal and all other solenoid circuit terminals (see table). Appropriate Terminal 811 86 89 84 88 83 810 85

DTC 31: FR-IN 32: FR-OUT 33: FL-IN 34: FL-OUT 35: RR-IN 36: RR-OUT 37: RL-IN 38: RL-OUT

1. Check for brake drag.

Do the brakes drag? YES-Repair the brake drag.• NO-Go to step 2. 2. Check the installation of the appropriate wheel sensor (see table). DTC 41 42 43 44

ABS CONTROL UNIT CONNECTOR B (12PI

Appropriate Wheel Sensor Right-front Left-front Right-rear Left-rear

Is it correct? 2

345 6 RR-OUT Fl-OUT RL-OUT FR-OUT (YElIWHTl (YEl/BlUl (YELlGlN) (YELlBlK)

YES-Go to step 3.• NO- Reinstall the wheel sensor correctly.•

8

7

9

10

11

Fl -IN RL -IN FR-IN RR-IN

12

3. Check the modulator using the Honda PGM Tester.

Is kick-back felt in the pedal? YES- The probable cause was the vehicle spun during cornering. If the problem recurs, check for loose connectors, or try a known-good A8S/TCS control unit.•


Is there less than 3 Q ? YES- Replace the modulator unit.• NO-Check for loose A8S control unit connectors. If necessary, substitute a known-good A8S control unit, and recheck.•

19-58

BACK

NO-Check for loose modulator unit connectors. If necessary, replac~ the modulator unit.•

~

~ DTC 52: Motor Stuck OFF

DTC 51: Motor Lock

1. Check the ABS MOTOR (30 A) fuse in the underhood fuse/relay box, and reinstall the fuse if it is OK.

1. Clear the DTC. 2. Test-drive the vehicle at 6 mph (10 km/h) or more.

Is the fuse OK? Does the ABS indicator come on, and is DTC 51 indicated?

YES- Go to step 3.

YES - Replace the modulator unit..

NO- Replace the fuse, and go to step 2.

NO-The system is OK at this time.•

2. Connect the pump motor relay connector terminal No.3 to No.4 with a jumper wire for a moment, and check the fuse.


~ 1

4

+B

(WHT)

3

MOTOR

(WHT/BLU)


Is the fuse blown? YES- Check for a short to body ground in the motor power source circuit.• NO- Go to step 3. 3. Check the ASS MTR CHK (7.5 A) fuse in the passenger's under-dash fuse/relay box, and reinstall the fuse if it is OK.

Is the fuse OK? YES-Go to step 5. NO - Replace the fuse, and go to step 4.

(cont'd)

BACK

19-59

ABS Components DTC Troubleshooting (cont'd) 4. Connect the pump motor relay connector terminal No.3 to No.4 with a jumper wire for a moment, and check the fuse.

9. Measure the voltage between the pump motor connector terminal No.1 and body ground. PUMP MOTOR CONNECTOR

~I !

PUMP MOTOR RELAV CONNECTOR

M. . . .

~

!W"""'"'

1

4

+B

(WHT)

3


MOTOR

(WHT/BLU)

Is there battery voltage? JUMPER WIRE

YES-Gotostep 10.


NO- Repair open in the wire between the underhood ABS relay box and the pump motor.•

Is the fuse blown? YES-Check for a short to body ground in the MCK circuit.•

10. Measure the voltage between the pump motor connector terminal No.1 and No.2. PUMP MOTOR CONNECTOR

NO - Go to step 5. MOTOR GND (BLK)t;joTOR (WHT/BLU)

2 1

5. Check the pump motor relay in the under-hood ABS relay box (see page 22-52).

':i

Is the relay OK? Terminal side of female terminals

YES-Go to step 6. NO- Replace the pump motor relay .•


6. Connect the pump motor relay connector terminal No.3 to No.4 with a jumper wire for a moment.

YES-Replace the modulator unit.• NO-Repair open in the wire between the pump motor and body ground (G303) .•

Does the pump motor operate? YES - Go to step 11.

11. Disconnect the pump motor connector B (12).

NO-Goto step 7.

12. Connect the pump motor relay connector terminal No.1 to No.4 with a jumper wire.

7. Disconnectthe pump motor connector. 8. Connect the pump motor relay connector terminal No.3 to No.4 with a jumper wire.

PUMP MOTOR RELA V CONNECTOR

JUMPER WIRE

~MR (VEL/RED) 2

1

4

3

+B(WHT)


19-60

BACK

~ ~ 13. Measure the voltage between the ABS control unit connector terminal B12 and body ground.

DTC 53: Motor Stuck ON 1. Check that the pump motor operates with the ignition switch OFF.

ABS CONTROL UNIT CONNECTOR B (12P)

Does the pump motor operate? YES-Replace the pump motor relay. (Pump motor relay stuck ON.). NO-Go to step 2. 2. Remove the ABS MTR CHK (7.5 A) fuse in the passenger's under-dash fuse/relay box.

=

Is the fuse OK?


YES- Remove the fuse, and go to step 3.

Is there battery voltage? NO - Replace the fuse, and recheck .• YES - Go to step 14. 3. Turn the ignition switch ON (II). NO- Repair open in the wire between the underhood ABS relay box and the ABS control unit.• 14. Remove the jumper wire from the pump motor relay connector.

4. Measure the voltage between the passenger's under-dash fuse/relay box 16P connector terminal No.5 and body ground. PASSENGER'S UNDER-DASH FUSE/RELAY BOX 16P CONNECTOR

15. Start the engine. 16. Measure the voltage between the ABS control unit connector terminal B12 and body ground.

MCK(GRN)



Is there approx. 10 V? YES - Go to step 5. Wire side of female terminals

NO- Repair open in the wire between the passenger's under-dash fuse/relay box and the ABS control unit.•

Is there battery voltage? YES - Repair a short to power between the underhood ABS relay box and the ABS control unit.

5. Reinstall the ABS MTR CHK (7.5 A) fuse in the passenger's under-dash fuse/relay box.

NO-If the problem recurs, replace the ABS control unit. (cont'd)

BACK

19-61

ABS Components DTC Troubleshooting (cont'd) 6. Disconnect the pump motor connector. 7. Measure the voltage between terminal No.1 and body ground.

9. Remove the pump motor relay, then connect relay terminals No.4 and No.5 together with a jumper wire. Does the pump motor run?

PUMP MOTOR CONNECTOR

YES-Go to step 10. NO- Replace the pump motor..

crrp

10. Disconnect the ABS control unit connector B (12P).

~MOTOR IWHT/BLUI

11. Check for continuity between terminal B12 and body ground.

=



Is there approx. 10 V? YES-Go to step 8. NO- Repair open in the wire between the underhood ABS relay box and the pump motor.• 8. Measure the voltage between the pump motor connector terminal No.1 and No.2.




YES- Repair short to body ground in the wire between the under-hood ABS relay box and the ABS control unit..

MOTOR GND (BLK[!jMOTOR (WHT/BLUI

2 1

NO -If the problem recurs, replace the ABS control unit.•

':L Terminal side offemale terminals

Is there approx. 10 V? YES-Go to step 9. NO- Repair open in the wire between the pump motor and body ground (G303) .•

19-62

BACK

~ ~ DTC 54: Fail-safe Relay

5. Connect the fail-safe relay connector terminal No.1 to No.2 with a jumper wire.

1. Check the ABS F/S (20 A) fuse in the under-hood fuse/relay box, and reinstall the fuse if it is OK.

FAIL-SAFE RELAY CONNECTOR

Is the fuse OK? +B (WHT/GRNI

YES- Go to step 2. NO - Replace the fuse, and recheck .•

~ SOLENOI~----OO (BRN/BLKI

JUMPER WIRE

2. Reinstall the fuse, and turn the ignition switch ON (II).

Does the fuse blow?


YES-Repair short to body ground in the wire between the fail-safe relay, pump motor relay, and modulator unit.• NO-Go to step 3. 3. Check the fail-safe relay in the under-hood ABS relay box (see page 22-52). The wire colors of failsafe relay connector are WHT/GRN, BRN/BLK, BLK, and YEL/GRN.

6. Disconnect the modulator unit connector. 7. Measure the voltage between terminal No.10 and body ground. MODULATOR UNIT CONNECTOR

Is the relay OK? YES - Leave the fail-safe relay removed, and go to step 4. NO- Replace the fail-safe relay .• 4. Measure the voltage between the fail-safe relay connector terminal No.1 and body ground.




+B(WHT~ YES - Go to step 8.

~~ = Terminal side of female terminals

NO-Repair open in the wire between the fail-safe relay and the modulator unit.• 8. Remove the jumper wire from the fail-safe relay connector.

Is there battery voltage? YES- Go to step 5. NO- Repair open in the wire between the underhood fuse/relay box and the fail-safe relay .• (cont'd)

BACK

19-63

ABS Components DTC Troubleshooting (cont'd) 9. Measure the voltage between the modulator unit connector terminal No. 10 and body ground.

13. Check for continuity between the ABS control unit connector terminal A21 and body ground.

MODULATOR UNIT CONNECTOR

ABS CONTROL UNIT CONNECTOR A (22P)

-=

-= Terminal side of female terminals




YES- Repair short to power in the wire between the fail-safe relay, modulator unit, and under-hood ABS relay box .•

YES- Repair short to body ground in the wire between the ABS control unit and the fail-safe relay .•

NO-Go to step 10.

NO-Go to step 14.

10. Disconnect the ABS control unit connector A (22P).

14. Check for continuity between the fail-safe relay connector terminal No.3 and body ground.

11. Turn the ignition switch ON (II). 12. Measure the voltage between terminal A21 and body ground.



-= Terminal side of female terminals

-= Is there continuity? Wire side of female terminals



NO-Repair open in the wire between the fail-safe relay and body ground .•

YES- Repair short to power in the wire between the ABS control unit and the fail-safe relay .• NO-Go to step 13.

19-64

BACK

~ EI) 15. Connectthe fail-safe relay connectorterminals No. 3 and No.4 with a jumper wire.

DTC 61, 62: Ignition Voltage 1. Clear the DTC.


2. Test-drive the vehicle at 6 mph (10 km/h) or more.

Does the ABS indicator come on?

~ 2

4

FSR IYEL/GRN)

YES - Go to step 3.

3

GND IBLK)

NO- The system is OK at this time.•

JUMPER WIRE

3. Verify the DTC.

Is DTC 61 or 62 indicated? Wire side of female terminals

YES-Check the charging system .• 16. Check for continuity between the ABS control unit connector terminal A21 and body ground.

NO- Do the appropriate troubleshooting for the DTC . •

ABS CONTROL UNIT CONNECTOR A I22P)


Is there continuity? YES-If the problem recurs, replace the ABS control unit.• NO- Repair open in the wire between the ABS control unit and the fail-safe relay .•

BACK

19-65

ABS Components DTC Troubleshooting (cont'd) DTC 71: Different Diameter Tire

DTC 81: Central Processing Unit (CPU) Diagnosis, and ROM/RAM Diagnosis

1. Clearthe DTC. 1. Clear the DTC. 2. Test-drive the vehicle. 2. Test-drive the vehicle.

Does the ABS indicator come on, and is DTC 71 indicated?

Does the ABS indicator come on, and is DTC 81 indicated?

YES- Make sure all four tires are the specified size.•

YES - Replace the ABS control unit.•

NO-Intermittent failure; the vehicle is OK at this time .•

NO-Intermittent failure; the vehicle is OK at this time.•

19-66

BACK

~ ~ ABS Indicator Circuit Troubleshooting 1. Turn the ignition switch ON (II), and watch the ABS indicator.

9. Check for continuity between the gauge assembly 16P connector terminal No. 10 and body ground.

Does the ABS indicator come on? GAUGE ASSEMBLY 16P CONNECTOR

YES -If the ABS indicator comes on and goes off, it's OK. If the ABS indicator stays on, go to step 13. NO-Goto step 2. 2. Turn the ignition switch OFF then ON (II) again.

Does the brake system indicator come on? YES-Goto step 3. Wire side of female terminals

NO- Repair open in the brake system indicator circuit.• • Blown BACK-UP LIGHT (7.5 A) fuse. • Open in the wire between the BACK-UP LIGHT (7.5 A) fuse and the gauge assembly. • Open circuit inside the fuse box.

Is there continuity? YES- Repair short to body ground in the wire between the gauge assembly and the ABS control unit.•

3. Turn the ignition switch OFF. NO- Go to step 10. 4. Disconnect the ABS control unit connector B (12P). 10. Connect the gauge assembly 16P connector. 5. Turn the ignition switch ON (II). 11. Connect the gauge assembly 22P connector terminal No. 16 to body ground with a jumper wire.

Does the ABS indicator come on? YES - Check for loose ABS control unit connectors. If necessary, substitute a known-good ABS control unit, and recheck. •


GAUGE ASSEMBLY 22P CONNECTOR

NO - Go to step 6. 6. Check the ABS indicator bulb in the gauge assembly.

Is the bulb OK? JUMPER WIRE

YES-Go to step 7.

GND (BlK)

-

NO- Replace the ABS indicator bulb .• Wire side of female terminals



8. Disconnect the gauge assembly 16P connector.

YES-Repair open in the wire between the gauge assembly and body ground (G501) .• NO-Replace the printed circuit board in the gauge assembly.• (cont'd)

BACK

19-67

ABS Components ABS Indicator Circuit Troubleshooting (cont'd) 13. Check the POWER MIRROR (7.5 A) fuse in the under-dash driver's fuse/relay box, and reinstall the fuse if it is OK.

17. Connect the ABS control unit connector terminal B1 to body ground with a jumper wire. ABS CONTROL UNIT CONNECTOR B (12PI

Is the fuse OK? YES-Go to step 14. NO - Replace the fuse, and recheck .•

WALP IBLU/WHTI JUMPER WIRE

14. Connect the ABS control unit connector terminal A 1 to body ground with a jumper wire. ABS CONTROL UNIT CONNECTOR A (22PI

=

GND3(BLKI

Wire side of female terminals JUMPER WIRE

Does the ABS indicator go off? YES - Check for loose ABS control unit connectors. If necessary, substitute a known-good ABS control unit, and recheck. •


NO-Go to step 18. 15. Turn the ignition switch ON (II). 18. Connect the gauge assembly 16P connector terminal No. 10 to body ground with a jumper wire.

Does the ABS indicator go off? YES-Repair open in the wire between the ABS control unit and body ground (G304) .• NO-Go to step 16.

GAUGE ASSEMBL V 16P CONNECTOR

16. Measure the voltage between the ABS control unit connector terminal A 11 and body ground. ABS CONTROL UNIT CONNECTOR A (22PI JUMPER WIRE

WALP IBLU/WHTI

IG2 (YEL/BLKI


Does the ABS indicator go off? Wire side of female terminals

YES-Repair open in the wire between the gauge assembly and the ABS control unit.•


NO-Replace the printed circuit board in the gauge assembly.•

YES- Go to step 17. NO- Repair open in the wire between the CLOCK (7.5 A) fuse and the ABS control unit.•

19-68

BACK

~

~ Modulator Unit Removal and Installation NOTE: • Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. • Take care not to damage or deform the brake lines during removal and installation. • To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material.

Removal 1. Disconnect the modulator unit connector (C) and the pump motor connector (B). 2. Disconnect the brake lines, then remove the modulator unit (A).

Installation 1. Install the modulator unit, then connect the brake lines. Tighten the flare nuts to 15 N·m (1.5 kgf·m, 11 Ibf·ft). 2. Connect the modulator unit connector and the pump motor connector. 3. Bleed the brake system, starting with the front wheels. 4. Start the engine, and check that the ABS indicator goes off. 5. Test-drive the vehicle, and check that the ABS indicator does not come on.

From right-front

6mmNUT 9.8 N·m (1.0 kgf.m, 7.2 Ibf·ft)

6mmBOLT 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft)

BACK

19-69

ABS Components ABS Control Unit Replacement

Wheel Sensor Inspection

1. Remove the driver's kick panel.

1. Inspect the front and rear pulsers for chipped or damaged teeth.

2. Disconnect the ABS control unit connectors (A). 2. Measure the air gap between the wheel sensor and pulser all the way around while rotating the pulser. Remove the rear brake disc to measure the gap on the rear wheel sensor. If the gap exceeds 1.0 mm (0.04 in), check for a bent suspension arm. Standard: 0.4-1.0 mm (0.02-0.04 in.) Front

====~

====l A

t

B

3. Remove the ABS control unit (B). 4. Install the ABS control unit in the reverse order of removal.

Rear

t

19-70

BACK

eplacement VVheelSensorR ----------------Install the se Front

________

• .• , ~::~.m:

nsors carefull y to avoid twO . Ires. Istmg the w·

6mmBOLT 9.8N·m (10k /.

gf~. 72''''''

WHEEL SENSOR

Rear

/l WHEEL SENSOR

BACK

19-71

BACK

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If body maintenance is required) The Accord Sedan/Coupe (L4) SRS includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensioners ('01-02 models) in the front seat belt retractors, and side airbags ('00-02 models) in the front seat-backs. Information necessary to safely service the SRS is included in this Service Manual. Items marked with an asterisk ( * ) on the contents page include or are located near SRS components. Servicing, disassembling, or replacing these items will require special precautions and tools, and should be done only by an authorized Honda dealer.

• To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all SRS service work must be performed by an authorized Honda dealer. • Improper service procedures, including incorrect removal and installation ofthe SRS, could lead to personal injury caused by unintentional deployment ofthe airbags and side airbags. • Do not bump the SRS unit. Otherwise, the system may fail in a collision, or the airbags may deploy when the ignition switch is ON (II). • SRS electrical connectors are identified by yellow color coding. Related components are located in the steering column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats, and around the floor. Do not use electrical test equipment on these circuits.

BACK

Body Door Component Location Index-Coupe ............... Component Location Index -Sedan Front Door ...................................... Component Location Index -Sedan Rear Door ....................................... Front Door Panel Removal/ Installation-Coupe .....•................................ Front Door Panel Removal/ Installation-Sedan ....................................... Front Door Outer Handle Replacement ........ Front Door Latch Replacement ..................... Front Door Glass and Regulator Replacement-Coupe ................................... Front Door Glass and Regulator Replacement-Sedan ....•.............................. Rear Door Panel Removal/Installation ......... Rear Door Outer Handle Replacement ......... Rear Door Latch Replacement ...................... Rear Door Glass, Quarter Glass and Regulator Replacement .............................. Sticker Replacement ...................................... Rear Door Hook Pin and Catcher Replacement ................................. Front Door Glass Adjustment-Coupe ........... Front and Rear Door Glass Adjustment -Sedan .................•........................•............... Door Position Adjustment ............................. Door Striker Adjustment ................................

Mirrors

Dashboard 20-2 20-4 20-6 20-8 20-9 20-11 20-14 20-14 20-16 20-17 20-19 20-21 20-22 20-25 20-26 20-26 20-28 20-29 20-30

Glass Component Location Index-Coupe ............... Component Location Index-Sedan ............... Windshield Replacement ............................... Rear Window Replacement ........................... Quarter Glass Replacement -Coupe ............... M~~~e;::f'acement ......................................

20-38 20-39 20-40 20-49 20-55 20-59

Component Location Index ........................... Symptom Troubleshooting Index ................. Glass Height Adjustment ............................... Glass Replacement ........................................ Drain Channel Replacement .......................... Sunshade Replacement ................................. Motor Replacement ....................................... Frame and Drain Tube Replacement ............ Drain Channel Slider and Cable Assembly Replacement ............................. Position Switch Adjustment .......................... Closing Force and Opening Drag Check ......

20-60 20-61 20-62 20-62 20-63 20-64 20-65 20-66 20-68 20-70 20-71

Interior Trim

Console

20-84 20-84 20-85 20-86 20-87 20-88 20-89 20-89 20-90 20-94

Seats

Component Location Index-Coupe ............... 20-31 Component Location Index-Sedan ............... 20-32 Mirror Holder Replacement-Coupe .............. 20-33 Manual Mirror Replacement-Sedan ...............20-34 Power Mirror Replacement ....•...................... 20-35 Mirror Holder Replacement-Sedan .............. 20-36 Rearview Mirror Replacement ...................... 20-37

Component Location Index-Coupe ............... Component Location Index-Sedan ............... Trim Removal/Installation -Door Area -Coupe ...................................... Trim Removal/Installation -Door Area -Sedan ...................................... Trim Removal/Installation -Rear Shelf Area -Coupe ............................ Trim Removal/Installation -Rear Shelf Area -Sedan ............................. Trim Removal/Installation-Trunk .................. Headliner Removal and Installation ............. *Carpet Replacement ......................................

Instrument Panel Removal/ Installation ................................................... *Driver's Dashboard Lower Cover Removal/Installation ................................... Passenger's Dashboard Lower Cover Removal/Installation .................................. Center Panel Removal/ Installation ............................•...................... *Glove Box Removal/Installation ................... Driver's Side Vent Removal/ Installation ................................................... Passenger's Side Vent Removal and Installation ................................................... Side Defogger Vent Trim Removal and Installation ........................................... *Dashboard Removal/lnstallation .................. Steering Hanger Beam Replacement ...............................................

20-72 20-73 20-74 20-75 20-76 20-77 20-78 20-79 20-81

Center Console Removal/Installation ........... 20-83

Component Location Index-Coupe ............... Component Location Index-Sedan ............•.. *Front Seat Removal/Installation ................... Front Seat Disassembly/Reassembly -Manual without Side Airbag-Coupe ........ *Front Seat Disassembly/Reassembly -Manual with Side Airbag-Coupe .............. Front Seat Disassembly/Reassembly -Manual without Side Airbag-Sedan ........ *Front Seat Disassembly/Reassembly -Manual with Side Airbag-Sedan .............. Front Seat Disassembly/Reassembly -Manual Height Adjustable without Side Airbag-Coupe ....................... Front Seat Disassembly/Reassembly -Manual Height Adjustable with Side Airbag-Coupe ............................. Front Seat Disassembly/Reassembly -Manual Height Adjustable without Side Airbag-Sedan ....................... *Front Seat Disassembly/Reassembly -Manual Height Adjustable with Side Airbag-Sedan ............................. Front Seat Disassembly/Reassembly -2-Way Powerwithout Side Airbag ........... *Front Seat Disassembly/Reassembly -2-Way Powerwith Side Airbag ................. *Front Seat Disassembly/Reassembly-8-Way power without Side Airbag-Coupe ........... *Front Seat Disassembly/Reassembly-8-Way power with Side Airbag-Sedan ................. *Front Seat Disassembly/Reassembly -8-Way power -Sedan ................................. Front Seat Wiring Harness and Cable Installation-Coupe ............................ Front Seat Wiring Harness Installation-Sedan ....................................... Front Seat Torsion Bar Replacement Manual Height Adjustable ......................... Front Seat Linkage Disassembly/ Reassembly 2-Way Power ......................... Front Seat Linkage Disassembly/ Reassembly-8-Way-Power ........................ *Front Seat Cover Replacement ..................... Rear Seat Removal/Installation-Coupe ........ Rear Seat Removal/Installation-Sedan ........ Rear Seat Arm rest/Tru nk Pass -through Cover Replacement-Sedan ........................ Trunk Pass-through Cover Key Cylinder Replacement ......................... Rear Seat-back Latch and Lock Cylinder Replacement-Coupe ...................................

20-97 20-98 20-99 20-102 20-103 20-104 20-105 20-106 20-107 20-108 20-109 20-110 20-111 20-112 20-113 20-114 20-115 20-118 20-120 20-121 20-122 20-123 20-128 20-129 20-130 20-131 20-132

Rear Seat-back Latch Replacement-Sedan ................................... Rear Seat-back Lock CylinderReplacement-Sedan ..................... Rear Seat Cover Replacement-Coupe .......... Rear Seat Cover Replacement-Sedan .......... Rear Seat Side Bolster Cover Replacement ............................................... Rear Seat Cushion Cover Replacement-Coupe ................................... Rear Seat Cushion Cover Replacement-Sedan ...................................

20-133 20-133 20-134 20-135 20-137 20-138 20-139

Bumpers Front Bumper Removal! Installation-Coupe ...................................... Front Bumper Removal! Installation-Sedan ....................................... Rear Bumper Removal/ Installation-Coupe ...................................... Rear Bumper Removal/ Installation-Sedan ................•......................

20-140 20-142 20-145 20-148

Hood Replacement ..............................•.................... Adjustment ..................................................... Hood Insulator Replacement ......................... Hood Seal Rubber and Hood Molding Replacement ...............................................

20-150 20-151 20-152 20-153

Trunk Lid Replacement ............. ..........•........ .............. ..... Adjustment .....................•............................... Trunk Lid Torsion Bar Replacement.. ............. Trunk Lid Dynamic Damper Replacement-Sedan ................................... Trunk Lid Weatherstrip Replacement ............

20-154 20-156 20-157 20-158 20-158

Exterior Trim Emblem Replacement-Coupe ....................... Emblem Replacement-Sedan ....................... Front Grille Replacement-Coupe .........•........ Roof Drip Molding Replacement -Coupe .•... Roof Drip and Rear Pillar Moldings Replacement-Sedan ................................... Roof Moldings Replacement ............•............ Door Moldings Replacement-Sedan ............ Side Sill Panel Replacement-Coupe ............. Side Sill Panel Replacement-Sedan .............

20-159 20-160 20-160 20-161 20-162 20-163 20-164 20-165 20-166

Fenderwell Inner Fender Replacement ...•............•........... 20-167 Fuel Pipe Protector Replacement .................. 20-167 Rear Air Outlet Replacement .................•...•... 20-168

Openers Component Location Index ............•.............. Hood Opener Cable Replacement ................ Trunk Lid Opener/Fuel Lid Opener Cable Replacement-Coupe ....................•... Trunk Lid Opener/Fuel Lid Opener Cable Replacement-Sedan ............•....•...... Hood Release Handle Replacement ............. Hood Latch Replacement ...........•...........•...... Trunk Lid Opener/Fuel Fill Door Opener Replacement .................................. Fuel Fill Door Latch Replacement ................. Trunk Lid Latch Replacement ..............•......... Trunk Lid Lock Cylinder Replacement ..........

20-169 20-170 20-171 20-173 20-175 20-175 20-176 20-177 20-178 20-179

Frame Sub-frame Replacement ................................ 20-180 *Frame Repair Chart ........................................ 20-182

Doors Component Location Index - Coupe

SASH TRIM DOOR WEATHERSTRIP

,/'

\

DOOR GLASS OUTER WEATHERSTRIP

I

S-DElENT ROD

LOWER WEATHERSTRIP

~1

I

SECURITY INDICATOR (Driver's) PULL POCKET

_______

DOOR GLASS INNER WEATHERSTRIP

tP

c;;> COURTESY \I LIGHT LENS

bo<®

~ .. ~

/ SWITCH PANEL POWER WINDOW SWITCH

~

llID

~~ "'-PULL POCKET BRACKET

/~::~ ARMREST

~~~ ~~HINGE

Passenger's: DOOR PANEL Removal/Installation, page 20-8

POWER MIRROR SWITCH

SWITCH PANEL

~

BACK

"Hi>

m

4

4

20-2

I

POWER /WINDOW SWITCH

GLASS Replacement, page 20-14 Adjustment, page 20-26 LOWER RUN CHANNEL ('99-02 modelsl

GLASS RUN CHANNEL ('98 model)

CENTER LOWER CHANNEL

/

~ POWER WINDOW MOTOR

\

~FRONT

LOWER CHANNEL

REGULATOR Replacement, page 20-14

~OUTER HANDLE

CYLINDER SWITCH

~~~( ~ ~ a ~Doo /

~NDER

/

IA/

G

.1

~/

~ '\'111(}

'*:: \

~

RETAINER CLIP

~

INNER HANDLE

ROD

~

o.~\ ~ ~,

LATCH PROTECTOR

POWER DOOR LOCK ACTUATOR

INNER HANDLE

BACK

dJ

'" POWER DOOR LOCK SWITCH

20-3

Doors Component Location Index - Sedan Front Door

FRONT DOOR UPPER SEAL FRONT DOOR SASH INNER TRIM ('99-02 models)

/

FRONT DOOR WINDOW OUTER TRIM ('99-02 models)

FRONT DOOR WINDOW INNER TRIM ('99-02 models)

DOOR WEATHERSTRIP

F"ONTDOOR~

DOOR GLASS OUTER WEATHERSTRIP

/ ~"""'h=""-

END INNER TRIM ('99-02 models)

PLASTIC COVER

~ ~(jl€§l~

~::--HINGE Ilill

LOWER WEATHERSTRIP

DOOR GLASS INNER WEATHERSTRIP /.

t"~

'--.-~ ~ '--.

.

~ ~

"---~'

_~

P;n!----PULL POCKET BRACKET

~

if ~

~

_____

~~~

.~

______ CENTER STIFFENER (Power window models)

@f

Passenger's:

---~ /PULL POCKET

i

TRIM

~

~

~

/?

~J

/ffS PULL POCKET (Manual window model)

20-4

I:;§!J £ ~LL POCKET

POWER WINDOW SWITCH FRONT DOOR PANEL Removal/Installation, page 20-9

BACK

CENTER LOWER GLASS RUN CHANNEL

GLASS Replacement. page 20-16 Adjustment, page 20-28 GLASS RUN CHANNEL

CENTER LOWER CHANNEL

~

....

~ POWER @j\ /WINDOW MOTOR

/

~~~

\ FRONT LOWER

~CHANNEL

REGULATOR Replacement, page 20-16

~~~

LOCK CYLINDER

~

REGULATOR HANDLE (Manual window model)

OUTER HANDLE Replacement, page 20-11 RETAINER CLIP ROD

~ ',Y J.~;-' """© 51f1Cl

~

~~Jl'j0 ~")

ROD "\

OUTER HANDLE PROTECTOR

~J<~/(;;"', ~ OIl

~S

LATCH PROTECTOR


"-

~ POWER DOOR LOCK SWITCH (Driver's)

LATCH Replacement, page 20-14

INNER HANDLE

STRIKER Adjustment, page 20-30

BACK

20-5

Doors Component Location Index - Sedan Rear Door

REAR DOOR WINDOW OUTER TRIM ('99-02 models) REAR DOOR UPPER SEAL

DOOR

WEA11iERST"~

REAR DOOR SASH INNER TRIM ('99-02 models)

(/J.~

REAR DOOR WINDOW INNER TRIM ('99-02 models)

REAR DOOR WINDOW END INNER TRIM ('99-02 models)

CHILD LOCK CAP ~

~~ CATCH Replacement, page 20-26

~

c:J'

REAR DOOR SASH END INNER TRIM ('99-02 models) -HINGE

S~_--DETENT

~~

HINGE

@~

LOWER WEATHERSTRIP

ROD

LOCK KNOB COVER

DOOR HOOK PIN Replacement, page 20-26

~ PULL POCKET TRIM

~

~~~

~LLPOCKET

PULL POCKET BRACKET

i g

PULL POCKET (Manual window model) POWER WINDOW SWITCH

20-6

BACK

QUARTER GLASS Replacement, page 20-22 GLASS Replacement, page 20-22 Adjustment, page 20-28

GLASS RUN CHANNEL

/ FRONT LOWER GLASS RUN CHANNEL

~

STICKER ('99-02 Replacement, page 20-25

mOd~) ~

/

FRONT LOWER CHANNEL

~E~WIN::; \\\\\1 ~DOW ~

COLLAR

~ _

MOTOR

REGULATOR HANDLE (Manual window model)

OUTER HANDLE Replacement, page 20-19

/

a

I(W

REGULATOR Replacement, page 20-22 ...,------ROD PROTECTOR

/~~-

G o

STRIKER Adjustment, page 20-30

e)/INNER HANDLE ROD

G

OG ~J

LATCH Replacement, page 20-21

l

LOCK KNOB

~ ~~

~~/

LATCH PROTECTOR

~~

1


BACK

G>"

~

LOCK CRANK

\

INNER HANDLE

20-7

Doors Door Panel Removal/Installation - Coupe Special Tool Required Trim Pad Remover, Snap-on A177A, or equivalent, commercially available. 1. Remove the mirror mount cover (see step 2 on page 20-35). Take care notto scratch the door panel. 2. Remove the inner handle (A). Take care not to scratch the door panel.

3. Remove the screw, and release the clips (A, B) that hold the door panel (C) with a commercially available trim pad remover (D), then remove the door panel by pulling it upward. Disconnect the power window switch connectors (E), and the power mirror switch connector (F) (driver's side), security indicator connector (G) (driver's side for some models), and courtesy light bulb socket (H). Remove the door panel with as little bending as possible to avoid creasing or breaking it.

- 1 Pry out the cap (B), and remove the screw. - 2 Pull the inner handle forward and out half-way. - 3 Disconnect the inner handle rod (C) and power door lock switch connector (D).

L£195mmI3.74in.J 12mm 10.47 in.1

Fastener Location ~ : Screw, 1

~

D B 1mm 10.04 in.1

~

1 = t=c:-~~ I.. .1 - - - -.....

r

45mm 11.77 in.J

Fastener Locations .. : Screw, 1

A [> : Clip, 10

B [>: Clip, 1

G

A

C

H

E

4. Install the door panel in the reverse order of removal; make sure the connectors and the courtesy light bulb socket are plugged in properly, and the inner handle rod is connected properly.

20-8

BACK

Front Door Panel Removal/Installation - Sedan Special Tools Required Trim Pad Remover, Snap-on A177A or equivalent, commercially available.

4. Power window models: Remove the pull pocket panel (A). Take care not to scratch the door panel.

1. Remove the mirror mount cover, power mirror (see step 2 on page 20-35), manual mirror (see step 2 on page 20-34). Take care not to scratch the door panel.

- 1 Pry out the cap (8), and remove the screw. - 2 Release the hooks (e), disconnect the power window switch connector (D), and the power mirror switch connector (E), driver's side only. Driver's

2. If applicable, remove the regulator handle (A) by pulling the clip (8) out with a wire hook (e).


c

c

~I c

./

B B

3. Remove the inner handle (A). Take care not to scratch the door panel.

E

- 1 Pry out the cap (8), and remove the screw. - 2 Pull the inner handle forward and out half-way. - 3 Disconnect the inner handle rod (e) and power door lock switch connector (D) (for some models).

D

Passenger's Fastener Location ~

: Screw. 1

~~I


D

B

c c

(cont'd)

BACK

20-9

Doors Front Door Panel Removal/Installation - Sedan (cont'd) 5. Manual window model: Remove the pull pocket (A). Take care not to scratch the door panel. - 1 Pry out the cap (B), and remove the screw. - 2 Lift out the pull pocket. Fastener Location

6. Release the clips (A, B) that hold the door panel (e) with a commercially available trim pad remover (D), then remove the door panel by pulling it upward. Disconnect the security indicator connector (E) (driver's) and courtesy light bulb socket (F). Remove the door panel with as little bending as possible to avoid creasing or breaking it.

~:Screw, 1

L~I3·";··) "I (D.47) •• ) I~ ~

12mm

~I B

ID~;•.)t=~

OF

45mm

(1.77 in.)

Fastener Locations A l>

: Clip, 8

B l> : Clip, 1

~~ C

F

20-10

BACK

Front Door Outer Handle Replacement 7. Install the door panel in the reverse order of removal, and note these items: NOTE: Put on gloves to protect your hands . • Make sure the connectors and the courtesy light bulb socket are plugged in properly, and the rod is connected properly . • If applicable, install the regulator handle so it points forward and up at a 45 degree angle with the glass fully closed.

\

1. Raise the glass fully. 2. Remove these items: • Mirror mount cover, power mirror (see step 2 on page 20-35), manual mirror (see step 2 on page 20-34) • Door panel - Coupe (see page 20-8) - Sedan (see page 20-9) • Plastic cover, as necessary - Coupe (see page 20-2) - Sedan (see page 20-4)

45"

\

\

3. Remove the bolt, then remove the center lower channel (A) with center lower glass run channel (B) by pulling it downward.

\

-----t--I

Fastener Location

Forward ~

~ : Bolt, 1

•

SX1.0mm 8N·m IO.8kgf·m, Slbf·ftl

A

_ _-8

(cont'd)

BACK

20-11

Doors Front Door Outer Handle Replacement (cont'd) 4. Disconnect the cylinder rod (A). Release the retainer clip (8), then remove the lock cylinder (C).

6. Disconnect the cylinder switch connector (A), and detach the harness clips (8).

0/ B

5. Remove the screw, then separate the lock cylinder (A) and cylinder switch (8). Fastener Location ~:

Screw, 1

7. Remove the hole seal (A), and remove the bolts securing the outer handle protector (8) and outer handle (C). Fastener Locations ~ : Bolt, 2

6x 1.0mm 9.8N·m (1.0kgf.m,

7.2Ibf·ft)

20-12

BACK

8. Remove the outer handle protector (A) from the outer handle (B) by releasing the hook (C).

10. Pull out the outer handle (A). Pry the outer handle rod (B) out of its joint (C) using diagonal cutters (D). NOTE: o To ease reassembly, note the distance (E) ofthe outer handle rod on the joint before disconnecting it. o Take care not to bend the outer handle rod. o Use a shop towel (F) to protect the opening in the door.

9. Detach the harness clip (D) from the outer handle protector, then remove the outer handle protector and cylinder switch (E) from the door.

F

11. Replace the bushing (G) on the outer handle. 12. Install the handle in the reverse order of removal, and note these items: o

o

o o

o

BACK

Make sure the cylinder switch harness is routed properly. Make sure the connector is plugged in properly, and each rod is connected securely. Make sure the door locks and opens properly. When installing the lock cylinder, leave the outer door handle bolts loose so the inner protector does not interfere with the lock cylinder. Install the lock cylinder retaining clip on the handle, then install the lock cylinder. Be sure the clip is fully seated in the slot on the lock cylinder.

20-13

Doors Front Door Latch Replacement

Door Glass and Regulator Replacement - Coupe

NOTE: Put on gloves to protect your hands. NOTE: Put on gloves to protect your hands.

1. Raise the glass fully.

1. Remove these items:

2. Remove these items: • Mirror mount cover, power mirror (see page 2035), manual mirror (see page 20-34) • Door panel - Coupe (see page 20-8) - Sedan (see page 20-9) • Plastic cover, as necessary • Outer handle (see page 20-11) 3. Detach the harness clip (A) and inner handle rod (B), and disconnect the actuator connectors (C).

• Mirror mount cover (see page 20-35) • Door panel (see page 20-8) • Plastic cover (see page 20-2) 2. Carefully lower the glass until you can see the bolts, then loosen them. Slide the guide (A) to the rear, then remove the glass from the guide, and lift it out through the window slot. Take care not to drop the glass inside the door.

Fastener Locations

Fastener Locations ~

~ : Screw, 3

: Bolt, 2

(@)-

6J

6x 1.0mm ~)))))))))))) 6 N·m (0.6 kgf·m, 4Ibf·ft)

6x 1.0 mm 9.8N·m (1.0 kgf.m, 7.2Ibf·ft)

F

4. Remove the screws, then remove the latch (D) through the hole in the door. Take care not to bend the outer handle rod (E), cylinder rod (F), lock rod (G) and inner handle rod (B). 5. Install the latch in the reverse order of removal, and note these items: • Make sure the actuator connectors are plugged in properly, and each rod is connected securely. • Make sure the door locks and opens properly.

20-14

BACK

A

3. Disconnect and detach the connector (A) and harness clip (8) from the door. Scribe a line around the rear roller guide bolt (C) to show the original adjustment. Remove the bolts (C, D) and loosen the bolts (E), then remove the regulator (F) through the hole in the door.

5. Using a Torx T20 bit, remove the screws, then separate the power window motor and regulator (8).

Fastener Locations ~ : Screw, 3

_@)mDDJ

Fastener Locations C, D ~: Bolt, 4

E ~:Bolt,2 6x1.0mm 8N·m

IO.8kgf·m, 6Ibf·ft)

J

~A F

6. Grease the moving portions of the regulator (A) indicated by the arrows.

B

4. Scribe a line (A) across the regulator (8) and sector gear (C).

7. Install the glass and regulator in the reverse order of removal, and note these items: • Roll the glass up and down to see if it moves freely without binding. • Make sure that there is no clearance between the glass and glass run channel when the glass is closed. • Adjust the position of the glass as necessary.

BACK

20-15

Doors Front Door Glass and Regulator Replacement - Sedan 1. Remove these items: • Mirror mount cover, power mirror (see page 2035), manual mirror (see page 20-34) • Door panel (see page 20-9)

5. Disconnect and detach the connector (A) and harness clip (B) from the door (power window models). Remove the bolts (C, D) and loosen the bolts (E), then remove the regulator (F) through the hole in the door .

2. Remove the screws securing the pull pocket bracket (A). On power window models, remove the nut securing the center stiffener (B). Fastener Locations ~:Screw,2

Power window models: Fastener Locations

c ~ : Bolt, 3

E ~ : Bolt, 3

~ 'j,

. : Nut, 1

~ :N~mm ~

D ~ : Bolt, 1

~

~

6x1.0mm 8N·m (0.8 kgf·m, 6Ibf·ft)

(0.8 kgf.m, 6Ibf·ft)

A

\

B

3. Remove the plastic cover (see page 20-4). 4. Carefully raise the glass until you can see the bolts, then remove them. Carefully pull the glass out through the window slot. Take care not to drop the glass inside the door. Fastener Locations ~ : Bolt, 2

6x1.0mm 9.8N·m (1.0 kgf.m, 7.2Ibf·ft)

20-16

Manual window models: Fastener Locations

:

c~ Bolt, 3

E ~:Bolt,4 6x 1.0 mm 8N·m (0.8kgf·m, 6Ibf·ft)

-j

BACK

Rear Door Panel Removall Installation 6. Grease all the sliding surfaces ofthe regulator (A) where shown.

Special Tools Required Trim Pad Remover, Snap-on A177A or equivalent, commercially available. 1. If applicable, remove the regulator handle (A) by pulling the clip (B) out with a wire hook (C).

7. Install the glass and regulator in the reverse order of removal, and note these items:

2. Remove the inner handle (A). Take care not to scratch the door panel.

• Roll the glass up and down to see if it moves freely without binding. • Make sure that there is no clearance between the glass and glass run channel when the glass is closed. • Adjust the position of the glass as necessary (see page 20-28).

- 1 Pry out the cap (B), and remove the screw. - 2 Move the inner handle forward and half-way out, then disconnect the inner handle rod (C). Fastener Location ~ : Screw, 1

~

B

c

A

c

(cont'd)

BACK

20-17

Doors Rear Door Panel Removal/Installation (cont'd) 3. Power window models: Remove the pull pocket panel (A). Take care not to scratch the door panel. - 1 Pry out the cap (8), and remove the screw. - 2 Release the hooks (C), and disconnect the power window switch connector (D).

5. Release the clips that hold the door panel (A) with a (commercially available) trim pad remover (8), then remove the door panel by pulling it upward, and removing the courtesy light bulb socket (C). Remove the door panel with as little bending as possible to avoid creasing or breaking it.

Fastener Location

12mm {O.47 in.)

1mm (O.04in.) 45mm (1.77 in.) Fastener Locations

C>: Clip, 7 4. Manual window model: Remove the pull pocket (A). Take care not to scratch the door panel.

_
A

- 1 Pry out the cap (8), and remove the screw. - 2 Lift out the pull pocket. Fastener Location

~:Screw, 1

~I B

---

--------

C

\(-rcr~ ~-~t~

\pJ

20-18

BACK

Rear Door Outer Handle Replacement 6. Install the door panel in the reverse order of removal, and note these items: NOTE: Put on gloves to protect your hands . • Make sure the connector and courtesy light bulb socket are plugged in properly. • If applicable, install the regulator handle so it points forward and up at a 45 degree angle with the glass fully closed.

1. Raise the glass fully . 2. Remove these items: • Door panel (see page 20-17) • Plastic cover, as necessary (see page 20-4) 3. Remove the screws, then remove the rod protector (A). Fastener Locations ~ : Screw, 3

A

Forward ~

(cont'd)

BACK

20-19

Doors Rear Door Outer Handle Replacement (cont'd) 4. Remove the screws, then remove the power door lock actuator (A) from the door. Take care not to bend the actuator rod (8).

6. Remove the bolts securing the outer handle (A). Fastener Locations

Fastener Locations ~

~:

Bolt, 2 6x 1.0mm

: Screw, 2

~ 9.8N·m

~

{1.0 kgf.m,. 721bf·ftl

V

A

/

)

5. Remove the screws, then move the latch (A) down. Take care not to bend the inner handle rod (8), lock rod (C) and actuator rod (D).

7. Release the hook (A) while holding the outer handle (8), then remove the outer handle and outer handle protector (C) from the door.

e

I

Fastener Locations ~ : Screw, 3 6x 1.0 mm

,,'\..-------' 11

~6N.m

~ (0.6 kgf·m,

4Ibf·ft)

A

8. Install the handle in the reverse order of removal, and make sure the door locks and opens properly.

20-20

BACK

Rear Door Latch Replacement NOTE: Put on gloves to protect your hands.

4. Disconnect the lock rod (A) from the lock crank (B).

1. Raise the glass fully.

-,-.~


.--

-----

• Door panel (see page 20-17) • Plastic cover, as necessary (see page 20-4) • Outer handle (see page 20-19)

....----.

.

/

/'

3. Disconnect the connectors (A) and actuator rod (B), then remove the power door lock actuator IC).

A

5. Move the latch (A) until you can disconnect each rod, and disconnect the inner handle rod (B), lock rod (C) and actuator rod (D) from the latch.Take care not to bend any of the rods.

A

(cont'd)

BACK

20-21

Doors Rear Door Glass, Quarter Glass, and Regulator Replacement

Rear Door Latch Replacement (cont'd) 6. With a shop towel (A) to protect the outer handle opening, remove the latch (B) through the outer handle opening.

NOTE: Put on gloves to protect your hands. 1. Remove these items:

B

• • • •

~'"

______----,

Door panel (see page 20-17) Pull pocket bracket (see page 20-6) Plastic cover (see page 20-6) Rod protector (see page 20-6)

2. Carefully move the glass (A) until you can see the bolts, then loosen them. Slide the guide (B) to the rear, then remove the glass from the guide, and carefully lower the glass. Take care not to drop the glass inside the door. Fastener Locations

A

~: Bolt, 2

7. Remove the inner handle rod (A) and lock rod (B) from the rod holder (C), and remove the lock crank (D) from the door.

@)m

6x1.0mm 9.8N·m (1.0kgf·m,

7.2Ibf·ft) A

8. Install the latch in the reverse order of removal, and note these items: • Make sure the connectors are plugged in properly, and each rod is connected securely . • Make sure the door locks and opens properly. B

20-22

BACK

3. Remove the bolts (A, B) and collar (C) from the rear channel (0). Pull the sub-seal (E) away as needed, and remove the screw (F). Pull the glass run channel (G) away as needed from the rear channel.

4. Move the rear channel (A) away from the quarter glass (B) and the rear door glass (C), then carefully remove the rear channel out through the window slot.

Fastener Locations A ~ : Bolt, 1

B ~: Bolt, 1

~L._

:~~m~

--IJJJJJ.J.JJJJ.J {O.8 kgf.m, ,..--)))J!J!J!))))))

•

6lbf·ftl

---F ~ : Screw, 1 4xO.8mm

~4N.m

~ {O.4 kgf·m,

3lbf·ftl

A

o

5. Carefully remove the glass (A) out through the window slot. Take care not to drop the glass inside the door.

t

LI

o (cont'd)

BACK

20-23

Doors Rear Door Glass, Quarter Glass, and Regulator Replacement (cont'd) Manual window models

6. Remove the quarter glass (A). Take care not to damage the door molding (B).

Fastener Locations B~:Bolt,2

C~:Bolt,2

6x1.0mm 8N·m (0.8 kgf·m, 6Ibf·ft)

) ~--------_.-//

------------------~/

7. Disconnect and detach the connector (A) from the door (power window models). Remove the bolts (B), and loosen the bolts (C), then remove the regulator (D) through the hole in the door.

8. Scribe a line across the regulator (A) and sector gear (B). Connect a 12 V battery supply to the power window motor, and move the regulator until you can remove the bolts securing the power window motor (C). Fastener Locations ~:Bolt,3

~

Power window models Fastener Locations B ~ : Bolt, 2

6x1.0mm 7N·m (0.7 kgf.m, 5Ibf·ft)

C ~ : Bolt, 2 6x 1.0 mm 8N·m (0.8 kgf·m, 6Ibf·ft)

B

9. Remove the bolts, then separate the regulator (A) and power window motor (C).

20-24

BACK

Sticker Replacement 1. Clean the quarter glass surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the surface.

10. Grease the moving portions of the regulator (A) indicated by the arrows.

2. Apply the sticker where shown.

~~(

~~.<~

~;~'~

~ __ - 0

11. Install the glass and regulator in the reverse order of removal, and note these items: • Roll the glass up and down to see if it moves freely without binding. • Make sure that there is no clearance between the glass and glass run channel when the glass is closed. • Adjust the position of the glass as necessary (see page 20-28)

BACK

:::c=~~~

..

mm /0.6' In.1

20-25

Doors Front Door Glass Adjustment Coupe

Rear Door Hook Pin and Catch Replacement 1. With a Torx T40 bit, remove the door hook pin (A) from the door.

NOTE: Check the weatherstrips and glass run channel for damage or deterioration, and replace them if necessary. 1. Place the vehicle on a firm, level surface.

A

_____

10x1.2Smm 32 N·m (3.3 kgf.m, 24Ibf·ft)

(

2. Remove these items: • • • •

-,'~ C'!

/

'UJ

Mirror mount cover (see page 20-35) Door panel (see page 20-8) Pull pocket bracket (see page 20-2) Plastic cover (see page 20-2)

2. With a Torx T40 bit, remove the bolts, then remove the catch (A) from the body. Fastener Locations ~

: Bolt, 2

0-» A

ax 1.2Smm 22N·m (2.2 kgf.m, 16Ibf.ft)

A..><_/

\(/!/; C 6x 1.0mm a N·m (o.a kgf.m, 6 Ibf·ft)

/ /

3. Install the hook pin and catch in the reverse order of removal, and apply liquid thread lock to the threads of the door hook pin.

4. Loosen the roller guide bolts (C), and adjust the glass (A) so it is parallel with the glass run channel (B).

5. Tighten the roller guide bolts (C).

20-26

BACK

6. Loosen the front lower channel mounting bolts (A) and nut (8), then lower the glass (C).

c

10. Check for water leaks. Run water over the roof and on the sealing area as shown, and note these items: • • • •

B 5xO.8mm 3 N·m {0.3 kgf·m, 2lbf·ft}

Use a 12 mm (1/2 in.) diameter hose (A). Adjust the rate of water flow (8) Do not use a nozzle. Hold the hose about 300 mm (12 in.) away from the door. 12 mm (1/2 In.1

~

"I

1

A

300

J

lr ./1 1 ,

05 m (18 m.1

~--A

mm (12 in. I

A 6x 1.0 mm 8 N·m {0.8 kgf·m, 6 Ibf·ftl

7. Push the front lower channel (D) against the glass (C) while you tighten the mounting bolts (A) and nut (8).

11. Reinstall all removed parts in the reverse order of removal.

8. Check that the glass moves smoothly. 9. Raise the glass fully, and check for gaps. Check that the glass (A) contacts the glass run channel (8) evenly.

BACK

20-27

Doors Front and Rear Door Glass Adjustment - Sedan NOTE: Check the weatherstrips and glass run channel for damage or deterioration, and replace them if necessary.

Rear:

1. Place the vehicle on a firm, level surface. 2. Remove these items: • Mirror mount cover, front door (see page 20-34) • Door panel - Front door (see page 20-9) - Rear door (see page 20-17) • Center stiffener, front door (see page 20-4) • Pull pocket bracket - Front door (see page 20-4) - Rear door (see page 20-6) • Plastic cover - Front door (see page 20-4) - Rear door (see page 20-6) 3. Carefully move the glass (A) until you can see the glass mounting bolts (8), then loosen them.

B

c

4. Push the glass (A) against the center channel (C), then tighten the glass mounting bolts.

Front:

c

A

5. Check that the glass moves smoothly. 6. Raise the glass fully, and check for gaps. Check that the glass (A) contacts the glass run channel (8) evenly.

B

20-28

BACK

Door Position Adjustment 7. Check for water leaks. Run water over the roof and on the sealing area as shown, and note these items: • • • •

Use a 12mm (1/2 in.) diameter hose (A). Adjust the rate of water flow as shown(B). Do not use a nozzle. Hold the hose about 300 mm (12 in.) away from the door.

12

8;' .;1r}·m"8mo' A

NOTE: After installing the door, check for a flush fit with the body, then check for equal gaps between the front, rear, and bottom door edges and the body. Check that the door and body edges are parallel. Before adjusting, replace the mounting bolts. 1. Place the vehicle on a firm, level surface when adjusting the doors. 2. Adjust at the hinges (A): • Loosen the door mounting bolts (B) slightly, and move the door in or out until it's flush with the body. • Remove the inner fender (see page 20-167). With a shop towel (C) on the jack (D), slightly loosen the hinge mounting bolts (E), and move the door backward or forward, up or down as necessary to equalize the gaps.

~A

300 mm (12 in.)

E 8x 1.25mm 29 N·m (3.0 kgf·m, 22 Ibf·ft)

B 8x1.25mm 29 N·m (3.0 kgf·m, 22Ibf·ft)

8. Reinstall all removed parts in the reverse order of removal.

#::/~

/-

/// ./,./

L-",,,,,,,,,,,,,,""""""'~'jt1-:bY

A

(cont'd)

BACK

20-29

Doors Door Position Adjustment (cont'd) 3. Check that the door and body edges are parallel. If necessary, adjust the door cushions (A) to make the rear of the doors flush with the body.

Door Striker Adjustment Make sure the door latches securely without slamming it. If necessary, adjust the striker (A); the striker nuts are fixed. The striker can be adjusted slightly up or down, and in or out. ,. Loosen the screws (8), then insert a shop towel (C) between the body and striker. A

A

4. Grease the pivot portions of the hinges indicated by the arrows.

B

c

8x1.25mm 18 N·m (1.8 kgf·m. 13lbf·ftl

2. Lightly tighten the screws. 3. Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer (0). Do not tap the striker too hard. 4. Loosen the screws and remove the shop towel. 5. Lightly tighten the screws.

5. Apply body paint to the hinge mounting bolts and around the hinges. 6. Check for water leaks (see step 7 on page 20-29).

20-30

BACK

6. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten the screws and recheck.

Mirrors Component Location Index - Coupe

MIRROR MOUNT COVER

RUBBER BOOT MIRROR HOLDER Replacement, page 20-33

BACK

20-31

Mirrors Component Location Index - Sedan

POWER MIRROR (Type A) Replacement, page 20-35

MANUAL MIRROR Replacement, page 20-34

MIRROR MOUNT COVER

&)~ MIRROR MOUNT COVER

MIRROR HOLDER

MIRROR HOLDER



MIRROR MOUNT COVER

POWER MIRROR (Type B) Replacement, page 20-35

~~ MOUNT

RETAINER SPRING

/~

MIRROR HOLDER Replacement, page 20-33

SPRING

REARVIEW MIRROR Replacement, page 20-37

20-32

BACK

Mirror Holder Replacement - Coupe 1. Pry the mirror holder (A) out from the bottom until you can see the pivot (B) of the actuator, then detach the pivot using a flat-tip screwdriver. Take care not to scratch the mirror(C). B

3. Remove the actuator shafts (A) and rubber boots (B) from the mirror holder (C). Check the actuator shaft and rubber boot for damage or deterioration, and replace them if necessary. A

~B

~~ C/,

A

2. Remove the actuator shafts (A) and release the hooks (B) from the actuator (C), then remove the mirror holder (0). If equipped, disconnect the mirror defogger terminals.

4. Install the mirror holder in the reverse order of removal, and note these items: • Before installing the mirror holder, install the actuator shafts and boots on the actuator. • Apply the grease to the pivot (A) and actuator shafts.(B). • Reattach the mirror holder (C) to the pivot (A) and actuator shafts (B) of the actuator, then carefully push on the pivot and actuator shaft portions of the holder until it locks into place. • If necessary, before installing the mirror holder, heat the pivot and actuator shafts joi nt portions of the holder. • Check the operation of the actuator. B

... IiiiPii

A

... ~

B

BACK

20-33

Mirrors Manual Mirror Replacement - Sedan 1. Lower the door glass fully.

2. Carefully pry out the mirror mount cover (Al by hand in the sequence shown.

4. While holding the mirror, push out the clip (Al, and remove the mirror. Take care not to scratch the door. A

5. Install the mirror in the reverse order of removal.

3. Remove the bolts securing the mirror. Fastener Locations ~:Bolt,3

5xO.8mm 5N·m IO.5kgf·m, 4lbf·ftl

20-34

BACK

Power Mirror Replacement 1. Lower the door glass fully.

5. While holding the mirror, push out the clip (A), and remove the mirror (8). Take care not to scratch the door.

2. Carefully pry out the mirror mount cover (A) by hand in the sequence shown.

A

B

(0

o

6. Install the mirror in the reverse order of removal, and note these items: • Make sure the connector is plugged in properly . • Attach the harness clip. 3. Remove the door panel (see page 20-9). 4. Disconnect the connector (A), and detach the harness clip (8), then remove the nuts or bolts securing the mirror. Fastener Locations ~: Bolt, 3

•

5XO.8m~

5N·m ~ 4Ibf·ft) (0.5 kgf·m,

: Nut, 3 (Type B) 5xO.8mm 5N·m (0.5 kgf·m, 4Ibf·ft)

J

BACK

20-35

Mirrors Mirror Holder Replacement - Sedan 3. If equipped, connect the mirror defogger terminals.

1. Carefully pull outthe bottom edge ofthe mirror holder (A) by hand. Take care not to scratch the mirror. A

D

I

c

4. Reattach the clips of the mirror holder to the actuator, then position the mirror holder on the actuator. Carefully push on the clip portions of the mirror holder until the holder locks into place. 5. Check the operation of the actuator.

B

2. Separate the mirror holder from the actuator (8) by slowly pulling them apart while removing the adhesive (C), and detaching the clips (D). If equipped, disconnect the mirror defogger terminals.

20-36

BACK

Rearview Mirror Replacement 1. Slide the rearview mirror (A) down toward the bottom of the windshield, then detach it from the spring (B) in the mount (e), and remove the rearview mirror. Take care not to scratch the mirror base (0).

4. Secure the mirror by turning the base 90°.

2. If necessary, remove the spring from the mount. 3. Fitthe mirror base over the mount.

BACK

20-37

Glass Component Location Index - Coupe

1

=/

MOLDING MIDDLE UPPER SEAL

WINDSHIELD MOLDING BUTYL TAPE, 2 ('98modell

ft)

~

~

/MOLDINGUPPERSEAL'

~~~c:s;:.

WINDSHIELD

/

He.lao,m,""

pa., 2O-MJ

FASTENER' 2 (Self-adhesive-type, glass side) /

FASTENER,2

~ ~ 1011....... body shiel ~

QUARTER GLASS Replacement, page 20-55

DASHBOARD SEAL

/

/

RUBBER DAM

,!PPER SPACER, 2 ( 00-02 models)

WINDOW ANTENNA TERMINAL COVER

~.

WINDOW ANTENNA TERMINAL BASE

I

~

~ ~

~

~

~

~

REAR WINDOW MOLDING

~

page 20-59 UPPER FASTENER, 2 (Self-adhesive-type, glass side) ~ ('98-99 models) .---UPPER FASTENER, 2 ~ (Clip-type, body side) ('98-99 models)

E:::i>

'I

I

___ REAR WINDOW

~

~


____ LOWER FASTENER, 2 (Self-adhesive-type, glass side)

~-----

m

- - - - - LOWER FASTENER, 2 (Self-adhesive-type, body side)

20-38

BACK

Component Location Index - Sedan MOLDING UPPER SEAL,2 ('98-00 models)

r

MOLDING CORNER SEAL,2 WINDSHIELD MOLDING

\

/

/J ~ ~ f;7 ~ ~- ~------~

\

~ -/ /

~

~

~

~ ~______

~

~

~

_/~

y

~

~/.~ ~~/ ~/ ~

~ ~ ~ V "7

~

A

~

~

RUBBER DAM

reinstallation on '99-02 models)

RUBBER DAM A

~

-.;;;;;;;;;::;:::::::::::,.

WINDSHIELD Replacement, page 20-40

RUBBER DAM B

'"

DASHBOARD SEAL

MOLDING SIDE SEAL, 2 ('98-00 models)

WINDOW ANTENNA TERMINAL COVER

I

WINDOW ANTENNA TERMINAL B A % E UPPER SPACER, 2 ('00-02 models, U.S.-Produced) UPPER FASTENER, 2 {:::::S. ' / (Self-adhesive-type, glass side) ~ ~ (Required for replacement or ~;::--.,. reinstallation on '99-02 models, ~ ~ Japan produced)

E::D~ ~

~

/ /

~~

~~~~~~~~~~~/~'~ ././~

J

/ / /

~

- - - - UPPER FASTENER, 2 (Self-adhesive-type, body side) (Required for replacement or reinstallation on '99-02 models, Japan produced) MOLDING CORNER SEAL, 2

/

::---=::::=::-

~

_ _ _~ ~

.~

REAR WINDOW MOLDING

FASTENER,2 (Clip-type, body side) (Required for replacement or ,einstallation on '99-02 models)

~ReqUired for replacement or

~,.~// h~

FASTENER' 2 (Self-adhesive-type, glass side) (Required for replacement or reinstallation on '99-02 models)

_---~.--..::.s:-::-.:/

LOWER CORNER FASTENER, 2 (Self-adhesive-type, glass side) (Required for replacement or reinstallation on '99-02 models)

LOWER CORNER FASTENER, 2 (Self-adhesive-type, body side) (Required for replacement or reinstallation on '99-02 models) LOWER CENTER FASTENER (Self-adhesive-type, glass side) ('01-02 models, Japan produced)

l£E]J ..

LOWER CENTER FASTENER (Self-adhesive-type, body side) ('01-02 models, Japan produced)

BACK

20-39

Glass Windshield Replacement NOTE: • Put on gloves to protect your hands. • Wear eye protection when removing the glass with piano wire. • Use seat covers to avoid damaging any surfaces.

4. Apply protective tape (A) along the edge of the dashboard (B) and body as shown. Using an awl, make a hole through the rubber dam (C), adhesive (0), and dashboard seal (E) from inside the vehicle. Push a piece of piano wire (F) through the hole, and wrap each end around a piece of wood.


A

F~L

• Rearview mirror (see page 20-37) • Sunvisors and holders, both sides, Roof console, Grab handles, both sides (see page 20-79) • Front door opening trim, both sides as necessary - Coupe (see page 20-74) - Sedan (see page 20-75) • Front pillar trim, both sides - Coupe (see page 20-74) - Sedan (see page 20-75) • Windshield wiper arms and cowl cover (see page 22-188)

~ A

/

D

2. Remove the molding (A) from the edge of the windshield (B). If necessary, cut the molding with a utility knife.

B

5. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the windshield as possible to prevent damage to the body and dashboard. Carefully cut through the rubber dam and adhesive around the entire windshield. A

~

B

3. Pull down the front portion of the headliner (see page 20-79). Take care not to bend the headliner excessively, or you may crease or break it.

20-40

~//

6. Carefully remove the windshield.

BACK

7. With a knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in) on the bonding surface around the entire windshield opening flange:

10. Glue the rubber dam (A), fasteners (B) and dashboard seal (C) to the inside face of the windshield (D) as shown:

• Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding. • Remove the rubber dam and fasteners from the body. • Mask off surrounding surfaces before painting.

• Be sure the rubber dam, fasteners, and dashboard seal line up with the alignment marks (E).

• Be careful not to touch the windshield where adhesive will be applied. Coupe:

8. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease, and water from getting on the clean surface. 9. If the old windshield is to be reinstalled, use a putty knife to scrape off all of the old adhesive, the fastener, the rubber dam, and the dashboard seal from the windshield. Clean the shaded portion of the windshield with alcohol where new adhesive is to be applied. Make sure the bonding surface is kept free of water, oil, and grease. Coupe:

Sedan:

A

(cont'd)

BACK

20-41

Glass Windshield Replacement (cont'd) 11. Apply primer (3M N-200, or equivalent) to the areas between the alignment marks (A), and glue the adhesive tape (B) (NITTO 501, or equivalent) to the edge of the windshield. Be careful not to touch the windshield where adhesive will be applied.

Sedan: 11 mm (0.43 in.'

12mm (0.47 in.'

Coupe: _

: Apply primer here.

A 1 1 1 1 1

I _I c

t

D

E

A

6mm (0.2 in.'

20-42

BACK

12. Glue the molding (A) with adhesive tape (B) to the edge of the windshield (e):

Sedan: ~:i'


• Be sure the alignment mark (D) of the molding lines up with the alignment mark (E) of the windshield . • Be careful not to touch the windshield where adhesive will be applied. Coupe:

¢ I I I

I I ~

50mm (2in.1 6mm (O.2in.1

(cont'd)

BACK

20-43

Glass Windshield Replacement (cont'd) Sedan:

13. Glue the molding middle upper seal (coupe) (A), molding upper seal (coupe) (B), molding Corner Seal (Sedan) (C) and molding side seal (coupe) (0) to the molding (E). Be careful not to touch the windshield where adhesive will be applied.

· f

Coupe:

B A

/

'.

.

~

E

A

l1J

20-44

BACK

(1.0~

~r,. ~;.~

B

J

~~~=

175mm175mm (6.89 in.) (6.89 in.)

I

24.5mm

~~

E

•

Sedan:

14. Install the fasteners to the body. Fastener Locations

[>: Fastener, 2

/

./

15. Set the windshield in the opening, and center it. Make alignment marks (A) across the windshield and body with a grease pencil at the four points shown. Be careful not to touch the windshield where adhesive will be applied. A

16. Remove the windshield.

(cont'd)

BACK

20-45

Glass Windshield Replacement (cont'd) 17. With a sponge, apply a light coat of glass primer around the edge of the windshield (A) between the dam (8) and molding (e) as shown, then lightly wipe it off with gauze or cheesecloth: • Apply glass primer to the molding. • Do not apply body primer to the windshield, and do not get the body and glass primer sponges mixed up. • Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the windshield properly, causing a leak after the windshield is installed. • Keep water, dust, and abrasive materials away from the primed surface.

Sedan: _

8.Smm (0.33 in')'-I--~:L.4

i I I I I I I

: Apply glass primer here.

8.Smm (0.33 in.) +-~'V

i

I

!

20-46

A

CD

Coupe: _

: Apply glass primer here.

A

BACK

18. With a sponge, apply a light coat of body primer to the original adhesive remaining around the windshield opening flange. Let the body primer dry for at least 10 minutes: • Do not apply glass primer to the body, and be careful not to mix up the glass and body primer sponges. • Never touch the primed surfaces with your hands. • Mask off the dashboard before painting the flange.

20. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the windshield (B) between the dam (e) and molding (D) as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner. Coupe: 2mm 10.OBin.) -H-

W&!, : Apply body primer here.

13mm I~ 10.51 in.) 1-1

..A

B mm 10.31 in.) A

~D

\

C

A

;1

D

5mm 10.2 in.)

19. Before filling a cartridge, cut a "v" in the end of the nozzle (A) as shown.

C

A \m.----B IO'O~

2.5 mm

7 mm 10.27 in.)

(cont'd)

BACK

20-47

Glass Windshield Replacement (cont'd) 21. Use suction cups (A) to hold the windshield over the opening, align it with the alignment marks (8) made in step 15, and set it down on the adhesive. Lightly push on the windshield until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry.

Sedan: 2mm

(O.OSin.' -I-!-

13mm I~

(0.51 in.' . . f.--I S mm (0.31 in.'

22. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the windshield, wipe with a soft shop towel dampened with alcohol.

B

23. Let the adhesive dry for at least 1 hour, then spray water over the windshield and check for leaks. Mark leaking areas, and let the windshield dry, then seal with sealant: o

2.5mm

(0.1 in.'

o

Let the vehicle stand for at least 4 hours after windshield installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly. Keep the windshield dry for the first hour after installation.

24. Reinstall all remaining removed parts. Install the rearview mirror after the adhesive has dried thoroughly. Advise the customer not to do the following things for 2 to 3 days: o

o

20-48

BACK

Slam the doors with all the windows rolled up. Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).

Rear Window Replacement NOTE: • Put on gloves to protect your hands. • Wear eye protection when removing the glass with piano wire. • Use seat covers to avoid damaging any surfaces. • Do not damage t~e rear window defogger grid lines, window antenna grid lines, and terminals.

5. Disconnect the rear window defogger connectors (A).

1. Remove the trunk lid (see page 20-154). 2. Remove these items: Sedan (see page 20-129) • Rear seat cushion • Rear seat side bolster (both sides) Coupe (see page 20-128) • Rear seat-back • Rear seat-cushion

A

6. Remove the molding (A) from the edge ofthe rear window (8). If necessary, cut the molding with a utility knife.

3. Remove these items: Sedan (see page 20-77) • Rear door opening trim (both sides as necessary) • Rear pillar trim (both sides) • Rear bulkhead cover • Center anchor bolt of the center belt • Center belt cover • High mount brake light • Lock cylinder trim • Rear shelf Coupe (see page 20-76) • Rear bulkhead cover • Rear shelf Coupe (see page 20-74) • Door sill trim • Rear side trim panel • Upper anchor bolts of the front and rear seat belts • Coat hanger • Quartertrim panel 4. Remove the window antenna terminal cover (A) from the window antenna terminal base (8), and disconnect the window antenna connector (C). - - - -_ .. ---

------

-

--.--c..J----

A------~

B

7. Pull down the rear portion of the headliner (see page 20-79). Take care not to bend the headliner excessively, or you may crease or break it.

(cont'd)

BACK

20-49

Glass Rear Window Replacement (cont'd) 8. Apply protective tape (A) along the inside and outside edges of the body as shown. Using an awl, make a hole through the adhesive (8) from inside the vehicle. Push a piece of piano wire (C) through the hole, and wrap each end around a piece of wood.

11. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in) on the bonding surface around the entire rear window opening flange: • Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding • Mask off surrounding surfaces before painting. • Remove the fasteners from the body. 12. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease, and water from getting on the surface. 13. If the old rear window is to be reinstalled, use a putty knife to scrape off all of the old adhesive, then clean the shaded portion of the rear window with alcohol where new adhesive is to be applied. Make sure the bonding surface is kept free of water, oil, and grease.

9. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the rear window as possible to prevent damage to the body, and carefully cut through the adhesive around the entire rear window. A

10. Carefully remove the rear window.

20-50

BACK

14. Glue the fasteners (A, B) and spacers (U.S.Produced); (C) to the inside face of the rear window as shown. If necessary, apply primer (3M N-200, or equivalent) to the areas where the window antenna terminal base (0) will be glued, then glue the base on:

Japan produced models: ~/J:;j:;


Fastener Locations A[> : Fastener. 2

13.5 mm

(0~53 in.~

• Be sure the fasteners, spacers (and window antenna terminal base cover) line up with the alignment marks (E). • Be careful not to touch the rear window where adhesive will be applied.

B [>: Fastener, 2

135 mm

(0.~3 in'l

",~~_,/-/~ " ..:~:;:.' -

A

~ E E -------- ------

C

U.S.-Produced models:

:t;';M: : Apply primer here. Fastener and spacer Locations

B [> : Fastener

2mm (0.08 in.)

Coupe, 2 (both sides) Sedan, 3 (both sides and center) C [>: Spacer, 2

13.5 mm (0.. 53in.)

13.5 mm

~~

~I~~Y 15. Apply the adhesive tape (A) (3M 4216, or equivalent) to the edge of the rear window (B): • Be sure the adhesive tape lines up with the alignment marks (C) . • Be careful not to touch the rear window where adhesive will be applied.

D

2mm (0.08 in.)

...

~

(cont'd)

BACK

20-51

Glass Rear Window Replacement (cont'd) 16. Glue the molding (A) around the edge of the rear window (B): • Be sure the joint (Cl lines up with the alignment mark (0) . • Be careful not to touch the rear window where adhesive will be applied.

18. Install the upper fasteners (A) (Japan-Produced models). Glue the lower fasteners (B) to the body as shown. Align the lower fasteners with 1.0 mm (0.04 in.) offset surface ofthe rear parcel shelf (C) . U.S.-Produced models: Fasterner Locations B [> : Fastener Coupe, 2 (both sides) Sedan, 3 (both sides and center)

~

I

-~-'

17. Sedan only, glue the molding corner seal (A) to the molding (B). Be careful not to touch the rear window where adhesive will be applied. Japan-Produced models: Fastener Locations

5mm

(0.2 in.)

A [> : Fastener, 2

~ ~ \\.---\..

B [> : Fastener, 2

.

--.

~,~ ----~~~~

20-52

BACK

19. Set the rear window in the opening, and center it. Make alignment marks (A) across the rear window and body with a grease pencil at the four points shown. Be careful not to touch the rear window where adhesive will be applied.

22. With a sponge, apply a light coat of body primer to the original adhesive remaining around the rear window opening flange. Let the body primer dry for at least 10 minutes: • Do not apply glass primer to the body, and be careful not to mix up the glass and body primer sponges . • Never touch the primed surfaces with your hands.

A

)lI,l;I,; : Apply body primer here. 5mm (0.2 in.)

20mm (0.79 in.)

20. Remove the rear window. 21. With a sponge, apply a light coat of glass primer along the edge of the rear window (A) and molding (B) as shown, then lightly wipe it off with gauze or cheesecloth: • Do not apply body primer to the rear window, and do not get the body and glass primer sponges mixed up. • Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the rear window properly, causing a leak after the rear window is installed. • Keep water, dust, and abrasive materials away from the primed surface. : Apply glass primer here.

23. Before filling a cartridge, cut a "V" in the end of the nozzle (A) as shown.

9 mm (0.35 in.)

. T~/B "., I "

. \.

A

/~ - - , 10 mm (0.39 in.)

!J

"-

"

~ ...

./

-1---I I

7 mm (0.27 in.)

A

B (cont'd)

BACK

20-53

Glass Rear Window Replacement (cont'd) 24. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Putthe cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the rear window (8) as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.

25. Use suction cups (A) to hold the rear window over the opening, align it with the alignment marks (8) you made in step 19, and set it down on the adhesive. Lightly push on the rear window until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry. A

2mm (0.08 in.) --t-t-

13mm (0.51 in.)

1~:A

I--..J 8 mm (0.31 in.)

f

(~'§ ~'§~ \""""""s,

26. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the rear window, use a soft shop towel dampened with alcohol. ' 27. Let the adhesive dry for at least 1 hour, then spray water over the rear window and check for leaks. Mark the leaking areas, let the rear window dry, then seal with sealant. Let the vehicle stand for at least 4 hours after rear window installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly. 28. Reinstall all remaining removed parts. Advise the customer not to do the following things for 2 to 3 days: B

20-54

• Slam the doors with all the windows rolled up. • Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).

A

BACK

Quarter Glass Replacement - Coupe NOTE: • Put on gloves to protect your hands . • Use seat covers to avoid damaging any surface.

Upper portion:

1. Remove these items (see page 20-128): • Rear seat-back • Rear seat cushion 2. Remove these items (see page 20-76): • • • • • •

Lower portion:

Rear bulkhead cover Center anchor bolt of the center belt Center belt lid High mount brake light Lock cylinder trim Rear shelf

3. Remove these items (see page 20-74): Center piller portion:

• Door sill trim • Rear side trim panel • Upper anchor bolts of the front and rear seat belts • Coat hanger • Quarter trim panel

I

C

~""~

4. From inside the vehicle, use a knife (A) to cut through the quarter glass adhesive (B) all the way around: • If the quarter glass (C) is to be reinstalled, take care not to damage the molding (D). • Ifthe molding is damaged, replace the quarter glass, molding and clips (E) as an assembly. • If any ofthe clips are broken, the quarter glass can be reinstalled using butyl tape (refer to step 9). • Apply protective tape (F) along the edge of the entire quarter glass opening flange.

0

! \ \ --

A

F

B

Clip portion:

5. Carefully remove the quarter glass, and check the molding for damage, and replace the quarter glass if necessary.

E

(cont'd)

BACK

20-55

Glass Quarter Glass Replacement - Coupe (cont'd) 6. With a knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire quarter glass opening flange:

9. If the old quarter glass is to be reinstalled (and either clip is broken off the molding), apply a light coat of primer (C-100, or equivalent), then apply butyl tape (A) and (B) to the molding (C) as shown:

• Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding. • If any of the clips are broken, remove them from the body. • Mask off surrounding surfaces before applying primer.

• Be careful not to touch the quarter glass where adhesive will be applied. • Do not peel the separator off the butyl tape.

7. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease, and water from getting on the glass surface.

B

8. Ifthe old quarter glass is to be reinstalled, use a putty knife to scrape off all traces of old adhesive from the quarter glass. Scrape the old adhesive from the molding with a knife, then clean the quarter glass and molding shaded portion of the with alcohol where adhesive is to be applied. Make sure the bonding surface is kept free of water, oil, and grease.

300mm

(1.2 in.1

~~/~ ~D----,\J

400 mm (15.7 in.1

A

A------/ c

20-56

BACK

10. If the old quarter glass is to be reinstalled (and either clip is broken off the molding), seal the body holes with pieces of urethane tape (A). Then set the quarter glass upright in the opening, and make alignment marks (B) across the quarter glass and body with a grease pencil at the three points shown. Be careful not to touch the quarter glass where adhesive will be applied.

11. Remove the quarter glass. 12. With a sponge, apply a light coat of glass primer to the inside face of the quarter glass (A) as shown, then lightly wipe it off with gauze or cheesecloth: • Do not apply body primer to the quarter glass, and do not get the body and glass primer sponges mixed up. • Never touch the primed surfaces with your hands. If you do the adhesive may not bond to the quarter glass properly, causing a leak after the quarter glass is installed. • Keep water, dust, and abrasive materials away from the primed surface.

0',.@'i : Apply glass primer here.

10mm (0.4 in.)

10mm (0.4 in.)

A

10mm (0.4 in.)

"...--A

(cont'd)

BACK

20-57

Glass Quarter Glass Replacement - Coupe (cont'd) 13. With a sponge, apply a light coat of body primer to the original adhesive remaining around the quarter glass opening flange. Let the body primer dry for at least 10 minutes:

15. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Putthe cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the quarter glass (B) as shown:

• Do not apply glass primer to the body, and be careful not to mix up the glass and body primer sponges. • Never touch the primed surfaces with your hands. • Mask off the dashboard before painting the flange.

• After applying the adhesive, peel the separator off the butyl tape . • Apply the adhesive within 30 minutes after applying the glass primer. Make slightly thicker bead at each corner. 2mm (0.08 in.)

. . : Apply body primer here.

-.f-i-

13mm I~ (0.51 in.) •

37mm (1.5 in.)

:A

f.-...j

8 mm (0.31 in.)

2mm (0.08 in.)

2 mm (0.08 in.)

A

14. Before filling a cartridge, cut a "V" in the end of the nozzle (A) as shown.

10 mm (0.39 in.)

7 mm (0.27 in.)

20-58

BACK

2mm (0.08 in.)

-r---~

Sticker Replacement 16. Use suction cups (A) to hold the quarter glass (8) over the opening, align the clips or the alignment marks (C) made in step 10, and set it down on the adhesive. Lightly push on the quarter glass until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry.

1. Clean the quarter glass surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the surface. 2. Apply the sticker where shown.

B

GLASS MOLDING

EDGE

_ _ BLACK C.ERAMIC EDGE (

17. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the quarter glass, wipe with a soft shop towel dampened with alcohol.

I

3 mm (0.11 in.)

"~-~i--

18. Let the adhesive dry for at least 1 hour, then spray water over the quarter glass and check for leaks. Mark the leaking areas and let the quarter glass dry, then seal with sealant. Let the vehicle stand for at least 4 hours after quarter glass installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly. 19. Reinstall all remaining removed parts. Advise the customer not to do the following things for 2 to 3 days: • Slam the doors with all the windows rolled up . • Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).

BACK

20-59

Moonroof Component Location Index GLASS Height Adjustment, page 20-62 Replacement, page 20-62 Closing Force and Opening Drag Check, page 20-71

~

SUNSHADE Replacement, page 20-64

CABLE ASSEMBLY Replacement, page 20-68 MOTOR Replacement, page 20-65

~

REAR DRAIN VALVE

~/

REAR DRAIN TUBE Replacement, page 20-66 FRAME Replacement, page 20-66

20-60

BACK

~

Symptom Troubleshooting Index Symptom

Water leaks


Also check for

1. Check for a clogged drain tube. 2. Check for a gap between the glass weatherstrip and the roof panel.

3. Check for a defective or an improperly installed glass weatherstrip.

4. Check for a gap between the drain seal and the roof panel. Wind noise

Motor noise

1.

Check for excessive clearance between the glass weatherstrip and the roof panel.

1.

Check for a loose motor.

2. Check for a worn gear or bearing. 3. Check for a deformed cable assembly. Glass does not move, but motor turns

1.

Check for a defective gear or inner cable.

2. Check for foreign material stuck between the guide rail and the slider.

3. Check for a loose inner cable. 4. Make sure the cable assembly is attached properly. 5. Check clutch adjustment. Glass does not move and motor does not turn (glass can be moved with moonroof wrench)

1.

2. 3. 4. 5. 6.

Check for a blown fuse. Check for a faulty moonroof switch. Check the open/close-tilt/close switches. Check for a run down battery. Check for a defective motor. Check for a faulty relay.

BACK

20-61

Moonroof Glass Height Adjustment

Glass Replacement

The roof panel (A) should be even with the glass weatherstrip (B), to within 2+0.5/-1 mm (0.08+0.02/0.04 in.) all the way around. If not, make the following adjustment:

1. Tilt the glass all the way up. 2. Slide the sunshade all the way back. 3. Remove the caps (A) and screws, then remove both bracket covers (B). Remove the nuts and shims (C) from both glass brackets (D). Fastener Locations ~ : Screw, 2

.:Nut.4

6x 1.0m~_j &m> I ~ ~O~·'kgf.m. 7lbf·ftl

\\ I~D// //'///.~/ // ~ ~ '"

----------.--

/'"

---;

-------

1. Open the glass all the way,and remove the bracket cover.

/IJ~

--/./'j

~_U-----T--\ #

2. Loosen the nuts (A), and install the shims (B) between the glass frame (C) and glass bracket (D) on each side.

... Forward

~

B

\

Shim thickness: Front and rear max. 2 mm (0.08 in.)

A

4. Remove the moonroof glass by lifting it up. Do not damage the roof panel.

...

Forward

A


3. Repeat on opposite side if necessary.

5. Install the glass in the reverse order of the removal, and adjust the glass height. 6. Check for water leaks_ Use free flowing water from a hose without a nozzle. Do not use high-pressure water.

20-62

BACK

Drain Channel Replacement 4. Remove the drain channel (A).

1. Remove the moonroof glass. 2. With the moonroof wrench, move both glass brackets (A) to the position where the moonroof normally pivots down, and remove the screws securing the drain channel (B). Fastener Locations ~ : Screw, 2

~I A

5. Install the drain channel in the reverse order of removal, and note these items:

/

• Push the drain channel onto the hooks until a faint click is heard . • Check the glass height adjustment.

3. Release the drain channel (A) from both hooks (B) of the drain channel slider by pulling the drain channel forward.

6. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray.

B

BACK

20-63

Moonroof Sunshade Replacement 4. While lifting the front portion of the sunshade (A), move the sunshade forward until you can see both sunshade rear hooks (B). Do not damage the sunshade and hooks•

1. Remove these items: • Glass (see page 20-62) • Drain channel (see page 20-63)

Fastener Locations

2. Slide the sunshade (A) until you can see both sunshade slider spacers (B).

~ : Screw, 4

B

~


B

5. Remove the screws, then remove both hooks.

3. Remove the screws, then remove both spacers.

20-64

BACK

Motor Replacement 6. Release both rear sunshade base sliders (A) from the guide rail portions of the frame, then remove the sunshade.

1. Remove the headliner (see page 20-79). 2. Put on gloves to protect your hands. Disconnect and detach the connector (A), and remove the bolts, then remove the motor (8). Fastener Locations ~ : 801t, 2

6x 1.0mm 9N·m (O.9kgf·m, 7Ibf·ft)

7. Remove both front sunshade base sliders (A).

8

A

/

3. Install the motor in the reverse order of removal, and note these items:

8. Install the sunshade in the reverse order of removal, and check the glass height adjustment (see page 20-62).

• Make sure the connector is plugged in properly. • Check the motor operation.

9. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray.

BACK

20-65

Moonroof Frame and Drain Tube Replacement 1. Remove these items: • Headliner (see page 20-79) • Moonroof glass (see page 20-62) 2. Put on gloves to protect your hands. Disconnect the motor connector (A), open/c1ose-tilt/close switch connector (B), and the drain tubes (e). Fastener Locations ~: Bolt, 10

6x 1.0mm 9.8N·m (1.0kgf·m,

F

7.2Ibf.ft)

c

G

c H

3. Remove the ceiling light harness (D) by detaching the harness clips (E), and remove the harness cushion (F). 4. With an assistant holding the frame (G), remove the bolts, and release the rear hooks (H) by moving the frame forward, then remove the frame. Remove the front bolts last. 5. With the help of an assistant, carefully remove the frame through the front door opening. Take care not to scratch the interior trim and body, or tear the seat covers.

20-66

BACK

6. To remove a front drain valve (A) from the body remove the kick panel. left or right (Sedan (see page 20-75). Coupe (see page 20-74)). Tie a string to the end of the front drain tube (B) then pull the drain tube down out ofthe front pillar.

8. Insta" the frame and drain tubes in the reverse order of removal. and note these items: • Before installing the frame. clear the drain tubes and drain valves using compressed air. • Check the frame seal. • Clean the surface of the frame. • When installing the frame. first attach the rear hooks into the body holes. • Make sure the connectors are plugged in properly. • When connecting the drain tube. slide it over the frame nozzle at least 10 mm (0.39 in.). • Insta" the tube clip (A) on the drain tube (B) as shown.

Up

7. To remove a rear drain valve (A) from the body. remove these parts (see page 20-78): 9. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray.

• Trunk floor • Trunk side trim panel • Trunk side pocket. left or right Tie a string to the top end of the rear drain tube (B). then pull back the trunk side trim panel and pull the drain tube down out of the pillar.

BACK

20-67

Moonroof Drain Channel Slider and Cable Assembly Replacement 1. Remove the frame (see page 20-66).

4. While pushing down on the hook (A), slide the drain channel sliders (B) back on both sides.

2. Remove these parts from the frame: • Drain channel (see page 20-63) • Sunshade (see page 20-64) • Moonroof motor (see page 20-65) 3. Put on gloves to protect your hands. Remove the slide stops (A), cable tube rear brackets (B), cable tube side bracket mounting bolts (e) and the cable tube mounting screws (D) from both sides of the frame (E). Fastener Locations D ~:Screw,2

C~:Bolt,2

@)mmn .

6 x 1.0 mm 9.8N·m (1.0 kgf·m,

7.2Ibf·ftl F ~ : Screw, 2

G~ : Screw, 2

B

\G zk1

E

20-68

BACK

6. Pivot the glass bracket (A) down by sliding the link lifter (B) back, then slide both glass brackets back with the link lifter.

8. Install the sliders and cables in the reverse order of removal, and note these items: • Damaged parts should be replaced. • Apply mUltipurpose grease to the glass bracket (A) and guide rail portion of the frame (B) indicated by the arrows. • Before reinstalling the moonroof motor, make sure both link lifters are parallel, and in the fully closed position. • Before reinstalling the moonroof motor, install the frame and glass, then check the opening drag (see page 20-71).

B

7. Slide the cable assembly (A) and both glass brackets (B) back, then remove them from the frame (e). B

B

\ A

BACK

20-69

Moonroof Position Switch Adjustment 1. Remove the headliner (see page 20-79). 2. With the moonroof wrench, close the glass (A) fully: • Make sure both link lifters (B) are parallel, and in the position shown. • Check the glass fit to the roof panel and the glass height (see page 20-62).

G C 6x 1.0mm 9.8 N·m (1.0 kgf·m, 7.2Ibf·ftl

3. With an open-end wrench, loosen the position switch mounting bolts (C). 4. Adjust the position switch (0): • Move the switch a little at a time, then secure it at the position where you hear a faint click when the switch cam (E) pushes the open/close switch (F). • Check that the switch contacts the switch bracket (G). 5. Check the operation of the glass (from the tilt-up position to the fully closed position, and from the fully open position to the fully closed position) by operating the moonroof switch.

20-70

BACK

Closing Force and Opening Drag Check 1. Remove the headliner (see page 20-79).

4. Opening drag check: Protect the leading edge of the glass with a shop towel (A). Measure the effort required to open the glass using a spring scale (8) as shown.

2. Closing force check: • With a shop towel (A) on the leading edge of the glass (8), attach a spring scale (C) as shown. • Have an assistant hold the switch to close the glass while you measure the force required to stop it. • Read the force as soon as the glass stops moving, then immediately release the switch and spring scale.

A

Closing Force:

200 - 290 N (20 - 30 kgt, 44 - 66 Ibtl B

A

5. If the load is over 40 N (4 kgf, 9 Ibf), check these items: • The side clearance and glass height adjustment (see page 20-62) . • For broken or damaged sliding parts. If any sliding parts are damaged, replace them.

c 3. If the force in not within specification, remove the moonroof motor (see page 20-65), then check these items: • The gear portion and the inner cable for breakage and damage. If the gear portion is broken, replace the motor. If the inner cable is damaged, remove the frame (see page 20-66), and replace the cable assembly (see page 20-68). • The moonroof motor (see page 20-65). If the motor fails to run or doesn't turn smoothly, replace it. • The opening drag. Go to step 4.

BACK

20-71

Interior Trim Component Location Index - Coupe

REAR SIDE TRIM PANEL page 20-74

REAR BULKHEAD COVER page 20-76

DOOR SILL TRIM page 20-74

REAR SHELF page 20-76

20-72

BACK

Component Location Index - Sedan

REAR PILLAR TRIM page 20-77 REAR DOOR OPENING TRIM page 20-75

CENTER PILLAR UPPER TRIM page 20-75 FRONT DOOR OPENING TRIM page 20-75 ~~~~~;;;;;;;,.....=~_ _ _ _ _ _-HEADLINER

-

Removal/Installation, page 20-79

TRUNK

SIDE POCKET page 20-78 TRUNK FLOOR page 20-78 TRUNK SIDE TRIM PANEL page 20-78 REAR BULKHEAD COVER page 20-77

TRUNK REAR TRIM PANEL page 20-78 TRUNK SIDE POCKET page 20-78

CENTER PILLAR LOWER TRIM PANEL page 20-75

BACK

20-73

Interior Trim Trim Removal/Installation - Door Area - Coupe NOTE:

• When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. • Take care not to bend or scratch the trim and panels. • Put on gloves to protect your hands. Remove the trim as shown. Install the trim in the reverse order of removal, and note these items: • Replace any damage clips. • Apply liquid thread lock to the front seat belt upper anchor bolt before installation. • Before installing the anchor bolts, make sure there are no twists or kinks in the belts. Fastener Locations

ACCESS

A

[>: Clip, 4

COAT HANGER

B

I 32 N·m (3.3 kgf·m,

24Ibf·ft)

E ~: Screw, 1

G ~:Screw, 1

~

FRONT SEAT BELT UPPER ANCHOR BOLT 7/16-20UNF 32 N·m (3.3 kgf·m,

REAR SIDE TRIM PANEL Remove: • Rear seat-back and / rear seat cushion • Rear bulkhead [A] cover

FRONT PILLAR TRIM

A

F

A

[B] portions:

DOOR OPENING TRIM

TRIM

TRIM

20-74

F~: Screw, 1

~I~

24Ibf·ft)

[A] portions:

D [>: Clip, 2

~~lMd~ DOOR OPENING TRIM

REAR SEAT BELT UPPER ANCHOR BOLT 7/16-20UNF

C [>: Clip, 13

[>: Clip, 3

BACK

Trim Removal/Installation - Door Area - Sedan NOTE: • Put on gloves to protect your hands. • When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. • Take care not to bend or scratch the trim and panels.

Remove the trim as shown. Install the trim in the reverse order of removal, and note these items: • Replace any damage clips. • Apply liquid thread lock to the front seat belt upper anchor bolt before installation. • Before installing the anchor bolts, make sure there are not twists or kinks in the belts.

FRONT SEAT BELT SHOULDER ANCHOR ADJUSTER

REAR DOOR SILL TRIM Remove the rear seat

cushion HOOK

[A] portions:

TRIM

CENTER PILLAR LOWER TRIM PANEL [B] portions:

DOOR TRIM

TRIM

BACK

20-75

Interior Trim Trim Removal/Installation - Rear Shelf Area - Coupe NOTE: • Put on gloves to protect your hands. • When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. • Take care not to bend or scratch the trim and panels. Remove the trim as shown. Install the trim in the reverse order of removal, and note these items: • Replace any damaged clips. • Before installing the anchor bolts, make sure there are no twists or kinks in the seat belts. Fastener Locations A

[>: Clip, 4

B

[>: Clip, 1

C

[>: Clip, 2

~~~ HIGHMOUNT BRAKE LIGHT _____ HIGH MOUN!!~~E LIGHT CONNECTOR

REAR SIDE LOCK CYLINDER TRIM TRIM PANEL

HO~K

~

,

is

~.

'98-00 models:

~CENTER BELT Remove the center belt lid from the center belt, and slip the center belt through the hole on the speaker grille.

CENTER BELT COVER

20-76

CENTER BELT CENTER ANCHOR BOLT 7/16-20UNF 32 N·m 13.3 kgf.m, 24 Ibf·ft) Remove the rear seat-back and rear seat cushion.

BACK

Trim Removal/Installation - Rear Shelf Area - Sedan NOTE: • Put on gloves to protect your hands. • When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. • Take care not to bend or scratch the trim and panels. Remove the trim as shown. Install the trim in the reverse order of removal, and note these items: • Replace any damage clips. • Apply liquid thread lock to the front seat belt upper anchor bolt before installation. • Before installing the anchor bolts, make sure there are not twists or kinks in the belts. Fastener Locations A

!> : Clip, 2

B !> : Clip, 6

C !> : Clip, 5

~J . ~J _ ~~' DOOR OPENING TRIM

HIGHMOUNT BRAKE LIGHT

REAR SHELF Remove the child seat tether anchors ('00-02 models).

HIGHMOUNT BRAKE LIGHT CONNECTOR

SLIT --CENTER BELT Remove the center belt cover from the center belt, and slip the center belt through the hole ~ in the speaker grille or the center belt cap.

REAR SEAT BELT CENTER BELT COVER

CENTER BELT CENTER ANCHOR BOLT 7/16-20 UNF 32 N·m (3.3 kgf·m, 24 Ibf·ft) Remove the rear seat cushion. SPEAKER GRILLE or CENTER BELT CAP (without rear speaker.)

-.~

CENTER BELT

BACK

20-77

Interior Trim Trim Removal/Installation - Trunk Area NOTE: • Put on gloves to protect your hands. • When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. • Take care not to bend or scratch the trim and panels.

Remove the trim as shown. Install the trim in the reverse order of removel, and replace any damaged clips. Fastener Locations

A I> : Clip, 6

B I> : Clip, 4

C

1>: Clip, 6

TRUNK SIDE TRIM PANEL

TRUNK SIDE POCKET

TRUNK SIDE TRIM PANEL

TRUNK REAR TRIM PANEL TRUNK SIDE POCKET

20-78

BACK

Headliner Removal/Installation NOTE: • When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. • Take care not to bend and scratch the headliner. • Be careful not to damage the dashboard and other interior trim.

5. If equipped, remove the roof console. - 1 Remove the lens (A). - 2 Remove the screws. - 3 Pull out the roof console (B), and disconnect the spotlight connector (C).

Fastener Locations

1. Remove these items: (Sedan (see page 20-75), Coupe (see page 20-74)) • Door opening trim (both sides as necessary) • Front pillar trim (both sides) • Front seat belt upper anchor bolt (both sides)

~

c

: Screw, 4

2. Remove these items: Sedan (see page 20-75) • Center pillar upper trim (both sides) Coupe (see page 20-74) • Coat hanger (left side) • Rear seat belt upper anchor bolt • Quarter trim panel

6. Remove the caps (A), and remove the ET screws and washers (B), then remove the grab handles (C) (driver's and each passenger's).

3. Remove the rear window antenna terminal cover (see step 4 on page 20-49).

Fastener Locations ~: ETscrew, 8

4. Remove the sunvisor (A) and holder (B) from each side. Disconnect the vanity mirror light connectors (C) (driver's and passenger's for some models).

5xO.8mm 4N·m (O.4kgf·m, 3Ibf·ft)

Fastener Locations

(cont'd)

BACK

20-79

Interior Trim Headliner Removal/Installation (cont'd) 7. Remove the headliner.

8. Install the headliner in the reverse order of removal, and note these items:

-1 Remove the upper portion of the rear pillar trim (A) from each side -Coupe (see page 20-74) -Sedan (see page 20-77) -2 For moon roof model: remove the socket plug (B) and roof trim (C). - 3 With help of an assistant, detach the clips, and lower the headliner (0). -4 Remove the headliner through the front passenger's door opening. Fastener Locations

• When reinstalling the headliner through the door opening, be careful not to fold or bend it. Also, be careful not to scratch the body. • For moonroof model: When reinstalling the roof trim (A), center the two joining ends (B) at the rear of the moonroof frame. • If the threads on a visor or grab handle ET screws are worn out, use an oversized ET screw (PIN 90137 -S30-0030)made specifically for this application. • Check that both sides of the headliner are securely attached to the trim.

B

20-80

BACK

A

Carpet Replacement SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service.

3. Remove the footrest. Fastener Locations ~

: Bolt, 2 6x 1.0mm 7N·m (0.7 kgf·m, 5Ibf·ft)

NOTE: • Put on gloves to protect your hands. • Take care not to damage, wrinkle or twist the carpet. • Be careful not to damage the dashboard or other interior trim pieces. 1. Remove these items: • Front seats, both sides (see page 20-99) • Driver's dashboard lower cover (see page 20-84) • Passenger's dashboard lower cover (see page 20-85) • Center console (see page 20-83) • Rear seat cushion - Coupe (see page 20-128) - Sedan (see page 20-129) • Front seat belt lower anchor bolt, both sides - Coupe (see step 8 on page 23-6) - Sedan (see step 6 on page 23-7) • Trunk lid/fuel lid opener (see page 20-176)

4. Remove the bolts from the parking brake lever. 2. Remove these items:

Fastener Locations ~ : Bolt, 2

Sedan (see page 20-75): • • • •

8x 1.25 mm 22N·m

Front door sill trim (both sides) Rear door sill trim (both sides) Center pillar lower trim panel (both sides) Kick panel (both sides)

12.2 kgf·m, 16Ibf·ft)

Coupe (see page 20-74): • Door sill trim (both sides) • Kick panel (both sides)

(cont'd)

BACK

20-81

Interior Trim Carpet Replacement (cont'd) 5. Remove the clips (A, B), and release the retainers (e), hooks (0) and fasteners (E), then remove the carpet (F). Put on gloves to protect your hands.

6. Install the carpet in the reverse order of removal, and note these items: • Take care not to damage, wrinkle or twist the carpet. • Make sure the seat harness is routed correctly. • Slip the slits in the carpet over the hooks. • Replace any damaged clips.

Coupe: . Fastener Locations

A I> : Clip, 2

B I> : Clip, 1

C I> : Clip, 2

~JillyJ

Sedan: Fastener Locations

A

I> : Clip, 3

B 1>: Clip, 1

~JU

20-82

E

BACK

Console Center Console Removal/Installation NOTE: • When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. • Take care not to scratch the front seat, dashboard and related parts. • Take care not to bend the parking brake cables.

Remove the center console as shown. Install the center console in the reverse order of removal, and note these items: • Replace any damaged clips. • Make sure the connectors are plugged in properly. • Readjust the parking brake cable, if necessary (see page 19-6). Fastener Locations

A [> : Clip, 4

. . : Screw, 8

J

_~¥D

B [> : Clip, 2

l_l_1!

C

[> : Clip, 2

D [> :Clip, 7

1ff.

I~

I

BEVERAGE HOLDER Carefully pry here. Do not pull on lid to remove. CONSOLE PANEL ·Remove the shift lever knob (MIT). ·Carefully pry here, then lift up the console panel to release the clips.

HARNESS CLIP Detach it from the center console.

ARMREST

BACK

20-83

Dashboard Instrument Panel Removal/ Installation

Driver's Dashboard Lower Cover Removal/Installation

NOTE: • When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage . • Take care not to scratch the dashboard and related parts.

SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service.

1. Tiltthe steering column down. 2. Remove the screws, and detach the clips, then carefully remove the instrument panel (A). Fastener Locations ~

1. Detach the clips, then remove the dashboard center lower cover.

1>: Clip, 2

: Screw, 2


~J~

Fastener Locations

C> : Clip, 4

/ 2. Detach the clips, and release the tabs (A), then remove the left fuse box cover.

A

3. Install the instrument panel in the reverse order of removal.

Fastener Locations

C> :Clip,3

~I

20-84

BACK

\

\

Passenger's Dashboard Lower Cover Removal/Installation 3. Remove the screws (A and B). Fastener Locations A ~ : Screw, 1

B ~ : Screw, 2


1>: Clip, 5

1. Remove the dashboard center lower cover (see step 1 on page 20-84). 2. Detach the clips, and release the tabs (A), then remove the right fuse box cover. Fastener Locations

I> : Clip, 3 ~ B

C

~

.-.~ 1/ ,.

/1 4. Detach the lower right clip (e) first by pulling down on the driver's dashbord lower cover (D), then detach the remaining clips and remove the lower cover. 5. Install the lower cover in the reverse order of removal.

(cont'd)

BACK

20-85

Dashboard Passenger's Dashboard lower Cover Removal/Installation (cont'd)

NOTE: • When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. • Take care not to scratch the dashboard and related parts.

3. Remove the screws (A and B). Fastener Locations A ~ : Screw, 1

B ~ : Screw, 2

Center Panel Removal/Installation

I> : Clip, 7

~ ~~i:=J

1. Detach the clips, and release the retaining tabs (A), then pull the clock out. Disconnect the clock connector (B) and hazard warning switch connector (C).

j~~

Fastener Locations

I> : Clip, 2

B

C

D

4. Detach the lower left clip (C) first by pulling down on the passenger's dashbord lower cover (D), then detach the remaining clips and remove the lower cover. B

5. Install the lower cover in the reverse order of removal.

20-86

BACK

Glove Box Removal/Installation 2. Remove the screws, and detach the clips (A), then detach the upper clips (A and B) to remove the center panel by disconnecting the heater control unit connectors (e). Fastener Locations ~ : Screw, 3

A [> : Clip, 5

B[>:Clip,2

~I~~

SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service. NOTE: Take care not to scratch the dashboard and related parts. 1. Remove these items: • Dashboard center lower cover (see step 1 on page 20-84) • Passenger's dashboard lower cover (see page 20-85) 2. Remove the screws from bottom of the glove box. Fastener Locations ~ : Screw, 4

3. Install the panel in the reverse order of removal, and make sure the connectors are plugged in properly.

(cont'd)

BACK

20-87

Dashboard Driver's Side Vent Removal! Installation

Glove Box Removal/Installation (cont'd) 3. Wrap a flat-tip screwdriver with protective tape, and apply protective tape around the related parts, to prevent damage. Insert a flat-tip screwdriver in the notch (A) of the cap (8), and release the hooks (C) by prying up the cap (8). Fastener Locations

1. Remove the coin pocket(A), then remove the screws from under the coin pocket. Fastener Locations ~: Screw, 2

[> : Clip,2

C

~ : Screw, 4

~I

E

D

4. Remove the screws. 5. Release the hooks (A), then pull down on the striker (8) to remove the glove box. Disconnect the glove box light connector (C).

A

2. Wrap a flat-tip screwdriver with protective tape, and apply protective tape around the related parts to prevent damage. Carefully insert a flat-tip screwdriver next to the clip, and detach the clips by prying on the driver's side vent (8). Take care not to scratch the dashboard and related parts. 3. Release the retaining tabs (C), and remove the vent. Disconnect the moonroof switch connector (D)(for some models) and the cruise control master switch connector (E)(for some models). 4. Install the vent in the reverse order of removal, and make sure the connectors are plugged in properly (for some models).

6. Install the glove box in the reverse order of removal, and make sure the glove box light connector is plugged in properly.

20-88

BACK

Passenger's Side Vent Removal and Installation 1. Wrap a flat-tip screwdriver with protective tape, and apply protective tape around the related parts to prevent damage. Carefully insert a flat-tip screwdriver next to the clip, and detach the clips (A) by prying on the passenger's side vent (B). Take care not to scratch the dashboard and related parts.

Side Defogger Vent Trim Removal and Installation 1. Wrap a flat-tip screwdriver with protective tape, and apply protective tape around the related parts to prevent damage. Carefully insert a flat-tip screwdriver next to the clip, and detach the clip by prying on the side defogger vent trim (A). Take care not to scratch the dashboard and related parts. Fastener Location

1>: Clip, 1

C

A

2. Remove the vent by detaching the clips (C).

2. Pull the vent trim out by releasing the hooks (B).

3. Reinstall the hook portions of the vent first, then push the clip portions into place securely.

3. Reinstall the hook portions of the vent trim first, then securely push the clips into place.

BACK

20-89

Dashboard Dashboard Removal/Installation SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service.

Driver's side:

5. From outside the driver's door, disconnect the side wire harness connectors (A), cabin wire harness connectors (B) and door wire harness connectors (C) from the left (driver's) fuse box (D). Disconnect the dashboard wire harness connector (E).

NOTE: • When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts to prevent damage. • An assistant is helpful when removing and installing the dashboard. • Take care not to scratch the dashboard, body and other related parts. • Put on gloves to protect your hands. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons.

o

2. Disconnect the negative cable from the battery. 3. Remove these items: • Center console (see page 20-83) • Glove box (see page 20-87) • Door opening trim, both sides as necessary, Coupe (see page 20-74) • Front door opening trim, both sides as necessary, Sedan (see page 20-75) • Front pillar trim, both sides - Coupe (see page 20-74) - Sedan (see page 20-75)

6. From under the dash, disconnect the dashboard wire harness connectors (A, B), steering hanger beam wire harness connector (C), and the brake switch connector (D). On MIT model, disconnect the clutch switch connectors (E).

4. Disconnect the combination switch connectors, ignition switch connectors and driver's airbag connector, and lower the steering column (see page 17-25). To prevent damage to the steering column, wrap it with a shop towel.

20-90

A

o

BACK

'00 model Coupe:

Middle portion:

D

7. From the passenger's side, pull the carpet (A) back as necessary (see page 20-81). Disconnect the SRS wire harness connector (8), ECM/PCM connector (C), air mix control motor connector (D), evaporator temperature sensor connector (E) and antenna lead (F). On '00 model Sedan and '01-02 models, disconnect the dashboard wire harness connector (s) (G). Detach the ECM/PCM and the antenna lead harness clips (H). On '00 model Coupe and '01-02 models, detach the connector holders (I) from the floor. Using a Torx T30 bit, remove the ground bolt. '98-99 models: B

A

/~

'01-02 models:

'00 model Sedan:

H~~( ~

A

\~

6x1.0mm 9.8 N·m (1.0 kgf·m,

7.2Ibf·ft)

(cont'd)

BACK

20-91

Dashboard Dashboard Removal/Installation (cont'd) 8. From the driver's side, disconnect the parking brake switch positive terminal (A), and detach the harness clips (8). On AT model, disconnectthe parking pin shift connector (C), and the shift lock solenoid connector (D).

B

D

Passenger's side: 9. From outside the front passenger's door, disconnect the side wire harness connector (A), cabin wire harness connectors (8), roof wire harness connector (e) and the door wire harness connectors (D) from the right (passenger's) fuse box (E). Disconnect the dashboard wire harness connector(s) (F).

B

10. From under the dash, disconnect the steering hanger beam wire harness connectors (A), blower motor connector (8), blower resistor connector (C) and the recirculation control motor connector (D), then detach the harness clip (E), harness holder (F) and connector clip (G). D

G

A

20-92

BACK

A

11. From outside the driver's door, remove the caps (A), then remove the bolts (B, C, D, E), and lift up on the dashboard (F) to release it from the guide pins (G). Fastener Locations B ~ : Bolt, 6

c ~ : Bolt, 4

D ~ : Bolt, 3

E ~ : Bolt. 1

~))))!))!))!O ~))!)))!I!))))!!I))!!O

8x 1.2Smm 22 N·m 12.2 kgf·m, 16Ibf.ft)

G

G

G

12. Carefully remove the dashboard through the front door opening. 13. Install the dashboard in the reverse order of removal, and note these items: • • • •

Make sure the dashboard fits onto the guide pins correctly. Before tightening the bolts, make sure the dashboard wire harnesses are not pinched. Make sure the connectors are plugged in properly, and the antenna lead is connected properly. Enter the anti-theft code for the radio. then enter the customer's radio station presets.

BACK

20-93

Dashboard Steering Hanger Beam Replacement NOTE: Put on gloves to protect your hands.

4. From the driver's side, if applicable, disconnect and detach the SRS wire harness connector (A). If equipped, disconnect the cruise control unit connector (8).

1. Remove the dashboard (see page 20-90). 2. Remove the following parts from the dashboard:

A

• Gauge assembly (see page 22-68) • Audio unit (see page 22-124) 3. From under the middle of the dash: release the passenger's airbag connector (A) from the connector holder (8), and disconnect the connector. Detach the harness clips (C), and remove the ground bolts (D).

c

c

A

5. Disconnect the dashboard wire harness connectors (A) from the right (passenger's) fuse box (8). Detach the harness clip (C) and connector clip (D), and remove the ground bolt (E).

c

C

D

C

B

A

6x 1.0mm 9.8 N·m (1.0 kgf·m, 7.2Ibf·ftl

D

A 6x1.0mm 9.8 N·m 11.0 kgf·m. 7.2Ibf·ft)

20-94

BACK

6. Disconnect the dashboard wire harness connectors (A) from the left (driver's) fuse box (B). Disconnect and detach the dashboard wire harness connector (C). Detach the dashboard wire harness connectors (D, E, F) from the connector holder (G), the steering hanger beam (H) and the driver's under-dash fuse/relay box (B). Detach the harness clip (I), and remove the ground bolt (J).

c

D

A

E

J H

B

6x1.0mm 9.8 N·m '1.0 kgf·m,

A

7.2Ibf·ft)

G

7. Remove the screws (A. B, C) and the front passenger's airbag mounting nuts from the dashboard. Fastener Locations A~ : Screw, 6

B~: Screw, 4

C ~: Screw, 2

.:Nut,4

® ~

6x1.0mm 9.8 N·m '1.0 kgf·m,

7.2Ibf·ft)

(cont'd)

BACK

20-95

Dashboard Steering Hanger Beam Replacement (cont'd) 8. Separate the dashboard (A) and steering hanger beam (B).

\

C

B

9. Install the steering hanger beam in the reverse order of removal, and note these items: • Make sure the dashboard wire harness (e) and steering hanger beam wire harness (0) are not pinched . • Make sure the connectors are plugged in properly.

20-96

BACK

Seats Component Location Index - Coupe

= SEAT-BACK LOCK CYLINDER

FRONT SEATS Removal/Installation, page 20-99 Disassembly/Reassembly, Manual Seat without Side Airbag, page 20-102 Manual Seat with Side Airbag, page 20-103 Manual Height Adjustable Seat without Side Airbag, page 20-106 Manual Height Adjustable Seat with Side Airbag, page 20-107 2-way Power Seat without Side Airbag, page 20-110 2-way Power Seat with Side Airbag, page 20-111 8-way Power Seat without Side Ai rbag, page 20-112 8-way Power Seat with Side Airbag, page 20-113 Seat Wiring Harness and Cable Installation, page 20-115 Torsion Bar Replacement, page 20-120 Seat Linkage Disassembly/Reassembly, 2-way Power Seat, page 20-121 8-way Power Seat, page 20-122 Seat Cover Replacement, page 20-123

BACK

REAR SEAT Removal/Installation, page 20-128 Seat-back Latch and Lock Cylinder Replacement, page 20-132 Seat-back Cover Replacement, page 20-134 Cushion Cover Replacement, page 20-138

20-97

Seats Component Location Index - Sedan

SEAT-BACK LATCH

REAR SEAT SIDE BOLSTER Removal/Installation, page 20-129 Side Bolster Cover Replacement, page 20-137

FRONT SEATS Removal/Installation, page 20-99 Disassembly/Reassembly, Manual Seat without Side Airbag, page 20-104 Manual Seat with Side Airbag, page 20-105 Manual Height Adjustable Seat without Side Airbag, page 20-108 Manual Height Adjustable Seat with Side Airbag, page 20-109 2-way Power Seat without Side Airbag, page 20-110 2-way Power Seat with Side Airbag, page 20-111 8-way Power Adjustable Seat, page 20-114 Seat Wiring Harness Installation, page 20-118 Torsion Bar Replacement, page 20-120 Seat Linkage Disassembly and Reassembly, 2-way Power Seat, page 20-121 8-way Power Seat, page 20-122 Seat Cover Replacement, page 20-123

20-98

BACK

REAR SEAT Removal/Installation, page 20-129 Armrest and Armrest Lid Replacement, page 20-130 Trunk Pass-through Cover Key Cylinder Replacement, page 20-131 Seat-back Latch Replacement, page 20-133 Seat-back Lock Cylinder Replacement, page 20-133 Seat-back Cover Replacement, page 20-135 Seat Cushion Cover Replacement, page 20-139

Front Seat Removal/Installation '00-02 models: SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service.

3. Lift up the front seat, then disconnect and detach the seat harness connector (A) and harness clip (8).

1. '00-02 models with side airbag: Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio preset buttons. Disconnect the negative cable from the battery, and wait at leasts 3 minutes before beginning work.

Manual seat (driver's seat): B A

2. Remove the seat track end covers (A), and remove the bolts securing the front seat (8). When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Take care not to scratch the body or tear the seat covers. Fastener Locations

To body.

~: Bolt. 4

~ '

10x1.25mm 34 N·m (3.5 kgf.m. 25Ibf·ft)

J

Manual seat ('98-99 models passenger's seat with seat heater):

-Without 8-way power seat:

With 8-way power seat:

B

To body.

(cont'd)

BACK

20-99

Seats Front Seat Removal/Installation (co nt'd) Manual seat ('00 model passenger's seat on Coupe with side airbag):

Manual height adjustable seat ('98-00 models, and '01-02 models without side airbag): B

A

A

-,.:;:::~ ~,-I

A

- - - - - - - -.. - - - . - - - - - -

A

B

II

To body.

!

.JniJ

Manual seat ('01-02 models passenger's seat on Coupe with side airbag):

·····ti· I

B

To body.

Manual height adjustable seat (,01-02 models with side airbag):

A

A A

A

A

To body.

B

20-100

BACK

To body.

8-way power seat ('98-99 models):


A A

A

To body.


B

A

2-way power seat ('01-02 models): A

B

A

A

A

To body. To body.

To body.

4. With the help of an assistant, carefully remove the front seat through the front door opening. 5. Install the seat in the reverse order of removal, and note these items: • Make sure the seat harness connector is plugged in properly . • '00-02 models: Enter the anti-theft code for the radio, then enter the customer's radio station presets.

BACK

20-101

Seats Front Seat DisassemblyIReassembly - Manual without Side Airbag - Coupe Disassemble the front seat as shown. Reassemble the seat in the reverse order of disassembly, and note these items: • • • •

Route the seat wire harness, recline cable and connecting cable ('99-02 models) correctly (see page 20-115'. Make sure the bushing and pivot washer are installed correctly. Apply multipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat-back cover, stretch the material evenly over the pad. HEADREST ('98-00 models)

~j HEADREST ('01-02 models)

_____ PIVOT NUT 8x1.25mm y-~~ 22 N·m (2.2 kgf·m, 16Ibf·ft)

~

~~

PIVOT WASHER

____ INNER SEAT TRACK

10 x 1.25 mm 47 N·m (4.8 kgf·m, 35Ibf·ft)

20-102

BACK

CONNECTING CABLE --~ ('99-02 models)

Front Seat DisassemblyIReassembly - Manual with Side Airbag - Coupe '00-02 models SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service. Disassemble the '00 model front seat as shown. '01-02 models disassembly/reassembly is similar except the seat wire harness locations are different. Reassemble the seat in the reverse order of disassembly, and note these items: • • • • • •

Route the seat wire harness and recline cable correctly (see page 20-115). Make sure the bushing and pivot washer are installed correctly. Apply multipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat-back cover, stretch the material evenly over the pad. Replace the back panel clips with new ones. If the seat-back pad or the OPDS unit is replaced, reinitialize the OPDS unit (see page 23-46).

CLIPS Replace. OPDS UNIT HARNESS

RECLINE COVER

BACK

20-103

Seats Front Seat DisassemblyIReassembly - Manual without Side Airbag - Sedan Disassemble the driver's seat as shown. The passenger's seat is similar except that it doesn't have a seat belt switch harness. Reassemble the seat in the reverse order of disassembly, and note these items: • • • •

Route the seat wire harness correctly (see page 20-118). Make sure the bushing and pivot washer are installed correctly. Apply multipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat-back cover, stretch the material evenly over the pad. HOOK /HEADREST

PIVOT NUT 8x 1.25 mm 22 N·m (2.2 kgf·m, 16Ibf.ft)

SEAT CUSHION

RECLINE ADJUSTER/ OUTER SEAT TRACK

10x 1.25mm 47 N·m (4.8 kgf·m, 35Ibf·ft)

10x 1.25mm 47 N·m (4.8 kgf·m, 35Ibf·ft)

INNER SEAT TRACK

CONNECTING WIRE

Twist 90· to connect.

20-104

10x1.25mm 47 N·m (4.8 kgf·m, 35Ibf·ft)

BACK

RECLINE LEVER RECLINE COVER

Front Seat DisassemblyIReassembly - Manual with Side Airbag - Sedan '00-02 models SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service. Disassemble the front seat as shown. Reassemble the seat in the reverse order of disassembly, and note these items: • • • • • •

Route the seat wire harness and recline cable correctly (see page 20-118). Make sure the bushing and pivot washer are installed correctly. Apply multipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat-back cover, stretch the material evenly over the pad. Replace the back panel clips with new ones. If the seat-back pad or the OPDS unit is replaced, reinitialize the OPDS unit (see page 23-46). HEADREST

BACKPANEL~ HOOKS

~

SEAT-BACK

ImRm SEAT CUSHION

~~

CLIPS

Replace.

CENTER COVER

~ //

10 x 1.25 mm


BACK

20-105

Seats Front Seat DisassemblyIReassembly - Manual Height Adjustable without Side Airbag - Coupe Disassemble the front seat as shown. Reassemble the seat in the reverse order of disassembly, and note these items: • • • • •

Route the seat wire harness correctly (see page 20-115). '99-02 models: Route the connecting cable correctly (see page 20-115). Make sure the bushing and pivot washer are installed correctly. Apply multipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat-back cover, stretch the material evenly over the pad. HEADREST HOOK

~O

~

I·....

~

rr

S£AT-"

\

/'

HEADREST 1'01-02 models)

HOOKS RECLINE ADJUSTER/ OUTER SEAT TRACK 10x1.25mm 47 N·m 14.8 kgf·m, 35 Ibf·tt)

RECLINE COVER

f/

A'

CONNECTING WIREI'98 model)

Twist 90· to connect.

20-106

BACK

Front Seat DisassemblyIReassembly - Manual Height Adjustable with Side Airbag - Coupe '01·02 model SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service. Disassemble the front seat as shown. Reassemble the seat in the reverse order of disassembly, and note these items: • • • • •

Route the seat wire harness correctly (see page 20-115). Route the connecting cable correctly (see page 20-115). Make sure the bushing and pivot washer are installed correctly. Apply multipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat-back cover, stretch the material evenly over the pad.

PIVOT NUT

HOOKS ___ BACK PANEL

HOOKS

CD

CLIPS

Replace.

f

~::

_____ RECLINE COVER

~~

7J;:%~RECLINE LEVER

01"--:7~ ~

--/~

~

(ffj)

8xl.25mm 22 N·m 12.2 kgf·m, U 16lbf·ftl CONNECTNG WIRE 1'98 model)

U,~HEIGHTKNOB ~

CLIP

Twist 90 0 to connect.

BACK

20-107

Seats Front Seat DisassemblyIReassembly - Manual Height Adjustable without Side Airbag - Sedan Disassemble the front seat as shown. Reassemble the seat in the reverse order of disassembly, and note these items: • • • •

Route the seat wire harness correctly (see page 20-118). Make sure the bushing and pivot washer are installed correctly. Apply multipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat-back cover, stretch the material evenly over the pad. HOOK

(

_________ HEADREST

PIVOT NUT 8x 1.25 mm 22 N·m (2.2 kgf.m, 16Ibf.ft)

CENTER COVER


8x 1.25 mm 22 N·m (2.2 kgf·m, 16Ibf·ft)

M

8x 1.25 mm 22 N·m (2.2 kgf·m, 16 Ibf·ft)

20-108

BACK

f~RECLlNE COVER

Front Seat DisassemblyIReassembly - Manual Height Adjustable with Side Airbag - Sedan '01-02 model SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service. Disassemble the front seat as shown. Reassemble the seat in the reverse order of disassembly, and note these items: • • • •

Route the seat wire harness correctly (see page 20-118). Make sure the bushing and pivot washer are installed correctly. Apply multipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat-back cover, stretch the material evenly over the pad.

~HEADREST HOOKS BACK PANEL

PIVOT NUT 8x 1.25 mm 22 N·m 12.2 kgf·m, 16Ibf·ft)

/

HOOKS

CLIPS Replace.

®

CENTER COVER

~ ,~)

WASHER

~~ / 0,/0\

( BUSHING

1,.,/

\ . ' 9' ~ ~ ~,

0&

/REClINEADJUSTERI /

OUTER SEAT TRACK

~ ~ 'dJ~ ~~'

~~'@

. . ~.::c

"/ (

8x1.25mm / (~ 22 N·m 12.2 kgf·m, . .;g 16Ibf·ft) "~ (CL.. WASHER" y END CAP '(/ ""'-. It!" .

t

TRACK

f.

10x1.25mm

~~S~r/47N.mI4'8kgf.m'35Ibf.ft) ,~ [

>

/ :;~

0~~

...

~

l;~ ~~ €)

~

~

WASHER

---

END CAP

~

8x1.25mm 22 N·m 12.2 kgf.m, 16 Ibf·ft)

BACK

RECLINE

~ ~ COVER ifjJ

('. /" ~

yr::.

WASHER CONNECTING WIRE Twist 90 0 to connect.

r

~

~

~ U

LEVER

~~ U HEIGHT '"

CLIP

KNOB

20-109

Seats Front Seat Disassembly/Reassembly - 2-Way Power without Side Airbag '98-00 models Disassemble the front seat as shown. Reassemble the seat in the reverse order of disassembly, and note these items: • • • • •

Route the seat wire harness correctly, Coupe (see page 20-115), Sedan (see page 20-118). Make sure the bushing and pivot washer are installed correctly. Apply multipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat-back cover, stretch the material evenly over the pad. Replace the back panel clips with new ones. /HEADREST HOOKS PIVOT NUT 8x1.25mm 22 N·m (2.2 kgf·m. 16Ibf·ft)

SEAT CUSHION

~

10x1.25mm 47 N·m (4.8 kgf·m. 35 Ibf·ft)

20-110

BACK

Front Seat Disassembly/Reassembly - 2-Way Power with Side Airbag '01-02 model SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service. Disassemble the front seat as shown. Reassemble the seat in the reverse order of disassembly, and note these items: • • • • •

Route the seat wire harness correctly, Coupe (see page 20-115), Sedan (see page 20-1181. Make sure the bushing and pivot washer are installed correctly. Apply mUltipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat-back cover, stretch the material evenly over the pad. Replace the back panel clips with new ones.

HOOKS

PIVOT NUT

CLIPS

Replace.

SEAT LINKAGE

BACK

20-111

Seats Front Seat DisassemblyIReassembly - 8-Way Power without Side Airbag Coupe '98-99 models Disassemble the front seat as shown. Reassemble the seat in the reverse order of disassembly, and note these items: • • • • •

Route the seat wire harness correctly (see page 20-115). Make sure the bushing and pivot washer are installed correctly. Apply mUltipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat-back cover, stretch the material evenly over the pad. Replace the back panel clips with new ones. _ /HEADREST PIVOT NUT ax 1.25mm 22 N·m (2.2 kgf·m, 16Ibf·ft)

HOOKS

WIRE TIE

SEAT

CU~

CLIPS Replace.

SEAT-BACK HEATER HARNESS (for some models) SEAT CUSHION HEATER HARNESS (for some models)

CLIP To seat cushion cover. CLIP

SEAT LINKAGE

10x 1.25mm 47 N·m (4.a kgf.m,

35Ibf·ft)

20-112

BACK

Front Seat DisassemblyIReassembly - a-Way Power with Side Airbag Coupe '00-02 models SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service. Disassemble the '00 model front seat as shown. '01-02 models Disassembly/Reassembly is similar except the seat wire harness locations are different. Reassemble the seat in the reverse order of disassembly, and note these items: • • • • •

Route the seat wire harness and recline cable correctly (see page 20-118). Make sure the bushing and pivot washer are installed correctly. Apply mUltipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat-back cover, stretch the material evenly over the pad. Replace the back panel clips with new ones. KNOB

HOOKS

SEAT-BACK HEATER HARNESS (for some models) SEAT CUSHION HEATER HARNESS (for some models) - - - - - - RECLINE CABLE Disconnect.

~Jl:~='3f~-SWITCH KNOBS

BACK

20-113

Seats Front Seat DisassemblyIReassembly - a-Way Power - Sedan '00-02 models: SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service. Disassemble the front seat as shown. Reassemble the seat in the reverse order of disassembly, and note these items: • • • • •

Route the seat wire harness correctly (see page 20-118). Make sure the bushing and pivot washer are installed correctly. Apply mUltipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat-back cover, stretch the material evenly over the pad. Replace the back panel clips with new ones.

PIVOT WASHER PIVOT NUT 8x 1.25 mm 22 N·m 12.2 kgf.m, 16lbf·ftl

SEAT CUSHION HEATER HARNESS Ifor some models)

CLIP To seat cushion cover.

CLIP

SEAT LINKAGE

10 x 1.25 mm 47 N·m 14.8 kgf·m, 35Ibf·ft)

20-114

BACK

Front Seat Wiring Harness and Cable Installation - Coupe When assembling the front seat, make sure the recline cable (A), and connecting cable ('99-02 models) (8), seat belt switch harnesses (C), seat harness (D), seat heater harness (E), side airbag harness ('00-02 models) (F), OPDS unit harness ('00-02 models) (G), connectors (H), clips (I) and wire ties (J) are fastened correctly.

Manual seat ('00-02 models passenger's seat with side airbag): -Seat back: G

J

Manual seat ('98-99 model passenger's seat with seat heater):

B

A

-Seat cushion ('00 model): D

H

B

E H

To seat-back heater.

To seat cushion heater.

To recline adjuster.

Manual seat ('00 model passenger's seat without side airbag): To recline adjuster.


[A]

[B]

-Seat cushion ('01-02 models): H

B

A

A

To seat belt buckle.

To recline To seat cushion adjuster. heater.


[A]

[B]

(cont'd)

BACK

20-115

Seats Front Seat Wiring Harness and Cable Installation - Coupe (cont'd) 2-way power seat ('98-00 models):

Manual height adjustable seat ('98-00 models):

D

B H

c

H


Manual height adjustable seat ('01-02 models with side airbag):


F

[A]

J

To power seat switch.

F H

I D

[A]

20-116

BACK

F

J

8-way power seat ('98-99 models with seat heater):


F

c H ~-



o

H



I

r

8-way power seat ('00 model with seat heater):


H

F


o J To seat cushion heater.


E

J

H

c


J F


BACK

20-117

Seats Front Seat Wiring Harness Installation - Sedan When assembling the front seat, make sure the seat belt switch harness (A). seat harness (8), seat heater harnesses (e), side airbag harness ('00-02 models) (D), OPDS unit harness ('00-02 models) (E), connectors (F), clips (G) and wire ties (H) are fastened correctly.

Manual seat ('00-02 models passenger's seat with side airbag): E

H

H

Manual seat (driver's seat):

H

-4VI J

[A] [8]

H

H F

Manual seat ('98-99 models passenger's seat with seat heater):

F

G G

G

F

F G

c

D

~' To seat-back heater.

20-118

,



BACK

[A]

[8]

Manual height adjustable seat (without side airbag):

2-way power seat ('98-00 models): B

G


G

Manual height adjustable seat ('01-02 models with side airbag): 2-way power seat ('01-02 models):

0

G

H G

H

G

0

A

G

F

B

~ [AJ

G

[AJ

(cant'd)

BACK

20-119

Seats Front Seat Wiring Harness Installation - Sedan (cont'd)

Front Seat Torsion Bar Replacement - Manual Height Adjustable

8-way power seat ('98-99 models with seat heater): NOTE: Take care not to tear the seams or damage the seat covers.

G

F

1. Remove the front seat (see page 20-99).

G A

G

F

2. Put on gloves to protect your hands. Remove the torsion bar (A) from the hook (8) with a flat-tip screwdriver (C), then pull out the torsion bar from the seat cushion frame (0).

G


F

B

To seat cushion To seat-back heater. heater.

C


D

F

G

G G G

A

r-

r':

F

G

D

20-120

D

G

~/

H

C

r\

[BJ To seat cushion heater.

[AJ

3. Install the torsion bar in the reverse order of removal.

B

G

BACK

Front Seat Linkage Disassembly/Reassembly - 2-Way Power NOTE: o Before removing the front seat from the vehicle, raise the seat cushion to its maximum height. o Put on gloves to protect your hands.

Disassemble the front seat linkage as shown. Reassemble the seat linkage in the reverse order of disassembly, and note these items: o o

o

Replace the bushings with new ones. Apply mUltipurpose grease to the sliding and pivoting portions of the linkage. Check operation ofthe recline and slide/up-down adjusters 8x1.25mm 12 N·m (1.2 kgf·m, 8.7Ibf·ft)

SLIDE/UP-DOWN ADJUSTER

LINK OUTER COVER

END CAP

~/

" WASHER 6x1.0mm 4.9 N·m (0.5 kgf·m, 3.6 Ibf.ft) POWER SEAT HARNESS 8x 1.25 mm 12 N·m (1.2 kgf·m, 8.7Ibf·ft)

"

~8X1.25mm

UP-DOWN MOTOR

BACK

12 N·m (1.2 kgf·m, 8.7 Ibf·ft)

20-121

Seats Front Seat Linkage Disassembly/Reassembly - B-Way Power Disassemble the front seat linkage as shown. Reassemble the seat linkage in the reverse order of disassembly. and note these items: • For the power height seat. replace the bushings with new ones. • Apply mUltipurpose grease to the sliding and pivot portions. • Check operation of the recline adjuster and slide/up-down adjuster.

SLIDE/UP-DOWN ADJUSTER

6x 1.0mm 8.5 N·m (0.87 kgf.m. 6.3 Ib'·ftl

POWER SEAT HARNESS

20-122

BACK

Front Seat Cover Replacement '00-02 models Sedan: SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service.

Seat-back Cover 1. '98-99 models: With seat heater, remove the seatback heater harness from the seat cushion: - 1 Remove the seat (see page 20-99). - 2 Disconnect the seat-back heater connector (A). - 3 Release the hooks (B), and pull back the seat cushion cover (C). - 4 Release the wire tie (D). - 5 Pull out the harness (E).

NOTE: • With side airbag ('00-02 models): The seat with a airbag is marked with a side airbag on the surface of the seat-back. Because the component parts (seatback cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. • '00-02 models Sedan: The front seats with side airbags are produced by three different suppliers. Before replacing the seat-back, make sure the seatback cover (A), pad (B) and frame (C) are from the same supplier. Before assembling the seat-back, make sure the suppliers identification (D) is the same on each part.

Driver's seat (the passenger's seat is similar):

B

A

c

D

E


2. Fold the seat-back forward. 3. If equipped, remove the back panel (refer to step 7). • With side airbag ('00-02 models): Do not repair any tears or frayed spots of the seat-back cover. If necessary, replace the seat-back cover. • Take care not to tear the seams or damage the seat covers. • With side airbag ('00-02 models): Do not touch the Occupant Position Detection System OPDS sensor in the seat-back pad. Keep the sensor free from grease oils and moisture, as they can damage the sensor. Oils can corrode the sensor, causing its faulty. • Put on gloves to protect your hands.

4. 8-way power seat on Coupe: Remove the rear seat access knob, '98-99 models (see page 20-112) or the access knob trim, '00-02 models (see page 20113).

(cont'd)

BACK

20-123

Seats Front Seat Cover Replacement (cont'd) 5. If equipped, remove the clip (A), then remove the lumbar support knob (8).

7. Release all of the inside springs (A), then fold back the seat-back cover (8), and release the hook strip (C).

'\.

Without back pane1('98-00 modelsl: B

c

A A

6. Without back panel, release the hook strip (A), and fold back the seat-back cover (8). B

Without back panel ('01-02 modelsl:

A

With back cover/Without side airbag (except leather seat cover, '98-00 model): B

c

c

c

A

A

20-124

BACK

9. Lift and pull out the release button (A), and remove the screw (8), then remove the headrest guide (e).

With back panel/Without side airbag (leather seat cover, '98-00 models):

c

B

c

A ~--t-l-• .!J~

c

10. Pull back the edge of the seat-back cover all the way around.

With side airbag ('00-02 models):

A~=======~~C

11. '98-00 models Sedan: Except leather seat cover, release the fastner (A).

A

c A

tlllilllllllli;

A

\

1------\\

c

8. '00-02 models: If equipped with side airbag, release all the hooks (D, E). Ifthere is no inside springs to release in step 7, release all of the clips from the locations which are showed as inside spring portions in this illustration.

12. Remove the seat-back cover.

(cont'd)

BACK

20-125

Seats Front Seat Cover Replacement (co nt'd) 13. Install the cover in the reverse order of removal, and note these items:

Seat Cushion Cover 1. Remove the front seat (see page 20-99).

• To prevent wrinkles when installing a seat-back cover, make sure the material is stretched evenly over the pad before securing the fastener, hook and inside springs. • '00-02 models: On some type seats with side airbag, replace the clips (A) with new ones using commercially available upholstery ring pliers (8). • Use only original Honda replacement seat-back covers ('00-02 models).

2. Remove the seat cushion (see page 20-112). 3. Release the clips (A) and hooks (8) from under the s eat cushion, then loosen the seat cushion cover (e). All except 8-way power seat: A

c

B

IJ-_-/

B

B

8-way power seat: A

c

o B

20-126

BACK

0

B

4. Pull back the edge of the seat cushion cover all the way around, and release the clips (A) and fastener (B), then remove the seat cushion cover. On a leather seat cover and '00-02 models seat cushion cover, there is no fastener to remove.

5. Install the cover in the reverse order of removal, and note these items.

Except leather seat cover ('98-00 models): A

• To prevent wrinkles when installing a seat cushion cover, make sure the material is stretched evenly over the pad before securing the clips and hooks . • Replace the released clips with new ones (A) using commercially available upholstery ring pliers (B). B

A

B

Except leather seat cover ('01-02 models): A

BACK

20-127

Seats Rear Seat Removal/Installation - Coupe NOTE: Take care not to scratch the body or tear the seat covers. Remove the rear seat as shown. Install the seat in the reverse order of removal, and note these items: • Before attaching the rear seat-back and cushion, make sure there are no twists or kinks in the rear seat belts and center belt. • When installing the seat cushion, slip the seat belt buckles through the openings in the seat cushion. • Make sure the seat-back locks securely. Fastener Locations B ~:Bolt,2

A ~ : Bolt, 4

@)mn

6x 1.0mm 9.8N·m (1.0 kgf·m, 7.2Ibf·ft)

8x1.2Smm 22N·m (2.2 kgf·m, 16Ibf·ft)

A [> : Clip. 1

C ~: Bolt, 1

~

D ~:Bolt, 1 6x1.0mm 9.8N·m (1.0kgf·m. 7.2Ibf·ft)

6x1.0mm

I 9.8N·m ~ (1.0 kgf·m.

7.2Ibf·ft)

B [>: Hook. 2 CENTER PIVOT BRACKET PIVOT BRACKET

RIGHT SEAT-BACK

~ LEFT - - SEAT-BACK CENTER BELT GUIDE

Remove the center belt from the center belt guide.

SEAT CUSHION

B

PIVOT BRACKET

OPENINGS

20-128

~---~

Remove the rear side trim panel.

BACK

Rear Seat Removal/Installation - Sedan NOTE: Take care not to scratch the body or tear the seat covers. Remove the rear seat as shown. Install the seat in the reverse order of removal, and note these items: • Before attaching the rear seat-back and cushion, make sure there are no twists or kinks in the rear seat belts and center belt. • When installing the seat cushion, slip the seat belt buckles through the slits in the seat cushion. • Make sure the seat-back locks securelly. Fastener Locations A ~ : Bolt, 4

•

B ~ : Bolt, 2

C~:Bolt,1

At>: Clip, 1

B t> : Hook, 2

6x1.0mm 9.8N·m 11.0kgf·m, 7.2Ibf.ftl

8X1.25mm 22N·m 12.2 kgf·m, 16lbf·ftl

HOOK

.J.----

LEFT SIDE BOLSTER

HOOK

CENTER BELT GUIDE

Remove the center belt from the center belt guide.

REAR SEAT BELT BUCKLE

REAR SEAT BELT BUCKLE

SEAT CUSHION

CENTER BELT BUCKLE

BACK

PIVOT BRACKET

20-129

Seats Rear Seat Armrest/Trunk Pass-through Cover Replacement - Sedan NOTE: Take care not to tear the seams or damage the seat covers.

3. Remove the beverage holder.

1. Remove the clip (A) from the left portion of the armrest pivot.

4. Fold the seat-back forward. 5. Remove the screws, and detach the hooks (A), then remove the trunk pass-through cover (B). 2. Remove the armrest. Fastener Locations ~: Screw, 2

- 1 Slide the armrest (A) toward the driver's side of the vehicle. - 2 Remove the pivot shaft (B) from the collar (e) on the passenger's side of the vehicle by pulling up on the armrest, and remove the pivot shaft (B) from the collar (D) by pulling up on the armrest.

~I

A

6. Install the armrest and trunk pass-through cover in the reverse order of removal.

20-130

BACK

Trunk Pass-through Cover Key Cylinder Replacement NOTE: • When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage . • Take care not to scratch the cover.

4. Remove the trunk handle (A) and rear seat handle (B) together at the same time.

1. Using a flat-tip screwdriver, pry the rear seat handle (A) up at either hook portion (B) on forward side of the trunk pass through cover (e). Then slide the handle half-way up.

2. From trunk compartment side of the cover, using a small screwdriver, press the inside hook (A) down through the access hole (B).

5. Remove the retainer clip (e), then remove the trunk pass-through cover key cylinder (0) from the cover (E).

6. Install the key cylinder in the reverse order of removal, and note these items: • Put the two handles together before installing them on the trunk pass-through cover. • Make sure the trunk pass-through cover opens properly and locks securely.

3. While pressing the hook, pry the trunk handle (e) up with a flat-tip screwdriver.

BACK

20-131

Seats Rear Seat-back Latch and Lock Cylinder Replacement - Coupe NOTE: • When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage . • Take care not to bend or scratch the interior trim.

1. Remove these items (see page 20-128): • Rear seat-backs and rear seat cushion 2. Remove these items (see page 20-76): • • • • • •

Rear bulkhead cover Center anchor bolt of the center belt Center belt lid High mount brake light Lock cylinder trim Rear shelf

3. Remove these items (see page 20-74): • Door sill trim (both sides) and rear side trim panel 4. Disconnect the cylinder rods (A) from the seat-back latch (8) on both sides. Fastener Locations C~:Bolt,4

•

D ~ : Screw, 2 6X1.0mm 9.8N·m 11.0 kgf·m, 7.2Ibf·ft)

' 4xo.7m~ .~ I 1.6N·m ~ . 10.16 kgf·m, 1.2 Ibf.tt)

5. Remove the bolts (C), then remove the seat-back latch. 6. Remove the screws (D), then remove the seat-back lock cylinder (E) and cylinder rods. 7. Install the latch and lock cylinder in the reverse order of removal, and note these items: • Make sure the cylinder rods are securely connected . • Make sure the seat-backs open properly.

20-132

BACK

Rear Seat-back latch Replacement Sedan

Rear Seat-back Lock Cylinder Replacement - Sedan

NOTE:

NOTE:

o

o

When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Take care not to bend or scratch the interior trim. 1. Remove these items: o o

When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Take care not to bend or scratch the interior trim.

o

o

1. Remove the seat side bolsters (both sides) (see page 20-129).

Seat side bolster, both sides (see page 20-129) Rear bulkhead cover (see page 20-77)

2. Disconnect the cylinder rod (A) from the trunk compartment.

2. Remove the rear door opening trim (both sides) (see page 20-75). 3. Remove these items (see page 20-75): o o

o o

o o

o o

Rear door opening trim (both sides) Rear pillar trim (both sides) Rear bulkhead cover Center anchor bolt of the center belt Center belt lid High mount brake light Lock cylinder trim Rear shelf

4. Disconnect the cylinder rod from the trunk compartment. Refer to the Seat-back Latch Replacement, step 2. 3. Remove the bolts, then remove the seat-back latch. 5. Remove the bolts, then remove the seat-back lock cylinder.

Fastener Locations ~:Bolt,2

Fastener Locations

6x 1.0mm 9.8N·m (1.0 kgf.m, 7.2Ibf·ft)

~ : Bolt, 2 6x1.0mm 9.8N·m (1.0 kgf·m. 7.2Ibf·ft)

I

4. Install the latch in the reverse order of removal, and note these items: o o

Make sure the cylinder rod is connected securely. Make sure the seat-back locks securely and opens properly.

6. Install the lock cylinder in the reverse order of removal, and note these items: o o

BACK

Make sure the cylinder rod is connected securely. Make sure the seat-back open properly.

20-133

Seats Rear Seat-back Cover Replacement - Coupe NOTE: • Take care not to tear the seams or damage the seat covers . • Put on gloves to protect your hands.

4. Release all the clips (A), and fold back the seat-back cover.

left seat-back: A

1. Remove the seat-backs (see page 20-128). 2. Remove the screws, then remove the center belt guide from right seat-back. Fastener Locations ~:Screw,2

~ ~'M~ ~~

Right seat-back: A

3. Remove the clips, and pull the seat-back mat (A) back, then separate the left seat-back (B) and right seat-back (e). Fastener Locations

C>: Clip, 16

jEJ

............................................

:

-~

. ........................... ~-

A

20-134

BACK

Rear Seat-back Cover Replacement - Sedan 5. Pull back of the seat-back cover (A) all the way around, release the clips (8) and hooks (e) from the pad (D). Left seat-back:

NOTE: • Take care not to tear the seams or damage the seat covers . • Put on gloves to protect your hands.

B

1. Remove the seat-back (see page 20-129). 2. If equipped, remove the armrest and armrest frame (see page 20-130). 3. Remove the screws, then remove the center belt guide. Fastener Locations ~:Screw,2

~ Right seat-back:

B

6. Install the cover in the reverse order of removal, and note these items: • To prevent wrinkles when installing a seat-back cover, make sure the material is stretched evenly over the pad before securing the hooks and clips . • Replace the released clips with new ones.

(cont'd)

BACK

20-135

Seats Rear Seat-back Cover Replacement - Sedan (cont'd) 4. Remove the clips, then pull back the seat-back mat.

5. Release all the clips (A) and hook strips (8), and fold back the seat-back cover (e).

With armrest: With armrest:

Fastener Locations

A

B

I> :Clip, 6

jEJ ,.. I

\

0<1

I><>

r~

0
[>0

\7

0

-~

0

\J

)

\

Q

~

/ Without armrest: Fastener Locations

B

1>: Clip,S

IJ

Without armrest: A

\

0<1

0
0

~

J

[>0

0

~

- \7 0

\J Q

1

20-136

1

C

BACK

B

Rear Seat Side Bolster Cover Replacement - Sedan 6. Pull back the edge of the seat-back cover (A) all the way around, and release the clips (B) and fasteners (C), then remove the seat-back cover. On a leather seat cover, there are no fasteners (C).

1. Remove the seat side bolster (see page 20-129). 2. Release all the hook strips (A), fold back the seat side bolster cover (B), and remove it.

All except leather seat cover:

B

C

B

A

Leather seat cover: B

B

3. Install the cover in the reverse order of removal, and to prevent wrinkles, make sure the material is stretched evenly over the pad before securing the hook strips.

A

7. Install the cover in the reverse order of removal, and note these items: • To prevent wrinkles when installing a seat-back cover, make sure the material is stretched evenly over the pad before securing the fasteners, hooks and clips . • Replace the released clips with new ones.

BACK

20-137

Seats Rear Seat Cushion Cover Replacement - Coupe 1. Remove the seat-backs and seat cushion (see page 20-128).

4. Install the cover in the reverse order of removal, and note these items: • To prevent wrinkles when installing a seat cushion cover, make sure the material is stretched evenly over the pad before securing the inside springs and clips . • Replace the clips with new ones (A) using commercially available upholstery ring pliers (B).

2. Release all the clips (A) from under the seat cushion, and fold back the seat cushion cover.

A

----8 A

3. Pull back the edge of the seat cushion cover all the way around, and release the clips (A) and inside springs (B), then remove the seat cushion cover. 8

20-138

A

8

BACK

Rear Seat Cushion Cover Replacement - Sedan 4. Install the cover in the reverse order of removal, and note these items:

1. Remove the seat cushion (see page 20-129). 2. Release all the clips (A) from under the seat cushion, and fold back the seat cushion cover.

• To prevent wrinkles, make sure the material is stretched evenly over the pad before securing the fasteners and clips . • Replace the clips with new ones (A) using commercially available upholstery ring pliers (8).

A

A

3. Pull back the edge of the seat cushion cover all the way around, and release the clips (A) and fasteners (8), then remove the seat cushion cover. On a leather seat cover, there are no fasteners (8).

BACK

20-139

Bumpers Front Bumper Removal/Installation - Coupe '98-00 models NOTE: • An assistant is helpful when removing the front bumper. • Take care not to scratch the front grille, front bumper and body. • Put on gloves to protect your hands.

Remove the front bumper as shown. Install the bumper in the reverse order of removal, and note these items: • Make sure the front bumper engages the side clips, and the hooks (of the corner upper beams) on each side securely. • Replace any damaged clips. Fastener Locations B ~: Screw. 2 A [>: Clip. 5

A ~:Bolt.2

B [>:Clip,6

6x 1.0 mm 9.8N·m (1.0 kgf·m.

7.2Ibf·ft)

LEFT CORNER BEAM

INNER FENDER

A

'Y---J B

FRONT BUMPER

20-140

BACK

'01-02 models NOTE: • An assistant is helpful when removing the front bumper. • Take care not to scratch the front grille, front bumper and body. • Put on gloves to protect your hands.

Remove the front bumper as shown. Install the bumper in the reverse order of removal, and note these items: • Make sure the front bumper engages the side clips, and the hooks (of the corner upper beams) on each side securely. • Replace any damaged clips. Fastener Locations A~:Bolt,2

B ~ : Screw, 2

._t~:o~ifm_,~ ~

A I> : Clip, 5

B I> : Clip, 4

t:J ~ //

CENTER UPPER BEAM

B

FRONT BUMPER B

BACK

A B

20-141

Bumpers Front Bumper Removal/Installation - Sedan '98-00 models NOTE: • An assistant is helpful when removing the front bumper. • Take care not to scratch the front bumper and body. • Put on gloves to protect your hands.

Remove the front bumper as shown. Install the bumper in the reverse order of removal, and note these items: • After reinstalling the center upper beam, check the aim of the headlights (see page 22-98). • Make sure the front bumper engages the side clips, and the hooks (of the center and corner upper beams) on each side securely. • Replace any damaged clips. Fastener Locations B ~ : Screw. 2

A ~ : Bolt. 2

AI>:Clip,2

B I> : Clip. 6

LEFT CORNER UPPER BEAM

B

B

~ B

FRONT BUMPER

20-142

BACK

! B

1 A

B

Fastener Locations B ~ : Bolt, 4 A ~ : Bolt, 6

C ~ : Bolt, 6 6x1.0mm 9.a N·m

j •

ax1.25mm 22 N.m (2.2 kgf.m, 16Ibf.ft)

(1.0 kgf·m, 7.2Ibf·ft)

------------

._._------

-----

------_ .. _--------

CENTER UPPER BEAM Remove both headlights.

C

/

LEFT CORNER UPPER BEAM

ABSORBER ABSORBER BOX

FRONT BUMPER BEAM

(cont'd)

BACK

20-143

Bumpers Front Bumper Removal/Installation - Sedan (cont'd) '01-02 models NOTE: • An assistant is helpful when removing the front bumper. • Take care not to scratch the front bumper and body. • Put on gloves to protect your hands.

Remove the front bumper as shown. Install the front bumper in the reverse order of removal, and note these items: • After reinstalling the center upper beam, check the aim of the headlights (see page 22-98). • Make sure the front bumper engages the side clips, and the hooks (of the center and corner upper beams) on each side securely. • Replace any damaged clips. Fastener Locations A~:Bolt.2

B ~: Screw, 2

At>: Clip,2

A FRONT BUMPER

20-144

B

B t>: Clip,S

~

BACK

B

Rear Bumper Removal/Installation - Coupe '98-00 models NOTE: • An assistant is helpful when removing the rear bumper. • Take care not to scratch the rear bumper and body. • Put on gloves to protect your hands.

Remove the rear bumper as shown. Install the bumper in the reverse order of removal, and note these items: • Make sure the rear bumper engages the side clips and the hooks (under the taillight) on each side securely. • Replace any damaged clips. Fastener Locations ~:Screw,2

A I> : Clip, 7

B 1>: Clip, 2

C 1>: Clip, 4

GROMMET

REAR BUMPER

j~ ~ rP...,..,_ CLIP

a=;

I

CLIP

REAR BUMPER HOOKS SIDE CLIP

LEFT SIDE MARKER LIGHT CONNECTOR

A Detach the clip by pulling out on the rear bumper.

REAR BUMPER Remove the trunk side trim to detach clips.

(cont'd)

BACK

20-145

Bumpers Rear Bumper Removal/Installation - Coupe (cont'd) Fastener Locations

. : Nut. 4 \ ~ @

8x1.25mm 22N·m (2.2 kgf·m. 16lbf·ftl

REAR BUMPER BEAM

RIGHT ABSORBER GUSSET LEFT ABSORBER

20-146

BACK

'01-02 models NOTE: • An assistant is helpful when removing the rear bumper. • Take care not to scratch the rear bumper and body. • Put on gloves to protect your hands.

Remove the rear bumper as shown. Install the bumper in the reverse order of removal, and note these items: • Make sure the rear bumper engages the side clips, rear clips, and the hooks (under the taillight) on each side securely. • Replace any damaged clips. Fastener Locations A ~ : Screw, 2

A

B [>: Clip, 2

[> : Clip, 7

REAR BUMPER HOOKS

LEFT SIDE MARKER LIGHT CONNECTOR

REAR BUMPER

Detach the clip by pulling out on the rear bumper.

A On each side, pull the bumper out to detach it from the side and rear clips.

BACK

A

20-147

Bumpers Rear Bumper Removal/Installation - Sedan NOTE: • An assistant is helpful when removing the rear bumper. • Take care not to scratch the rear bumper and body. • Put on gloves to protect your hands.

Remove the rear bumper as shown. Install the bumper in the reverse order of removal, and note these items: • Make sure the rear bumper engages the side clips and the hooks (under the taillight) on each side securely. • Replace any damaged clips. Fastener Locations

~ : Screw, 2

A

I> : Clip, 7

B

CLIP

1>: Clip, 2

REAR BUMPER HOOKS

SIDE CLIPS

20-148

BACK

Fastener Locations

•

: Nut. 4 8x 1.25mm 22N·m 12.2 kgf·m 16lbf.ft) •

REAR BUMPER BEAM

ABSORBER ABSORBER BOX

BACK

20-149

Hood Replacement NOTE: • An assistant is helpful when removing and installing the hood. • Take care not to damage the hood and body.

Remove the hood as shown. Install the hood in the reverse order of removal, and note these items: • Make sure the windshield washer tubes are connected properly. • Make sure the hood opens properly and locks securely. • Adjustthe hood alignment (see page 20-151). Fastener Locations ~ : Bolt, 4

6x1.0mm 9.8N·m (1.0kgf·m,

7.2Ibf.ftl

HOOD

/

WINDSHIELD WASHER TUBES

20-150

BACK

WINDSHIELD WASHER NOZZLES

HOOD HINGE

Adjustment 1. Slightly loosen each hood hinge bolt. 2. Adjust the hood alignment in this sequence. • Adjust the hood right and left, as well as forward and rearward, by using the elongated holes on the hood hinge (A).

• Turn the hood edge cushions (8), as necessary, to make the hood fit flush with the body at front and side edges. • Adjust the hood latch (e) to obtain the proper height at the forward edge, and move the hood latch right or left until the striker (0) is centered in the hood latch.

6x 1.0mm 9.8 N·m (1.0 kgf.m, 7.2Ibf.ft)

I

:.~:

~~~~:-::-il~-::;::::;-- 6 x 1.0 mm

:5,)"

li

D

'..

9.8 N·m (1.0 kgf·m, 7.2 Ibf·ft) _.,----_-'-., r I

I

C

L~_~J~

,,~-~

(cont'd)

BACK

20-151

Hood Adjustment (cont'd)

Hood Insulator Replacement

3. Tighten each bolt securely.

NOTE: Take care not to scratch the hood. 1. Remove the hood insulator (A).

4. Check that the hood opens properly and locks securely. 5. Apply body paint to the hinge mounting bolts and around the hinges. 6. Grease each location of the hood latch and hood hinge as indicated by the arrows.

- 1 Disconnect the windshield washer tubes (8) from the windshield washer nozzles (C). - 2 Release the windshield washer tube from the clips (D). - 3 Using a clip remover, detach the clips (D, E) release the hooks (F), and remove the hood insulator. Fastener Locations

D 1>: Clip, 1

E

I> : Clip, 11

A

B 2. Install the insulator in the reverse order of removal, and note these items:

• Replace any damaged clips . • Make sure the washer tubes are connected properly.

20-152

BACK

Hood Seal Rubber and Hood Molding Replacement 1. Using a clip remover, detach the clips, then remove the hood seals (A). On Canadian models, remove the hood molding (8). On '00-02 Canadian Coupe model, Carefully peel the hood molding adhesive tapes (F) off of the hood. Take care not to scratch the hood.

Sedan: Fastener Locations

C [> : Clip, 12

0[>: Clip, 7

Coupe: Adhesive tape ('00-02 models): 3M3511, or equivalent Thickness: 1 mm (0.04 in.) Width: 5 mm (0.2 in.)

E [> : Clip, 11

Fastener Locations

C [> : Clip, 12

B

0 [> : Clip, 9

/ 1F'NN'tY

'98-'99 models:

~b

,

A

/

Y

o

'00-'01 models:

E~IF~ /B D~X X Iiyr--;;;;;;;:.' X X~D \: o

A

A

2. Install the hood seal and hood molding in the reverse order of removal, and note these items: • Replace any damaged clips . • On '00-02 Canadian Coupe model: If the old hood molding is to be reinstalled, scrape off all traces of the old adhesive tape, then clean the molding surface with alcohol. Apply primer (3M K500, or equivalent) to the hood molding where the new adhesive tape will attach, then give the molding into place securely with new adhesive tape.

A

BACK

20-153

Trunk Lid Replacement NOTE: Put on gloves to protect your hands. ,. Coupe only, remove the screws, then remove the taillight lid cover (A) from each side. Fastener Locations ~: Screw, 2

o:nwl

2. Disconnect the taillight connectors (A), license plate light connector (8), trunk lid latch actuator connector (C), trunk lid cylinder switch connector (D) and remove trunk lid opener cable (E). B

o A

A

3. Detach the harness clips and connector clips (F), then remove the wire harness (G) and trunk lid opener cable from the trunk lid.

20-154

BACK

4. Remove the bolts, then remove the trunk lid. Fastener Locations ~ : Bolt, 4 6x 1.0mm 9.8N·m (1.0kgf·m,

7.2Ibf·ftl

5. Install the trunk lid in the reverse order of removal, and note these items: • Make sure the connectors are plugged in properly, and opener cable is connected properly, and the wire harness and opener cable are routed properly. • Make sure the trunk lid opens properly and locks securely. • Adjust the trunk lid alignment (see page 20-156).

BACK

20-155

Trunk Lid Adjustment 1. Slightly loosen each bolt. 2. Adjust the trunk lid alignment in the following sequence. • Remove the rear shelf - Coupe (see page 20-76) - Sedan (see page 20-77) • Adjust the trunk lid hinges (A) right and left. as well as forward and rearward. by using the elongated holes. Take care not to hit the rear window when loosening the bolts (B). • Turn the trunk lid edge cushions in or out (C). as necessary. to make the trunk lid fit flush with the body at the rear and side edges. • Adjust the fit between the trunk lid and the trunk lid opening by removing the striker (D). B 6x1.0mm 9.8 N·m 11.0 kgf·m.

7.2Ibf·ft)

6x1.0mm 9.8 N·m 11.0 kgf·m.

7.2Ibf·ft)

3. Tighten each bolt securely. 4. Make sure the trunk lid opens properly and locks securely.

20-156

BACK

o

Trunk Lid Torsion Bar Replacement 1. Remove the torsion bars (A) from the torsion bar center clip (8).

3. Remove the torsion bar center clip from the body.

B

2. Put on gloves to protect your hands. Remove the torsion bars with the torsion bar tool (A) from both trunk lid hinges. First remove the right torsion bar (8), and then remove the left torsion bar (e).

4. Install the torsion bars in the reverse order of removal, and note these items: o

o

Adjust the torsion bars forward or rearward with the torsion bar assembly tool. Make sure the trunk lid opens properly and locks securely.

o =Normal position • = Higher tension

BACK

20-157

Trunk Lid Trunk Lid Weatherstrip Replacement

Trunk Lid Dynamic Damper Replacement - Sedan 1. Remove the cover (A), and remove the bolts, then remove the trunk lid dynamic damper (8). Take care not to scratch the trunk lid. Fastener Locations

1. Remove the trunk lid weatherstrip by pulling it off. 2. Apply sealant (Cemedine PIN 08712-0004, or equivalent) (A) in the groove of the trunk lid weatherstrip (8) in the areas indicated by arrows.

~: Bolt, 2

@I

Unit: mm (in.)

6x1.0mm 9.8N·m (1.0 kgf.m, 7.2Ibf·ft)

587 (23.1)

Center

(!----=t1

-"

Forward

'------- - - - - - -

\

-

B

3. Locate the painted alignment mark (A) on the trunk lid weatherstrip (8). Align the painted mark with the alignment tab in the center of the trunk, and install the weatherstrip all the way around facing in the direction shown. Make sure there are no wrinkles in the weatherstrip.

--B

2. Install the damper in the reverse order of removal. A

Forward

4. Check for water leaks.

20-158

BACK

Exterior Trim Emblem Replacement - Coupe 1. Clean the trunk lid surface with a sponge dampened in alcohol. After cleaning. keep oil. grease and water from getting on the surface. 2. Apply the emblem where shown.

ACCORD EMBLEM

Unit: mm (in.)

1310.51)

Edge ofthe trunk lid.

BACK

20-159

Exterior Trim Emblem Replacement - Sedan

Front Grille Replacement - Coupe '98-00 models

1. Clean the trunk lid surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the surface.

1. Remove the front bumper. 2. Remove the front grille by removing the screws from the front bumper. Take care not to scratch the front grille and front bumper.

2. Apply the emblem where shown. TRUNK LID

Fastener Locations ~:Screw,4

~J ACCORD EMBLEM VERSION EMBLEM

17 (0.67)

17 (0.67)

3. Install the grille in the reverse order of removal. Edge of the trunk lid. Unit· mm (in.)

jL

ACCORD EMBLEM

\ ~

40 (1.6)! [~

~

/ L

.f

VERSION EMBLEM (SPECIAL EDITION)

~r.::"I~ 'I

. \

\

Jl

h25 (0.98)

\

Edge of the trunk lid.

('00 model)

20-160

BACK

Roof Drip Molding Replacement - Coupe NOTE: Put on gloves to protect your hands. 1. Detach the moldings from each clip, then remove the roof drip molding (A) from the quarter glass molding (8). Take care not to scratch the body. Fastener locations

!>: Clip, 9 B

B A

2. Install the molding in the reverse order of removal, and replace any damaged clips.

BACK

20-161

Exterior Trim Roof Drip and Rear Pillar Moldings Replacement - Sedan NOTE: Put on gloves to protect your hands. 1. Detach the moldings from each clip, then remove the roof drip molding (A) and rear pillar molding (B) as an assembly. Take care not to scratch the body. Fastener Locations C I> : Clip, 10

01>: Clip, 1

EI>: Clip, 1

FI>: Clip, 1

('"

2. Separate the roof drip molding and rear pillar molding. 3. Install the molding in the reverse order of removal, and note these items: • After joining the rear pillar molding (B) with the roof drip molding (A), lightly tap the locking tabs (e) . • Replace any damaged clips.

A

20-162

BACK

Roof Molding Replacement 1. Apply protective tape to the body (A). Using a flattip screwdriver wrapped with protective tape (8), pry up on the roof molding (C). Take care not to scratch the body.

4. Pull up and release the rear bracket (A) from the pin (8), then remove the roof molding (C).

5. Install the molding in the reverse order of removal, and note these items: • Take care not to damage the windshield and rear window moldings . • Make sure the roof molding is installed securely.

2. Pull up and slide the roof molding to release the front bracket (0) from the pin (E). 3. Pull up the front portion of roof molding.

BACK

20-163

Exterior Trim Door Moldings Replacement - Sedan NOTE: • Wrap the blade of your putty knife or flat-tip screwdriver with protective tape to prevent damage to the door. • Be careful not to pry too far or you may bend the molding. • Put on gloves to protect your hands.

1. Prepare to release the molding clips from inside the vehicle . • To remove the front door molding, remove the front door panel (see page 20-9) and plastic cover . • To remove the rear door molding, remove the rear door panel (see page 20-17) and plastic cover. 2. Release the clips, and gently pry the front door molding (A) or rear door molding (B) away from the door while removing the adhesive tape (e). Fastener Locations

1>: Clip, 12

•

3. Install the moldings in the reverse order of removal, and replace any damaged clips and adhesive tape.

20-164

BACK

Side Sill Panel Replacement - Coupe 1. Remove the side sill panel. -

1 If equipped, remove the splash guard (A). 2 Pull the inner fender (B) back as necessary, and remove the expansion clips (e). 3 Slide the side sill panel (0) forward and remove it. Side clips (E) will stay in the body. 4 Remove the side clips from the body.

Fastener Locations ~:Screw,4

C[>: Clip, 4

E [> : Clip, 12

~~

;~----------

D

2. Replace any damaged clips. 3. Install the side clips on the side sill panel. 4. Hold the panel up, and fit all the side clips into the holes in the body, then push on the panel until the clips snap into place. 5. Install all the expansion clips. 6. Reinstall the inner fender and splash guard (if equipped).

BACK

20-165

Exterior Trim Side Sill Panel Replacement - Sedan 1. Remove the side sill panel. -

1 If equipped, remove the splash guard (A). 2 Pull the inner fender (B) back as necessary, and remove the expansion clip (e). 3 Slide the side sill panel (0) forward and remove it. Side clips (E) will stay in the body. 4 Remove the side clips from the body.


C [> : Clip, 4

E [> : Clip, 9

2. Replace any damaged clips. 3. Install the side clips on the side sill panel. 4. Hold the panel up, and fit all the side clips into the holes in the body, then push on the panel until the clips snap into place. 5. Install all the expansion clips. 6. Reinstall the inner fender and splash guard (if equipped).

20-166

BACK

Fenderwell Inner Fender Replacement 1. Remove the inner fender as shown. Take care to scratch the body.

Fuel Pipe Protector Replacement 1. Remove the fuel pipe protector as shown. Take care to scratch the body.

Fastener Locations B~:Screw.2

A~: Bol1.2

6x1.0mm

~9.8N.m

~ (1.0 kgf.m. _ _ _7:....:..2=..:.::lb.:....f.ft:..::''-----'

C [> : Clip. 7

Fastener Locations

[>: Clip, 3

~

~

~

D [> : Clip. 3

~~ Ex_'

FUEL PIPE PROTECTOR

'01-02 modeb Coupe, / "

2. Install the protector in the reverse order of removal, and replace any damaged clips.

D

2. Install the inner fender in the reverse order of removal, and replace any damaged clips.

BACK

20-167

Fenderwell Rear Air Outlet Replacement 1. Remove the rear bumper -Coupe (see page 20-145) -Sedan (see page 20-148) 2. Remove the screws, then remove the rear air outlet (A). Take care not to scratch the body.

Fastener Locations .. : Screw, 2

~I

3. Install the air outlet in the reverse order of removal.

20-168

BACK

Openers Component Location Index

FUEL FILL DOOR LATCH Replacement, page 20-177 TRUNK LID LATCH Replacement, page 20-178 TRUNK LID OPENER/ FUEL FILL DOOR OPENER CABLE Replacement, page 20-171, page 20-173 TRUNK LID

LOCK CYLINDER Replacement, page 20-179

HOOD OPENER CABLE Replacement, page 20-170 HOOD LATCH


TRUNK LID/FUEL FILL DOOR OPENER Replacement, page 20-176 HOOD RELEASE HANDLE Replacement, page 20-175

BACK

20-169

Openers Hood Opener Cable Replacement 1. Remove these items from the left side of the vehicle (see page 20-167): • Splash guard (for some models) • Inner fender 2. Remove these items for the left side of the vehicle: Coupe (see page 20-74): • Door opening trim • Kick panel Sedan (see page 20-75): • Door opening trim • Kick panel 3. Disconnect the hood opener cable (A) from the hood latch (B) (see page 20-175) and hood release handle (C) (see step 2 on page 20-175). Fastener Locations

D [>: Clip, 3

E [> : Clip, 3

4. Using a clip remover, detach the clips (0, E) from the body, then remove the hood opener cable from the vehicle. Take care not to bend the cable. 5. Install the cable in the reverse order of removal, and replace any damaged clips.

20-170

BACK

Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement - Coupe '00-02 models: SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service. 1. Remove these items (see page 20-128): • Rear seat-back • Rear seat cushion 2. Remove these items: • Rear bulkhead cover (see page 20-76) • Front seat belt lower anchor bolt (left side) (see step 8 on page 23-6) 3. Remove these items (see page 20-74): • Door sill trim (left side) • Rear side trim panel 4. Remove these items (see page 20-78): • Trunk floor • Trunk rear trim panel • Trunk side pocket (left side) • Trunk side trim panel (left side) 5. Pull the carpet back as necessary (see page 20-81). 6. Disconnect the fuel fill door opener cable (A) from the opener (B) (see page 20-176). Fastener Locations C

!>: Clip, 1

0

!> : Clip, 1

E !>: Cushion tape, 2

~I ~~~~~/~2J,:--,~, ~

F

/~ ~

----

A

7. Release the opener cable from the clips (e, D), and remove the cushion tapes (E), then remove the fuel fill door latch (F) and the opener cable junction box (G) from the body. (cont'd)

BACK

20-171

Openers Trunk Lid 0 penerIFuel Fill DoorOp . 8. Disconnect the trunk r ener Cable Repla trunk lid latch IBIIsee,d open« cable IAl f rom t h e ' page 20-1781 WIth

.

.

cement· Coupe (cont'dl

W.....utp

'oat

power trunk lid lock'

~41

.

owe. trunk lid 10...·

~41 D~C'P

Fastener Locat' c[> Ions D[>,Clip

E ~~.~;ble cushion models. 1

onw LocatiOM c[>·cr

~ i;j~~ E~r~ ~~ ~r

~

~

B ~ -:;;--~ --=----

--

('

'-6~~-r~ A

CC

!~'tD~(j \~

~'-~~-

~c;;.~/

II~.~B L :/E

-cc

~ )"0 o~ener cable 9 U . Junction box. . cable sing cush. a clip rem over, detach th I" lid hing e. Ion (E) from the bod y,e trunk c IPS (C,D) and/or lid and t runk

10. Remove t he trunk I"d from the vehicle T I k opener/fuel lid ope neropener cable cable. . a e care not to b end the

11. Install the cable· and replace any I~a~:~:~e~~~:rder of removal,

20-172

BACK

Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement - Sedan '00-02 models: SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service. 1. Remove these items (see page 20-129): • Rear seat cushion • Rear seat side bolster 2. Remove these items: • Rear bulkhead cover (see page 20-77) • Front seat belt lower anchor bolt (left side) (see step 6 on page 23-7) 3. Remove these items (see page 20-75): • Front door sill trim (left side) • Rear door sill trim (left side) • Center pillar lower trim panel 4. Remove these items (see page 20-78): • Trunk floor • Trunk rear trim panel • Trunk side pocket (left side) • Trunk side trim panel (left side) 5. Pull the carpet back as necessary (see page 20-81). 6. Disconnect the trunk lid opener/fuel fill door opener cable (A) from the opener (8) (see page 20-176). Fastener Locations C

1>: Clip. 1

D I> : Cushion tape. 1

To trunk lid

latch.

F

7. Release the opener cable from the clip (e), and remove the cable cushion (D), then remove the fuel fill door latch (E) and the opener cable junction box (F) from the body. (cont'd)

BACK

20-173

Openers Trunk Lid Opener/Fuel Fill Door Opener Cable Replacement - Sedan (cont'd) 8. Disconnect the trunk lid opener cable (A) from the trunk lid latch (8) (see page 20-178).

Without power trunk lid lock: Fastener Locations

With power trunk lid lock:

C 1>: Clip, 3

Fastener Locations

.JiJ

C 1>: Clip, 3

D 1>: Clip, 2

B

:::::--::::::;

-:::::...--,--' ~ " ~~""(

B

-----

C(f;C:>~~

A

r/~

C

C

c

C

~ arlL ~--~:::==-?_.. y

-~

~~

~/

/

/

L... junction To opener cable box.

c

'L... To opener cable junction box.

9. Using a clip remover, detach the clips (C, D) from the trunk lid hinge. 10. Remove the trunk lid opener/fuel fill door opener cable from the vehicle. Take care not to bend the cable. 11. Install the cable in the reverse order of removal, and replace any damaged clips.

20-174

BACK

Hood Release Handle Replacement 1. Remove these items for the left side of the vehicle.

Hood Latch Replacement 1. Remove the cover (A) from the hood latch (8). Fastener Locations Bolt, 3

Coupe (see page 20-74): • Door sill trim • Kick panel

~:

Sedan (see page 20-75): • Front door sill trim • Kick panel

-

~ ~ r;~o~;~: -

-- -

7.2Ibf·ft)

-- -

-------

[>: Clip, 1

J 1W&h J --- --

2. Disconnect the hood opener cable (A) from the hood release handle (8). Take care not to bend the cable. Fastener Locations ~ : Bolt, 2

6x 1.0mm 9.8N·m (1.0 kgf·m,

7.2Ibf·ft)

2. Remove the bolts, then remove the hood latch from the body. 3. Disconnect the hood opener cable (C) and hood latch switch connector (D), then detach the hood latch switch connector from the body. Take care not to bend the cable.

3. Remove the bolts, then remove the hood release handle. 4. Install the handle in the reverse order of removal, and note there items: • Make sure the hood opener cable is connected properly . • Make sure the hood opens properly.

(cont'd)

BACK

20-175

Openers Hood Latch Replacement (cont'd)

Trunk Lid Opener/Fuel Fill Door Opener Replacement

4. Install the latch in the reverse order of removal, and note these items: • Grease each location of the hood latch indicated by the arrows. • Make sure the hood opener cable is connected properly and hood latch switch connector is connected properly. • Adjust the hood latch alignment (see page 20151 ). • Make sure the hood locks securely.

1. Using a flat-tip screwdriver wrapped with protective tape, pry open the cover (A), and remove the opener lock cylinder (B) from the opener (C).

2. Pry out the access hole cover (A), and loosen the bolt. Fastener Location .. : Bolt, 1 6x1.0mm 9.8N·m (1.0 kgf·m,

7.2Ibf.ft)

B

3. Remove the opener (B) from the bolt, and release the hook (C) by sliding the opener backward.

20-176

BACK

Fuel Fill Door Latch Replacement 1. Remove the following items (see page 20-78): 4. Disconnect the trunk lid/fuel fill door opener cable (A), then remove the opener (8).

• Trunk floor • Trunk rear trim panel • Trunk side pocket, left side 2. Pull the rear edge of the left trunk side trim panel back (see page 20-78). 3. Turn the fuel fill door latch (A) 90°, and remove it.

5. Install the opener in the reverse order of removal, and note these items: • Make sure the opener cable is connected properly . • Make sure the trunk lid and fuel fill door open properly.

(cont'd)

BACK

20-177

Openers Fuel Fill Door Latch Replacement (cont'd)

Trunk Lid Latch Replacement 1. Disconnect the cylinder rod from the lock cylinder (see page 20-179).

4. Install the latch in the reverse order of removal, and note these items: • Grease each location indicated by the arrows. • Make sure the fuel fill door opens properly and locks securely.

2. Disconnect the trunk lid opener cable (A) and trunk lid latch switch connector (B). If equipped with a power trunk lid lock, detach the trunk lid latch switch connector from the trunk lid. Take care not to bend the opener cable. With power trunk lid lock: Fastener Locations ~ :80It.2

@)nm

6x 1.0mm 9.8N·m (1.0 kgf·m.

7.2Ibf·ft)

5. Check that the fuel fill door fits flush against the body. If necessary, adjust it. Fastener Locations ~ :80It.2

6x 1.0mm 9.8N·m (1.0 kgf·m.

Without power trunk lid lock:

7.2Ibf·ftl

~:Bolt,2

Fastener Locations

@)nm

6 x 1.0 mm 9.8N·m (1.0kgf·m.

7.2Ibf·ftl

3. Remove the bolts from the trunk lid latch (C).

20-178

BACK

Trunk Lid Lock Cylinder Replacement 4. Pull the trunk lid latch out with the cylinder rod (A). Take care not to bend the cylinder rod. 1. Disconnect the cylinder rod (A) and cylinder switch connector (8), then detach the cylinder switch connector from the trunk lid.

5. Disconnect the cylinder rod from the trunk lid latch. 6. Install the latch in the reverse order of removal, and note these items:

B

2. Remove the bolt securing the lock cylinder. Then turn the trunk lid lock cylinder (A) 45°, and remove it.

• Grease the locations of the trunk lid latch indicated by the arrows. • Make sure the connector is plugged in properly and the cylinder rod is connected properly. • Make sure the trunk lid opens properly and locks securely.

Fastener Location Bolt, 1

~:

@

6X1.0~~mJ

N·m . 1i)l111)))))I))) 9.8 (1.0 kgf·m, 7.2Ibf·ft)

3. Install the lock cylinder in the reverse order of removal, and note these items: • Make sure the connector is connected properly and the cylinder rod is connected properly . • Make sure the trunk lid opens properly and locks securely.

BACK

20-179

Frame Sub-frame Replacement After loosening the sub-frame mounting bolts, be sure to replace them with new ones.

FRONT SEAM

8x 1.25mm 26 N·m (2.7 kgf·m, 20Ibf.ft) FRONT SEAM

~l~

SPECIAL SOLT 14x1.5mm 103 N·m (10.5 kgf·m, 76Ibf·ft) Replace.

20-180

BACK

_

.~

/

SPECIAL SOLT 14x 1.5 mm 103 N·m (10.5 kgf·m, 76 Ibf·ft) Replace.

12x 1.25 mm 64 N·m (6.5 kgf·m, 47 Ibf·ft)

SPECIAL BOLTS 14x 1.5 mm 103 N·m (105 Replace. . k gf·m, 76 Ibf·ftl

BACK

20-181

Frame Frame Repair Chart Top View Unit: mm (in.) Ill: Inner diameter

POINTh POINTg POINTf

i ~NT;

/

LfA

POINT a

v[) .:1: oyr4 . "" t rf

-~

I

~

/

is

• ~

"

1ft

N ;:::-

CENTER UNE

-..,

KWa •

/ 1>1

..,~

01--

1

iii ..;

GO

en

II)

iii

~ CD

~

r.C

POINTb1~ POINTb2~

7L

~

~

!

......

:;

0 0

CD

~

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iii ..,-I- !:!ai"

~

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iii

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0

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~ ~1 ~[)

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..-t:!

:J

\....;T

4 130 10.21 15.12; Fj'7713.01

POINTb3

.5

. 0

...If'""1\,....

t'l-

o

I

V

8817.401 280 111.01 23819.371 268110.61 361114.21 490119.31

425116.71 595123.41 610124.01 1425156.101

...

c(

c.J

i=UI ffi~ > ...

20-182

0

V

c;;

..,

...

I

-It-

r

~

"! "': "l Gi .., en en GO CD !:! ~~ g: oo NCD ;;r-~ CD CD 5! o en "en

"

POI:;'!nk

BACK

0

I

POINTn POINTq

POINT 0

POINTm POINT I

F

\

(/.

~

@

~ !)

I

0

-......;:::

I I

0

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~

~ ~'®~ "-8

0

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~ ~E 1\

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iii

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I

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iI

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) I

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@ ~

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I

2145 184.45) 2365193.111 2750 1108.3) 2899 1114.1) 29981118.0) 32001126.0) 36221142.6)

~

.

~ • ":Jt":7

~r

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iii

iii CD

CD

\

II

[\' \ \

POINT V

([ t - -

I \~~W

_-_._-

(cont'd)

BACK

20-183

Frame Frame Repair Chart (cont'd) Side View 811.5 (0.453)

Unit: mm (in.) D: Inner diameter

2-811 (0.43) 811.5 (0.453)

POINTe

811.5 (0.453)

POINTf

269 110.6) SECTIONAA

SECTION BB

POINTe

POINTe Front Damper Center

815 (0.59) Transmission Mount Point M12 x 1.25

\ POINTh 1111 (0.43) Engine Mount Point

M14x 1.5

iii ~

.,;

iii

,..;

~

~

...

N ~ ... ... ... ...... = ... ...

~

en en

of

po

po

po po

~

po

oci po po

~

N

~

... .... ....

.t

00

0:>

0:>

BASE LINE

:~

~

POINTu

For Front Beam

825 (1.0) Locate Hole

I

For Rear Beam POINTbl

M4 x 1.5


813 (0.5) Engine Mount Point POINTb2 1113 (0.5) Engine Mount Point

20-184

BACK

POINTi 817 (0.7) For Rear Beam


HVAC (Heating, Ventilation, and Air Conditioning) Heating Special Tools ................................ Component Location Index ........ General Troubleshooting Information ............................... DTC Troubleshooting Index ....... Symptom Troubleshooting Index ......................................... System Description ..................... Circuit Diagram ............................ DTC Troubleshooting .................. Recirculation Control Motor Circuit Troubleshooting .......... Blower Motor Circuit Troubleshooting ...................... Heater Control Power and Ground Circuits Troubleshooting ........ Air Mix Control Motor Test and Replacement ............. Mode Control Motor Test and Replacement ............. Recirculation Control Motor Test and Replacement ............. Heater Fan Switch Test ............... Evaporator Temperature Sensor Test .............................. Heater Control Panel Removal and Installation ........ Heater Control Panel Disassembly and Reassembly .............................. Dust and Pollen Filter Replacement ............................ *Blower Unit Removal and Installation ................................ Blower Unit Components Replacement ............................ *Heater Unit/Core Replacement ............................ Heater Valve Cable Adjustment ...............................

21-2 21-3 21-4 21-5 21-6 21-7 21-8 21-9 21-14 21-15

21-19 21-20 21-21 21-22 21-23 21-23 21-24

21-24 21-25 21-26 21-27 21-28 21-30

Air Conditioning Component Location Index ........ AlC Service Tips and Precautions ............................... AlC Refrigerant Oil Replacement ............................ Symptom Troubleshooting Index ......................................... System Description ..................... Circuit Diagram ............................ Condenser Fan Circuit Troubleshooting ...................... Radiator and Condenser Fans Common Circuit Troubleshooting ...................... Compressor Clutch Circuit Troubleshooting ...................... AlC Pressure Switch Circuit Troubleshooting ...................... AlC System Tests ........................ Evaporator Removal and Installation ................................ Evaporator Components Replacement ............................ Compressor Replacement .......... Compressor Clutch Check .......... Compressor Clutch Overhaul ..... Compressor Relief Valve Replacement ............................ Condenser Replacement ............ Refrigerant Recovery .................. System Evacuation ...................... System Charging ......................... Refrigerant Leak Test ..................

21-31 21-32 21-32 21-34 21-35 21-36 21-37

21-38 21-39 21-41 21-43 21-46 21-47 21-48 21-50 21-51 21-52 21-53 21-54 21-55 21-56 21-57

HVAC {Heating, Ventilation, and Air Conditioning} Special Tools Tool Number 07SAZ-OO 1OOOA

Descri tion

CD

21-2

BACK

Heating Component Location Index

HEATER VALVE CABLE Adjustment. page 21-30 HEATER UNIT/CORE Replacement, page 21-28 HEATER DUCT (Without A/C) EVAPORATOR (With A/C) Removal and Installation, page 21-46 EVAPORATOR COMPONENTS (With AlC) Replacemant, page 21-47 RECIRCULATION CONTROL MOTOR Test, page 21-22 Replacement, page 21-22

BLOWER UNIT ... /

Removal and Installation, page 21-26 - BLOWER UNIT COMPONENTS Replacement, page 21-27

BLOWER RESISTOR

~

DUST AND PDLLEN FILTER Replacement, page 21-25

EVAPORATOR TEMPERATURE SENSOR (With AlC) Test, page 21-23 HEATER FAN SWITCH Test, page 21-23 AIR MIX CONTROL MOTOR Test, page 21-20 Replacement, page 21-20 MODE CONTROL MOTOR Test, page 21-21 Replacement, page 21-21

BACK

21-3

Heating General Troubleshooting Information How to Retrieve a DTC The heater control panel has a self-diagnosis function. Running the Self-diagnosis Function 1. Turn the ignition switch ON (II). 2. Turn the fan switch OFF, and the recirculation control switch to Recirculate (recirculation indicator comes on). 3. Press and hold the recirculation control switch to Fresh (recirculation indicator goes off). Continue to hold the switch until the recirculation indicator comes on for 2 seconds, then it will blink the Diagnostic Trouble Code (DTC) to indicate a faulty component. RECIRCULATION INDICATOR

FAN SWITCH RECIRCULATION CONTROL SWITCH

Example of OTC Indication Pattern (OTC 2):

0.3 sec

0.3 sec

-

Recirculation _ indicator on

1-------------4

Recirculation .......•• indicator off

----2 sec 2 sec

-

-

rm

I.... •• :~.:~ ••

1 sec

Press and hold the recirculation control switch

Resetting the Self-diagnosis Function Turn the ignition switch OFF to cancel the self-diagnosis function. After completing repair work, run the self-diagnosis function again to make sure that there are no other malfunctions.

21-4

BACK

DTC Troubleshooting Index DTC (Recirculation Indicator Blinks) 1 2 3 (WithA/C)

Detection Item

A problem in the air mix control motor circuit A problem in the mode control motor circuit A problem in the evaporator temperature sensor circuit

Page

(see page 21-9) (see page 21-10) (see page 21-12)

In case of multiple problems. the recirculation indicator will indicate only the DTC with the least number of blinks.

BACK

21-5

Heating Symptom Troubleshooting Index Symptom


Recirculation control doors do not change between Fresh and Recirculate.

Recirculation Control Motor Circuit Troubleshooting (see page 21-14)

Blower motor runs, but one or more speeds are inoperative.

Blower Motor Circuit Troubleshooting (see page 21-15)

Blower motor does not run at all.

Blower Motor Circuit Troubleshooting (see page 21-15)

Both heater and AlC do not work.

Heater Control Power and Ground Circuits Troubleshooting (see page 21-19)

21-6

BACK

Also check for

• Blown fuse No.3 (7.5A) in the driver's under-dash fuse/relay box • Cleanliness and tightness of all connectors • Blown fuse No. 56 (40A) in the under-hood fuse/relay box, and No.3 (7.5A) in the driver's underdash fuse/relay box • Poor ground at G202 and G401 • Cleanliness and tightness of all connectors • Blown fuse No. 56 (40A) in the under-hood fuse/relay box, and No.3 (7.5A) in the driver's underdash fuse/relay box • Poor ground at G202 and G401 • Cleanliness and tightness of all connectors • Blown fuse No. 54 (40A) in the under-hood fuse/relay box, No.3 (7.5A) in the driver's under-dash fuse/relay box, and No. 13 (7.5A) in the passenger's under-dash fuse/relay box • Poor ground at G202 and G401 • Cleanliness and tightness of all connectors

System Description Heater Control Panel Inputs and Outputs HEATER CONTROL PANEL 22P CONNECTOR Wire side of female terminals

t,

1

2

3

4

5

r-'

><

6

7

8

9 10

11 12 13 14 15 161XI17 18 19 20 21 22

Cavity

Wire color

1 2 3 4 5 (With AlC) 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 (with AlC) 21 22

GRN/WHT BLK/YEL WHT/YEL BRN/YEL YEL/GRN BLU/GRN LTGRN/BLK GRN/YEL BLK RED/BLK GRN/RED RED/YEL RED/WHT BLU/WHT BLU/BLK GRY YEL/GRN GRN/BLK PNK/BLK BRN GRN RED

Signal RECIRCULATE IG2 (Power) +B (Power) REAR WINDOW DEFOGGER RELAY AlC PRESSURE SWITCH MODE 4 MODE 3 MODE 2 GROUND COMBINATION LIGHT SWITCH or TAILLIGHT RELAY FRESH AIR MIX HOT AIR MIX COOL MODEVENT+ MODEDEF+ AIR MIX POTENTIAL +5 V SENSOR COMMON GROUND MODE 1 AIR MIX POTENTIAL EVAPORATOR TEMPERATURE SENSOR FAN SWITCH MULTIPLEX CONTROL UNIT (DRIVER'S)

BACK

INPUT INPUT INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT

21-7

Heating Circuit Diagram

UNDER·HOOD FUSEIRELAY BOX BATIERY

No.4. (.OOA)

+

No.54 (40A)

r--O""

I

No.42 (50A)

WHT

I

I

NO.56 (40A)

BLOWER MOTOR RELAY

~ IG2

No.13 (7.5A)

PASSENGER'S UNDER·DASH FUSEIRELAY BOX

YE L----~
BLKlYEL

I·

4

12

3

YE'~

~---------~~ BLOWER MOTOR

B~K -,

Y~L


IGNITION SWITCH

~

BLU/RED

BLOWER RESISTOR

..-'IM....'VV'v1"'V'IJ'v-t---

BLUIRED

4

BLUIYEL BLU

BLU/BLK ...---- BLU/RED

6

3

3

GRN

SV

BLK

GRN EVAPORATOR TEMPERATURE SENSOR (With AlC) WHT/YEL

BRN

..l..@-

S·COM

GRY AC

PRESSURE~

SWITCH (WilhACl

YEUGRN

YEUGRN M·HOT

-

AIR MIX CONTROL MOTOR

M-VENT M·DEF REAR

~~gg~ER ~

MODEl BRNlYEL

MODE2

RELAY

5

S-COM

7

MODE CONTROL MOTOR

MODE3 MODE4

COMSINATION LIGHT SWITCH or TAILLIGHT RELAY

~

RED/BLK

7

LIGHTS

MULTIPLEX CONTROL UNIT
BLK

~

BLK BLKlYEL

BACK

BLK

11 G401

HEATER CONTROL PANEL

21-8

FRS RECIRCULATION CONTROL REC MOTOR IG2

G202

DTC Troubleshooting DTC 1: A problem in the air mix control motor

circuit

5. Turn the ignition switch ON (II), and check the same terminals for voltage. HEATER CONTROL PANEL 22P CONNECTOR

1. Disconnect the air mix control motor 7P connector.


2. Test the air mix control motor (see page 21-20).

Is the air mix control motor OK?

234 YES - Go to step 3.

5

7

8

9

10

21 22

11

NO- Go to step 8. 3. Disconnect the heater control panel 22P connector. 4. Check for continuity between body ground and the heater control panel 22P connector terminals No. 12,13,16,17 and 19 individually. HEATER CONTROL PANEL 22PCONNECTOR

= Is there any voltage? YES- Repair any short to power in the wire(s) between the heater control panel and the air mix control motor. This short also damages the heater control panel. Repair the short to power before replacing the heater control panel..


NO- Go to step 6.

=

=

Is there continuity? YES- Repair any short to body ground in the wire(s) between the heater control panel and the air mix control motor.•

NO - Go to step 5.

(cont'd)

BACK

21-9

Heating DTC Troubleshooting (cont'd) 6. Turn the ignition switch OFF.

DTC 2: A problem in the mode control motor circuit

7. Check for continuity between following terminals of the heater control panel 22P connector and the air mix control motor 7P connector. 22P: 7P: No.12 No.2 No.13 No.1 No.16 No.7 No.17 No.5 No. 19 No.3

1. Disconnect the mode control motor 7P connector. 2. Test the mode control motor (see page 21-21).

Is the mode control motor OK? YES - Go to step 3. NO- Go to step 8.

HEATER CONTROL PANEL22P CONNECTOR

Wire side of female termimals

3. Disconnect the heater control panel 22P connector. 4. Check for continuity between body ground and the heater control panel 22P connector terminals No.6, 7,8, 14, 15, 17 and 18 individually. HEATER CONTROL PANEL 22P CONNECTOR


RED/WHT

AIR MIX CONTROL MOTOR 7P CONNECTOR Wire side of female terminals

Is there continuity? YES-Check for loose wires or poor connections at the heater control panel 22P connector and at the air mix control motor 7P connector. If the connections are good, substitute a known-good heater control panel, and recheck. If the symptom/ indication goes away, replace the original heater control panel..

=

NO- Repair any open in the wire(s) between the heater control panel and the air mix control motor.• 8. Remove the air mix control motor (see page 21-20). 9. Check the air mix control linkage and door for smooth movement.

Do the air mix control linkage and door move smoothly? YES- Replace the air mix control motor.• NO- Repair the air mix control linkage or door.•

21-10

BACK

Is there continuity? YES- Repair any short to body ground in the wire (s) between the heater control panel and the mode control motor.• NO - Go to step 5.

5. Turn the ignition switch ON (II), and check the same terminals for voltage

6. Turn the ignition switch OFF. 7. Check for continuity between following terminals of the heater control panel 22P connector and the air mix control motor 7P connector. 22P: 7P: No.6 No.3 No.7 No.4 No.8 No.5 No.14 No.2 No. 15 No.1 No. 17 No.7 No.18 No.6

HEATER CONTROL PANEL 22P CONNECTOR Wire side of female terminals

HEATER CONTROL PANEL 22P CONNECTOR Wire side of female terminals

Is there any voltage? YES- Repair any short to power in the wire(s) between the heater control panel and the mode control motor. This short also damages the heater control panel. Repair the short to power before replacing the heater control panel.. NO - Go to step 6.

BLU/BLK

VEL IGRN

LTGRN/BLK MODE CONTROL MOTOR 7P CONNECTOR Wire side of female terminals

Is there continuity? YES-Check for loose wires or poor connections at the heater control panel 22P connector and at the mode control motor 7P connector. lfthe connections are good, substitute a known-good heater control panel, and recheck. If the symptom/ indication goes away, replace the original heater control panel.. NO - Repair any open in the wire(s) between the heater control panel and mode control motor..

(cont'd)

BACK

21-11

Heating DTC Troubleshooting (cont'd) 8. Remove the mode control motor (see page 21-21). 9. Check the mode control linkage and doors for smooth movement.

DTC 3: A problem in the evaporator temperature sensor circuit 1. Disconnect the evaporator temperature sensor 2P connector.

Do the mode control linkage and doors move smoothly?

2. Measure the resistance between the No.1 and No.2 terminals of the evaporator temperature sensor.

YES - Replace the air mix control motor.•

EVAPORATOR TEMPERATURE SENSOR

NO- Repair the air mix control linkage or doors.•


40

30

RESISTANCE kQ

20

~

10

~

--50

68

10

20

86°F 86°C

TEMPERATURE Is the resistance within the specifications shown on the graph? YES-Go to step 3. NO- Replace the evaporator temperature sensor.• 3. Disconnect the heater control panel 22P connector.

21-12

BACK

4. Check for continuity between the No. 20 terminal of the heater control panel 22P connector and body ground. HEATER CONTROL PANEL 22P CONNECTOR

6. Check for continuity between the No. 17 terminal of the heater control panel 22P connector and the No.1 terminal of the evaporator temperature sensor 2P connector. HEATER CONTROL PANEL 22P CONNECTOR Wire side of female terminals


234 11

5

12 13 14 15

8

9

10

18 19 20

21

22

6

7


2P CONNECTOR Wire side of female terminals


Is there continuity? YES- Repair short to body ground in the wire between the heater control panel and the evaporator temperature sensor.. NO-Go to step 5. 5. Check for continuity between the No. 20 terminal of the heater control panel 22P connector and the No.2 terminal of the evaporator temperature sensor 2P connector. HEATER CONTROL PANEL 22P CONNECTOR Wire side of female terminals

YES-Check for loose wires or poor connections at the heater control panel 22P connector and at the evaporator temperature sensor 2P connector. If the connections are good, substitute a known-good heater control panel, and recheck. If the symptom/ indication goes away, replace the original heater control panel.. NO- Repair open in the wire between the heater control panel and the evaporator temperature sensor..


2P CONNECTOR Wire side of female terminals


YES - Go to step 6. NO- Repair open in the wire between the heater control panel and the evaporator temperature sensor.•

BACK

21-13

Heating Recirculation Control Motor Circuit Troubleshooting 1. Check the No.3 (7.5A) fuse in the driver's underdash fuse/relay box.

8. Check for continuity between the No.1 and No. 11 terminals of the heater control panel 22P connector and body ground individually.

Is the fuse OK? HEATER CONTROL PANEL 22P CONNECTOR

YES - Go to step 2.


NO - Replace the fuse, and recheck.• GRN/WHT

2. Disconnect the recirculation control motor 7P connector.

1

2

3

4

5

11 12 13 14 15

6

7

8

9 10

18 19 20 21 22


4. Measure the voltage between the No.1 terminal of the recirculation control motor 7P connector and body ground.

=

RECIRCULATION CONTROL MOTOR 7P CONNECTOR



YES- Repair any short to body ground in the wire (s) between the heater control panel and the recirculation control motor.• NO-Go to step 9.

BLK/YEL

9. Turn the ignition switch ON (II), and check the same wires for voltage. HEATER CONTROL PANEL 22P CONNECTOR Wire side of female terminals


GRN/WHT 1

YES-Go to step 5.

2

3

4

5

11 12 13 14 15

6

7

8

9

10

18 19 20 21 22

NO-Repair open in the wire between the No.3 fuse in the driver'S under-dash fuse/relay box and the recirculation control motor.• 5. Turn the ignition switch OFF.

6. Test the reci rculation control motor (see page 2122).

Is there any voltage? YES- Repair any short to power in the wire(s) between the heater control panel and the recirculation control motor. This short also damages the heater control panel. Repai r the short to power before replacing the heater control panel..

Is the recirculation control motor OK? YES-Go to step 7. NO-Go to step 12. 7. Disconnect the heater control panel 22P connector.

NO-Goto step 10.

21-14

BACK

Blower Motor Circuit Troubleshooting 10. Turn the ignition switch OFF.

1. Turn the ignition switch ON (II) and the heater fan switch ON.

11. Check for continuity between the following terminals of the heater control panel 22P connector and the recirculation control motor 7P connector. 22P: 7P: NO.1 No.7 No.11 No.5 HEATER CONTROL PANEL 22P CONNECTOR

Does the blower run? YES-Go to step 2. NO-Go to step 16. 2. Turn the heater fan switch OFF.


3. Make sure the ignition switch ON (II).

Does the blower motor run? YES - Go to step 4. NO-Go to step 9. 4. Turn the ignition switch OFF. 5. Disconnect the blower motor 2P connector.



6. Disconnect the blower resistor 5P connector.

Is there continuity? 7. Disconnectthe heater fan switch 7P connector. YES- Check for loose wires or poor connections at the heater control panel 22P connector and at recirculation control motor 7P connector. If the connections are good, substitute a known-good heater control panel, and recheck. If the symptom/ indication goes away, replace the original heater control panel..

8. Check for continuity between the No.3, 4, 5 and 6 terminals of the heater fan switch 7P connector and body ground individually. HEATER FAN SWITCH 7P CONNECTOR

Wire side of female terminals BLU/RED

NO-Repair any open in the wire(s) between the heater control panel and the recirculation control motor.• 12. Remove the recirculation control motor (see page 21-22). 13. Check the recirculation control linkage and doors for smooth movement.

Do the recirculation control linkage and doors move smoothly?


YES- Replace the recirculation control motor..

YES-Repair any short to body ground in the wire (s) between the blower motor, the blower resistor and the heater fan switch .•

NO - Repair the recirculation control linkage or doors.•

NO- Replace the heater fan switch .•

(cont'd)

BACK

21-15

Heating Blower Motor Circuit Troubleshooting (cont'd) 9. Turn the ignition switch OFF. 10. Disconnect the blower resistor 5P connector.

15. Ground each of the heaterfan switch 7P connector terminals individually in the following order: No.4, 5,6 and 3. HEATER FAN SWITCH 7P CONNECTOR Wire side of female terminals

11. Measure the resistance between the No.1 and No.5 terminals of the blower resistor.

BLU/RED

BLOWER RESISTOR

4 BLU BLU/VEL

=

=

Does the blower motor run at progressively higher speeds? YES - Replace the heater fan switch .•

Is there about 3- 3.5 ohms? NO-Repair any open or cause of excessive resistance in the appropriate wire(s) between the blower resistor and the heater fan switch .•

YES-Go to step 12. NO- Replace the blower resistor.• 12. Reconnect the blower resistor 5P connector. 13. Disconnect the heater fan switch 7P connector. 14. Turn the ignitio·n switch ON (II).

16. Turn the heater fan switch OFF and the ignition switch OFF. 17. Check the No. 56 (40 A) fuse in the under-hood fuse /relay box, and the No.3 (7.5 A) fuse in the driver's under-dash fuse/relay box.

Are the fuses OK? YES-Go to step 18. NO- Replace the fuse(s), and recheck .• 18. Connect the No.2 terminal of the blower motor 2P connector to body ground with a jumper wire. BLOWER MOTOR 2P CONNECTOR Wire side of female terminals

BLU/RED JUMPER WIRE

=

21-16

BACK


26. Check for continuity between the No.1 terminal of the heater fan switch 7P connector and body ground.

Does the blower motor run?

HEATER FAN SWITCH 7P CONNECTOR Wire side of female terminals

YES - Go to step 20. NO-Goto step 27.

BlK

2

20. Turn the ignition switch OFF. 21. Disconnect the jumper wire.

4

5

3

6

22. Disconnect the heater fan switch 7P connector. 23. Turn the ignition switch ON (II). 24. Measure the voltage between the No.3 terminal of the heater fan switch 7P connector and body ground.

= Is there continuity?

HEATER FAN SWITCH 7P CONNECTOR Wire side of female terminals

YES- Replace the heater fan switch .•

NO - Check for an open in the wire between the heater fan switch and body ground. If the wire is OK, check for poor ground at G401 .•

BLU/RED

27. Disconnect the jumper wire.

4

28. Disconnect the blower motor 2P connector. 29. Measure the voltage between the No.1 terminal of the blower motor 2P connector and body ground. BLOWER MOTOR 2P CONNECTOR Wire side offemale terminals

Is there battery voltage? YES-Go to step 25. NO- Repair open in the wire between the blower motor and the heater fan switch .• 25. Turn the ignition switch OFF.


YES - Replace the blower motor.• NO - Go to step 30.

(cont'd)

BACK

21-17

Heating Blower Motor Circuit Troubleshooting (cont'd) 34. Measure the voltage between the No.1 terminal of the blower motor relay 4P socket and body ground.

30. Turn the ignition switch OFF. 31. Remove the blower motor relay from the underhood fuse/relay box, and test it (see page 22-52).

BLOWER MOTOR RELAY 4P SOCKET

/s the relay OK?

YES - Go to step 32. NO- Replace the blower motor relay.• 32. Measure the voltage between the No.4 terminal of the blower motor relay 4P socket and body ground. BLOWER MOTOR RELAY 4P SOCKET

= /s there battery voltage? YES- Go to step 35. NO- Repair open in the wire between the No.3 fuse in the driver's under-hood fuse/relay box and the blower motor relay .• 35. Turn the ignition switch OFF.

= /s there battery voltage?

36. Check for continuity between the No.2 terminal of the blower motor relay 4P socket and body ground. BLOWER MOTOR RELAY 4P SOCKET


NO - Replace the under-hood fuse/relay box .• 33. Turn the ignition switch ON (II).

= /s there continuity?

YES - Repair open in the wire between the blower motor relay and the blower motor.. NO-Check for an open in the wire between the blower motor relay and body ground. Ifthe wire is OK, check for poor ground at G202 .•

21-18

BACK

Heater Control Power and Ground Circuits Troubleshooting 1. Check the No. 54 (40A) fuse in the under-hood fuse/ relay box, the No.3 (7.5A) fuse in the driver's under-dash fuse/relay box, and the No. 13 (7.5A) fuse in the passenger's under-dash fuse/relay box.

6. Measure the voltage between the No.3 terminal of the heater control panel 22P connector and body ground. HEATER CONTROL PANEL 22P CONNECTOR


Are the fuses OK? YES - Go to step 2. NO- Replace the fuse(s), and recheck .• 2. Disconnect the heater control panel 22P connector. 3. Turn the ignition switch ON (II).

=

4. Measure the voltage between the No.2 terminal of the heater control panel 22P connector and body ground.


HEATER CONTROL PANEL 22P CONNECTOR

YES- Go to step 7.


NO- Repair open in the wire between the No. 13 fuse in the passenger's under-dash fuse/relay box and the heater control panel..

BLK/YEL

234

5

11 12 13 14 15

6

7

8

9 10

7. Check for continuity between the No.9 terminal of the heater control panel 22P connector and body ground.

18 19 20 21 22



-= Is there battery voltage? YES - Go to step 5. NO- Repair open in the wire between the No.3 fuse in the driver's under-dash fuse/relay box and the heater control panel .•

.Q

=

5. Turn the ignition switch OFF. Is there continuity?

YES - Check for loose wires or poor connections at the heater control panel 22P connector. If the connections are good, substitute a known-good heater control panel, and recheck. If the symptom/ indication goes away, replace the original heater control panel.. NO-Check for an open in the wire between the heater control panel and body ground. If the wire is OK, check for poor ground at G401 .•

BACK

21-19

Heating Air Mix Control Motor Test

Air Mix Control Motor Replacement

1. Disconnect the 7 P connector from the ai r mix control motor. 2. Connect battery power to the No.1 terminal of the air mix control motor, and ground the No.2 terminal; the air mix control motor should run, and stop at Max Cool. If it doesn't, reverse the connections; the air mix control motor should run, and stop at Max Hot. Ifthe air mix control motor does not run, remove it, then check the air mix control linkage and door for smooth movement.

1. Disconnect the 7P connector (A) from the air mix control motor (B). Remove the rod (C) of the air mix control motor from the air mix control linkage (D). Remove the self-tapping screws and the air mix control motor from the heater unit.

D

• If the linkage and door move smoothly, replace the air mix control motor . • If the linkage or door sticks or binds, repair them as needed. AIR MIX CONTROL MOTOR

234

2. Install the motor in the reverse order of removal. After installation, make sure the motor runs smoothly.

567

3. Measure the resistance between the No.5 and NO.7 terminals. It should be between 4.2 k to 7.8 k

Q. 4. Measure the resistance between the No.3 and NO.5 terminals. Max Cool-0.58 k to 109 k Q Max Hot-3.52 k to 6.55 kQ

21-20

BACK

Mode Control Motor Test

Mode Control Motor Replacement

1. Disconnect the 7P connector from the mode control motor. 2. Connect battery power to the No.2 terminal, and ground the No.1 terminal; the mode control motor should run smoothly, and stop at Vent. If it doesn't, reverse the connections; the mode control motor should run smoothly, and stop at Defrost. When the mode control motor stops running, disconnect battery power immediately.

1. Remove the wire harness clip (A), then disconnect the 7P connector (8) from the mode control motor (C). Remove the rods (D) of the mode control motor from the mode control linkage (E). Remove the selftapping screws and the mode control motor from the heater unit.

MODE CONTROL MOTOR

3

4

5

6

7 2. Install the motor in the reverse order of removal. After installation, make sure the motor runs smoothly.

3. Use a digital multimeter with an output of 1 mA or less at the 20 k Q range. With the mode control motor running as in step 2, check for continuity between the No.3, 4, 5, 6 terminals and the NO.7 terminal individually. There should be continuity for a moment at each terminal. 4. If the mode control motor does not run in step 2, remove it, then check the mode control linkage and doors for smooth movement. • If the linkage and doors move smoothly, replace the mode control motor. • If the linkage or doors sticks or binds, repair them as needed.

BACK

21-21

Heating Recirculation Control Motor Test

Recirculation Control Motor Replacement

1. Disconnect the 7P connector from the recirculation control motor. 1. Remove the glove box (see page 20-87).

INOTICE I Incorrectly applying power and ground to the recirculation control motor will damage it. Follow the instructions carefully.

2. Disconnect the 7P connector (A) from the recirculation control motor (B). Remove the selftapping screws and the recirculation control motor from the blower unit.

2. Connect battery power to the No.1 terminal, and ground the No.5 and No.7 terminals; the recirculation control motor should run smoothly. To avoid damaging the recirculation control motor, do not reverse power and ground. Disconnect the No.5 or No.7 terminals from ground; the recirculation control motor should stop at Fresh or Recirculate. Don't cycle the recirculation control motor for a long time.

B

RECIRCULATION CONTROL MOTOR

3. Install the motor in the reverse order of removal. After installation, make sure the motor runs smoothly.

23456

7

3. If the recirculation control motor does not run in step 2, remove it, then check the recirculation control linkage and doors for smooth movement. • If the linkage and doors move smoothly, replace the recirculation control motor. • If the linkage or doors sticks or binds, repair them as needed.

21-22

BACK

Evaporator Temperature Sensor Test

Heater Fan Switch Test Check for continuity between the terminals in each switch position according to the table. Terminal

1\

\

Position

1

2

3

4

5

1. Dip the sensor in ice water, and measure the resistance between its terminals. 6

OFF

EVAPORATOR TEMPERATURE SENSOR Terminal side of male terminals

1

2

3 4

~

~

~

2 HEATER FAN SWITCH

2. Then pour hot water on the sensor, and check for a change in resistance. 3. Compare the resistance readings with the specifications shown in the graph; the resistance should be within the specifications. 40

30 RESISTANCE

kQ

20

10

i~

~ 50 10

..........

..........

68 20

86°F 30°C TEMPERATURE

BACK

21-23

Heating Heater Control Panel Removal and Installation 1. Remove the center panel together with the heater control panel (see page 20-86). 2. Remove the self-tapping screws and the heater control panel (A) from the center panel (B).

Heater Control Panel Disassembly and Reassembly 1. Remove the fan switch (A) and temperature control dial (B), then remove the front panel (e). Remove the mode control switch (0), recirculation control switch (E), rear defogger switch (F) and Ale switch lid (G) (or Ale switch (H)) buttons.

A

~Q

!e

2. Reassemble the control panel in the reverse order of removal.

B

3. Install the control panel in the reverse order of removal. After installation, operate the control panel controls to see whether it works properly. 4. Run the self-diagnosis function to confirm that there are no problems in the system (see page 214).

21-24

BACK

Dust and Pollen Filter Replacement The dust and pollen filter should be replace every 30,000 miles (48,000 km) or 24 months whichever comes first. Replace the filter more often if the airflow is less than usual.

4. Remove the filter (A) from the housing (B), and replace it.

1. Remove the glove box (see page 20-87). 2. Remove the bolt, the screws and the glove box frame.

5. Install the filter in the reverse order of removal. Make sure that there is no air leaking out of the evaporator. 3. Remove the filter lid (A) from the evaporator, then pull out the lower dust and pollen filter (B) and the upper dust and pollen filter (e) in that order.

BACK

21-25

Heating Blower Unit Removal and Installation SRS components are located in this area. Review the SRS components locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-28).

6. Disconnect the connectors (A) from the blower motor, the blower resistor and the recirculation control motor, then remove the wire harness clip (B). Remove the mounting nuts, the mounting bolt and the blower unit (e).

1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons.

6x 1.0mm

9.8 N·m (1.0 kgf·m, 7.2Ibf·ft)

2. Disconnect the negative cable from the battery. 3. Remove the dashboard (see page 20-90).

A

\

4. With air conditioning; remove the evaporator (see page 21-46).

u\:\; /

5. Without air conditioning; remove the self-tapping screws, the moutning nut, the mounting bolts and the heater duct.

I--
B

6x 1.0 mm 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft)

\,//

6x 1.0 mm 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft)

7. Install the unit in the reverse order of removal, and note these items: • Make sure that there is no air leakage. • Enter the anti-theft code for radio, then enter the customer's radio station presets.

6x 1.0 mm 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft)

21-26

BACK

Blower Unit Components Replacement Note these items when overhauling the blower unit: • The recirculation control motor (AI. the blower resistor (BI and the blower motor (CI can be replaced without removing the blower unit. • Before reassembly. make sure that the recirculation control linkage and doors move smoothly without binding. • After reassembly. make sure the recirculation control motor runs smoothly (see page 21-221.

c

BACK

21-27

Heating Heater Unit/Core Replacement SRS components are located in this area. Review the SRS components locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-28). 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons.

5. Remove the heater valve mounting nut. Slide the hose clamps (A) back, then disconnect the inlet (B) and outlet (C) heater hoses from the heater unit. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on electrical parts or painted surfaces. If any coolant spills, rinse it off immediately. C

2. Disconnect the negative cable from the battery. 3. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). Turn the heater valve arm to the fully opened position as shown.

A

\

()

/~

A

6x 1.0mm 9.a N·m (1.0 kgf·m, 7.2Ibf·ft)

6. Remove the mounting nut from the heater unit. Take care not to damage or bend the fuel lines, the brake lines, etc.

4. When the engine is cool, drain the engine coolant from the radiator (see page 10-10).

ax 1.25 mm

13 N·m 11.3 kgf.m. 9.4Ibf·ft)

21-28

BACK

7. Remove the dashboard (see page 20-90).

11. Install the heater core in the reverse order of removal.

8. Remove the heater duct (see page 21-26) or evaporator (see page 21-46).

12. Install the heater unit in the reverse order of removal, and note these items:

9. Remove the mounting bolts and the heater unit. • Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely. • Refill the cooling system with engine coolant (see page 10-10). • Adjust the heater valve cable (see page 21-30). • Make sure that there is no coolant leakage. • Make sure that there is no air leakage. • Enter the anti-theft code for the radio, then enter the customer's radio station presets.

10. Remove the self-tapping screws and the bracket (A), then carefully pull out the heater core (B) so you don't bend the inlet and outlet pipes.

BACK

21-29

Heating Heater Valve Cable Adjustment 1. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (8) from the heater valve arm (C). A

5. From under the hood, turn the heater valve arm (C) to the fully closed position as shown, and hold it. Attach the heater valve cable (8) to the heater valve arm, and gently pull on the heater valve cable housing to take up any slack, then install the heater valve cable housing into the cable clamp (A). A

c

B

2. From under the dash, disconnect the heater valve cable housing from the cable clamp (A), and disconnect the heater valve cable (8) from the air mix control linkage (C). A

D

3. Set the temperature control dial on Max Cool (60°F or 18°C) with the ignition switch ON (II). 4. Attach the heater valve cable (8) to the air mix control linkage (C) as shown above. Hold the end of the heater valve cable housing against the stop (D), then snap the heater valve cable housing into the cable clamp (A).

21-30

BACK

c

B

Air Conditioning Component Location Index

SERVICE VALVE (HIGH-PRESSURE SIDE)

/

CONDENSER Replacement. page 21-53

BACK

21-31

Air Conditioning A/C Service Tips and Precautions

A/C Refrigerant Oil Replacement Recommended PAG oil: DENSO NO-OIL 8:

AWARNING • Compressed air mixed with R-134a forms a combustible vapor. • The vapor can burn or explode causing serious injury. • Never use compressed air to pressure test R-134 a service equipment or vehicle air conditioning systems.

ACAUTION • Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. • Be careful when connecting service equipment. • Do not breathe refrigerant or vapor.

The air conditioning system uses HFC-134a (R-134a) refrigerant and polyalkyleneglycol (PAG) refrigerant oil, which are not compatible with CFC-12 (R-12) refrigerant and mineral oil. Do not use R-12 refrigerant or mineral oil in this system, and do not attempt to use R-12 servicing equipment; damage to the air conditioning system or your servicing equipment will result. Use only service equipment that is U.L.-listed and is certified to meetthe requirements of SAE J2210 to remove R-134a from the air conditioning system.

• PIN 38897 - PR7 - A01AH: 120 m.e (4 fl·oz) • PIN 38899-PR7-A01: 40 m.e (11/3fl·oz) Add the recommended refrigerant oil in the amount listed if you replace any of the following parts. • To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. • Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. • Do not spill the refrigerant oil on the vehicle; it may damage the paint; if it gets on the paint, wash it off immediately. Condenser ............ 25 m.e (5/6 fl·oz, 0.9 Imp·oz) Evaporator ............ 40 m.e (1 1/3 fl·oz, 1.4 Imp·oz) Line or hose .......... 10 m.e (1/3 fl·oz, 0.4Imp·oz) Receiver/Dryer ...•. 10 m.e (1/3 fl·oz, 0.4Imp·oz) Leakage repair ..... 25 m.e (5/6 fl·oz, 0.9 Imp·oz) Compressor ......... For compressor replacement, subtract the volume of oil drained from the removed compressor from 160 m.e (51/3 fl·oz, 5.6Imp·oz), and drain the calculated volume of oil from the new compressor: 160 m.e (5 1/3 fl·oz, 5.6Imp·oz) - Volume of removed compressor = Volume to drain from new compressor.

If accidental system discharge occurs, ventilate work area before resuming service.

NOTE: Even if no oil is drained from the removed compressor, don't drain more than 50 m.e (1 2/3 fl·oz, 1.8 Imp·oz) from the new compressor.

R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. • Always disconnect the negative cable from the battery whenever replacing air conditioning parts. • Keep moisture and dirt out of the system. When disconnecting any lines, plug or cap the fittings immediately; don't remove the caps or plugs until just before you reconnect each line. • Before connecting any hose or line, apply a few drops of refrigerant oil to the O-ring. • When tightening or loosening a fitting, use a second wrench to support the matching fitting. • When discharging the system, use a R-134a refrigerant recovery/recycling/charging station; don't release refrigerant into the atmosphere.

21-32

NEW

REMOVED COMPRESSOR

BACK

00

~ tl

-SAME

COMPRESSOR

~VEL

00

_.J)} D

A: 160 mA (5 1/3 fl·oz. 5.6Imp·oz)

.-NWG } VOLUME

:A

EVAPORATOR

SUCTION HOSE

~JjjS:w------®

CONDENSER UNE DISCHARGE HOSE

~COMPRESSOR

®

BRACKET

CD Discharge hose to the compressor (6 x 1.0 mm): 9.8 N·m (1.0 kgf·m. 7.2Ibf.ft) ® Discharge hose to the condenser (6 x 1.0 mm) : 9.8 N·m (1.0 kgf·m. 7.2Ibf.ft) ® Condenser line to the condenser (6 x 1.0 mm): 9.8 N·m (1.0 kgf·m. 7.2Ibf.ft) ® Condenser line to the receiver/dryer: 9.8 N·m (1.0 kgf.m. 7.2 Ibf.ft)

@ Receiver line to the receiver/dryer: 9.8 N·m (1.0 kgf·m. 7.2Ibf.ft)

@ Receiver line to the evaporator: 13 N·m (1.3 kgf·m. 9.4Ibf.ft) (j) Suction hose to the evaporator: 31 N·m (3.2 kgf·m. 23 Ibf.ft) ® Suction hose to the compressor (6 x 1.0 mm) : 9.8 N·m (1.0 kgf·m. 7.2Ibf.ft) ® Compressor to compressor bracket (8 x 1.25 mm) : 22 N·m (2.2 kgf·m. 16Ibf.ft) @Compressorbrackettoengineblock (10 x 1.25 mm): 49 N·m (5.0 kgf·m. 36Ibf.ft)

BACK

21-33

Air Conditioning Symptom Troubleshooting Index Symptom


Condenser fan does not run at all (but radiator fan runs with the AlC on)

Condenser Fan Circuit Troubleshooting (see page 21-37)

Both fans do not run with the AlC on

Radiator and Condenser Fans Common Circuit Troubleshooting (see page 21-38)

Compressor clutch does not engage

Compressor Clutch Circuit Troubleshooting (see page 21-39)

AlC system does not come on (both fans and compressor)

AlC Pressure Switch Circuit Troubleshooting (see page 21-25)

21-34

BACK

Also check for

• Blown fuse No. 58 (20A) in the under-hood fuse/relay box, and No.3 (7.5A) in the driver's underdash fuse/relay box • Poor ground at G201 • Cleanliness and tightness of all connectors • Blown fuse No. 57 (20A) and No. 58 (20A) in the under-hood fuse/ relay box, and No.3 (7.5A) in the driver's under-dash fuse/relay box • Poor ground at G201 • Cleanliness and tightness of all connectors • Blown fuse No. 58 (20A) in the under-hood fuse/relay box, and No.3 (7.5A) in the driver's underdash fuse/relay box • Cleanliness and tightness of all connectors Cleanliness and tightness of all connectors

System Description The air conditioning system removes heat from the passenger compartment by circulating refrigerant through the system as shown below. BLOWER FAN

EVAPORATOR EVAPORATOR (Absorption of heat) TEMPER%TURE SENSOR

EXPANSIONVALVE~

(Meters the required amount of refrigerant into the evaporator)

EQUALIZING TUBE (Meters pressure and improves the expansion valve reaction time)

\

CAPILLARY TUBE SENSING BULB (Controls the temperature of the refrigerant leaving the evaporator by metering the expansion valve)

A/C PRESSURE SWITCH When the refrigerant is below 196 kPa (2.0 kgf/cm' ,28 psi) or above 3,140 kPa (32 kgf/cm' , 455 psi), the NC pressure switch opens the circuit to the NC switch and stops the air conditioning to protect the compressor.

RELIEF VALVE (Relieves pressure at the compressor when the pressure is too high)

HIGH PRESSURE VAPOR RECEIVER/DRYER (Traps debris, and removes moisture)

HIGH PRESSURE LIQUID CONDENSER (Radiation of heat)

EWit-

LOW PRESSURE LIQUID LOW PRESSURE VAPOR

This vehicle uses HFC-134a (R-134a) refrigerant which does not contain chlorofluorocarbons. Pay attention to the following service items: • Do not mix refrigerants CFC-12 (R-12) and HFC-134a (R-134a). They are not compatible. • Use only the recommended polyalkyleneglycol (PAG) refrigerant oil (DENSO ND-OIL8) designed for the R-134a compressor. Intermixing the recommended (PAG) refrigerant oil with any other refrigerant oil will result in compressor failure. • All NC system parts (compressor, discharge line, suction line, evaporator, condenser, receiver/dryer, expansion valve, O-rings for joints) have to be proper for refrigerant R-134a. Do not confuse with R-12 parts. • Use a halogen gas leak detector designed for refrigerant R-134a. • R-12 and R-134a refrigerant servicing equipment are not interchangeable. Use only a recovery/recycling/charging station that is U.L.-listed and is certified to meetthe requirements of SAE J2210 to service R-134a air conditioning system. • Always recover the refrigerant R-134a with an approved recovery/recycling/charging station before disconnecting any NC fitting.

BACK

21-35

Air Conditioning Circuit Diagram UNDER·HOOD FUSE/RELAY BOX BATIERY

~

No.42 (50A)

No.41 (100A)

+


IGNITION SWITCH WHT

r

YEL

IG2

No.3 (7.5A)

PASSENGER'S UNDER·DASH FUSE/RELAY BOX

NO.54 (40A)

No.13 (7.5A) YEL

"'"'

I BL KNEl

NO.S6 (20A)

~(20A)

BlKNEL

1

1

3

~~----------i

RADIATOR FAN RELAY

~~----- ------'I

GRN

4

CDNDENSER FAN RELAY 4

2

4

2

3

)

BLU/YEl

1

~----------~1 3

2

RED

RED

COM PRESSOR CLUTCH RELA Y

1 ~GRN

I

GRN

BLU/BLK

~

COMP RESSOR ClUTCH

GiN

.JL

FANC SV RADIATOR FAN SWITCH 1 (Closed: Above ) 199°F (93°C) BlUiRED

M

RADIATOR FAN MOTOR

M

CONDENSER FAN MOTOR

l' 1


.-"----..(5}-- YEUGRN

BLK

BLK

BLK BlK

G201

21-36

G101

G401

G201

BACK

~~ESSURE SWITCH

Condenser Fan Circuit Troubleshooting 1. Check the No. 58 (20 A) fuse in the under-hood fuse/relay box, and the No.3 (7.5 A) fuse in the driver's under-dash fuse/relay box.

4. Connect the No.1 and No.2 terminals of the condenser fan relay 4P socket with a jumper wire. CONDENSER FAN RELAV 4P SOCKET

Are the fuses OK? YES - Go to step 2. NO- Replace the fuse(s), and recheck .•

JUMPER WIRE

1

2. Remove the condenser fan relay from the underhood fuse/relay box, and test it (see page 22-52).

2 BLU/VEl

3

4

Is the relay OK? YES - Go to step 3. NO- Replace the condenser fan relay .•

Does the condenser fan run?

3. Measure the voltage between the No.1 terminal of the condenser fan relay 4P socket and body ground.

YES - Go to step 5. NO-Go to step 8.

CONDENSER FAN RELAV 4P SOCKET

5. Disconnect the jumper wire. 6. Turn the ignition switch ON (II). 2

4

7. Measure the voltage between the No.3 terminal of the condenser fan relay 4P socket and body ground.

3

CONDENSER FAN RELA V 4P SOCKET

2

= 4

Is there battery voltage? YES-Go to step 4. NO- Replace the under-hood fuse/relay box .•

Is there battery voltage? YES - Replace the under-hood fuse/relay box.• NO-Repair open in the wire between the No.3 fuse in the driver's under-dash fuse/relay box and the condenserfan relay .• 8. Disconnect the jumper wire. 9. Disconnect the condenser fan 2P connector. (cont'd)

BACK

21-37

Air Conditioning Condenser Fan Circuit Troubleshooting (cont'd)

Radiator and Condenser Fans Common Circuit Troubleshooting

10. Check for continuity between the No.2 terminal of the condenser fan relay 4P socket and the No.2 terminal of the condenser fan 2P connector.

1. Check the No. 57 (20A) and No. 58 (20A) fuses in the under-hood fuse/relay box, and the No.3 (7.5A) fuse in the driver's under-dash fuse/relay box.

CONDENSER FAN RELAV 4P SOCKET

Are the fuses OK?

1----1 BLU/VEL

YES-Go to step 2.

2 4

NO- Replace the fuse(s), and recheck .•

3

Q

2. Remove the condenser fan relay from the underhood fuse/relay box. 3. Turn the ignition switch ON (II). 4. Measure the voltage between the No.3 terminal of the condenser fan relay 4P socket and body ground.

CONDENSER FAN 2P CONNECTOR


CONDENSER FAN RELA V 4P SOCKET

Is there continuity? YES-Go to step 11.

2

NO- Repair open in the wire between the condenser fan relay and the condenser fan .•

4

3

11. Check for continuity between the No.1 terminal of the condenser fan 2P connector and body ground.

BLK/VEL

CONDENSER FAN 2P CONNECTOR


= Is there battery voltage? YES - Go to step 5.

BLK

NO- Repair open in the wire between the No.3 fuse in the driver's under-dash fuse/relay box and the condenser fan relay .•

=



6. Reinstall the condenser fan relay.

YES - Replace the condenser fan motor.•

7. Make sure the Ale switch is OFF.

NO-Check for an open in the wire between the condenser fan and body ground. If the wire is OK, check for poor ground at G201 .•


21-38

BACK

Compressor Clutch Circuit Troubleshooting 9. Using a 8ackprobe Set, measure the voltage between the No. 20 terminal of the PCM connector A (32P) and body ground with the PCM connectors connected.

1. Check the No. 58 (20A) fuse in the under-hood fuse/ relay box, and the No.3 (7.5A) fuse in the driver's under-dash fuse/relay box.

PCM CONNECTOR A (32P) Wire side of female terminals

Are the fuses OK?

GRN

5 6 / 8 9 V12 3 4 1121 13 14 15 16 17 18 19 20 21 / 25 26 27 28 29 30 /

YES - Go to step 2.

-

10 23 32

/1 24

NO - Replace the fuse(s), and recheck .•

I

2. Check the engine coolant temperature (Use the Honda PGM Tester PGM-FI data list if possible).

'Y.

Is the coolant temperature higher than nomal?

=

YES- Troubleshoot and repair cause of high engine coolant temperature .•


NO - Go to step 3. YES-Check for loose wires or poor connections at the PCM connector A(32P). If the connections are good, substitute a known-good PCM,and recheck. If the symptom/indication goes away, replace the original PCM .•

3. Remove the compressor clutch relay from the under-hood fuse/relay box, and test it (see page 2252).

Is the relay OK? NO- Repair open in the wire between the radiator and the condenser fan relays and PCM .•

YES-Go to step 4. NO- Replace the compressor clutch relay .• 4. Measure the voltage between the No.1 terminal of the compressor clutch relay 4P socket and body ground. COMPRESSOR CLUTCH RELAV 4P SOCKET

2 4

3

= Is there battery voltage? YES - Go to step 5. NO- Replace the under-hood fuse/relay box.• (cont'd)

BACK

21-39

Air Conditioning Compressor Clutch Circuit Troubleshooting (cont'd) 5. Connect the No.1 and No.2 terminals of the compressor clutch relay 4P socket with a jumper wire. COMPRESSOR CLUTCH RELA V 4P SOCKET

9. Turn the ignition switch OFF. 10. Reinstall the compressor clutch relay. 11. Make sure the AlC switch is OFF. 12. Turn the ignition switch ON (II). 13. Using the Backprobe Set, measure the voltage between the No. 17 terminal of the PCM connector A (32P) and body ground with the PCM connectors connected.

JUMPER WIRE

1

2 PCM CONNECTOR A (32P)

RED


3

4

23456

Does the compressor clutch click?

25 26 27

YES - Go to step 6.

RED

NO- Go to step 14. 6. Disconnect the jumper wire. 7. Turn the ignition switch ON (II).

Is there battery voltage? 8. Measure the voltage between the No.4 terminal of the compressor clutch relay 4P socket and body ground.

YES - Check for loose wi res or poor connections at the PCM connector A (32P). If the connections are good, substitute a known-good PCM, and recheck. If the symptom/indication goes away, replace the original PCM .•

COMPRESSOR CLUTCH RELAV 4P SOCKET

NO- Repair open in the wire between the compressor clutch relay and the PCM .•

2

4

3

14. Disconnectthe jumper wire.

BlK/VEl

15. Disconnectthe compressor clutch 1P connector.

= Is there battery voltage? YES-Go to step 9. NO-Repair open in the wire between the No.3 fuse in the driver's under-dash fuse/relay box and the compressor clutch relay .•

21-40

BACK

AIC Pressure Switch Circuit Troubleshooting 16. Check for continuity between the No.2 terminal of the compressor clutch relay 4P socket and the No.1 terminal of the compressor clutch 1P connector. COMPRESSOR CLUTCH RELAY 4P SOCKET

4


RED

2

1. Disconnect the AlC pressure switch 2P connector.

3. Measure the voltage between the No.2 terminal of the AlC pressure switch 2P connector and body ground.

3

AIC PRESSURE SWITCH 2P CONNECTOR Wire side of female terminals

COMPRESSOR CLUTCH 1P CONNECTOR Terminal side of male terminals

BLU/RED

Is there continuity? YES - Check the compressor clutch clearance and the compressor clutch field coil (see page 21-50) .• NO- Repair open in the wire between the compressor clutch relay and the compressor clutch .•

Is there about 5 volts? YES - Go to step 4. NO-Gotostep 10. 4. Turn the ignition switch OFF. 5. Check for continuity between the No.1 and No.2 terminals of the AlC pressure switch. AIC PRESSURE SWITCH

'-----~.Qr-----'

Is there continuity? YES- Go to step 6. NO-Gotostep 11. (cont'd)

BACK

21-41

Air Conditioning AIC Pressure Switch Circuit Troubleshooting (co nt'd) 6. Reconnect the AlC pressure switch 2P connector. 7. Disconnect the heater control panel 22P connector.

10. Using a Backprobe Set, measure the voltage between the No. 27 terminal of the PCM connector A (32P) and body ground with the PCM connectors connected.

8. Turn the ignition switch ON (II). PCM CONNECTOR A (32P)


9. Measure the voltage between the No.5 terminal of the heater control panel 22P connector and body ground.

1/ 2

3 4 5 6/ 8 9 12 13 14 15 16 17 18 19 20 21 V 25 26 27 28 29 30



fu/~D

VEL/GRN

2 11

3

4

12 13 14 15

6

7

8

9

L

10 23 32

/ 24

10

18 19 20 21 22

= Is there about 5 volts? YES- Repair open in the wire between the PCM and the AlC pressure switch .•

= Is there about 5 volts? YES-Check for loose wires or poor connections at the heater control panel 22P connector and at the AlC pressure switch 2P connector. If the connections are good, substitute a known-good heater control panel, and recheck. If the symptom/ indication goes away, replace the original heater control panel..

NO-Check for loose wires or poor connections at the PCM connector A (32P). If the connections are good, substitute a known-good PCM, and recheck. If the symptom/indication goes away, replace the original PCM .• 11. Check for proper AlC system pressure.

NO-Repair open in the wire between the heater control panel and the AlC pressure switch .•

Is the pressure within specifications? YES - Replace the AlC pressure switch .• NO- Repair the AlC pressure problem .•

21-42

BACK

Ale System Tests Pressure Test Test results

Discharge (high) pressure abnormally high

Related symptoms

After stopping compressor, pressure drops to about 196 kPa (2.0 kgf/cm', 28 psi) QuicklY, and then falls araduallv. Reduced or no air flow through condenser Line to condenser is excessively hot.

Discharge pressure abnormally low

Suction (low) pressure abnormally low

Suction pressure abnormally high

Suction and discharge pressures abnormally high Suction and discharge pressure abnormally low Refrigerant leaks

High and low pressures are balanced soon after stopping compressor. Low side is hiaher than normal. Outlet of expansion valve is not frosted, low-pressure gauge indicates vacuum. Expansion valve is not frosted, and low-pressure line is not cold. Lowpressure gauge indicates vacuum. Discharge temperature is low, and the air flow from vents is restricted. Expansion valve is frosted. Receiver/dryer outlet is cool, and inlet is warm (should be warm during operation). Low-pressure hose and check joint are cooler than the temperature around evaporator. Suction pressure is lowered when condenser is cooled by water. High and low-pressure are equalized as soon as the compressor is stopped, and both gauges fluctuate while runnina. Reduced air flow through condenser.

Low-pressure hose and metal end areas are cooler than evaporator. Temperature around expansion valve is too low compared with that around receiver/dryer. COlTlPressor clutch is dirty. Compressor bolt(s) are dLrty. Compressor aasket is wet with oil.

Probable cause

Air in system • Clogged condenser or radiator fins • Condenser or radiator fan not workina properlv Restricted flow of refrigerant in svstem • Faulty compressor discharge valve • Faulty compressor seal • Faulty expansion valve • Moisture in system • Frozen expansion valve (Moisture in system) • Faulty expansion valve Frozen evaporator Cloaaed expansion valve Clogged receiver/dryer

Remedy

Recover, evacuate (see page 21-55), and recharge with specified amount (see paae 21-56). • Clean • Check voltage and fan rpm. • Check fan direction. Restricted lines Replace the compressor. • Replace • Recover, evacuate, and recharge with specified amount. • Recover, evacuate, and recharge with specified amount. • Replace the expansion valve. Run the fan with compressor off, then check evaporator temperature sensor. Clean or replace. Replace

• Expansion valve open too long • Loose expansion capillary tube

Repair or replace.

Excessive refrigerant in system

Recover, evacuate, and recharge with specified amount. Replace the compressor.

• Faulty gasket • Faulty high-pressure valve • Foreign particle stuck in highpressure valve • Clogged condenser or radiator fins • Condenser or radiator fan not workina properly Clogged or kinked low-pressure hose parts Clogged high-pressure line Compressor shaft sealleakina Leaking around bolt(s) Gasket leaking

• Clean • Check voltage and fan rpm. • Check fan direction. Repair or replace. Repair or replace. Replace the compJessor. Tiahten boltls) or replace compressor. Replace the compressor.

(cont'd)

BACK

21-43

Air Conditioning Ale System Tests (cont'd) Performance Test

3. Insert a thermometer in the center air vent.

AWARNING • Compressed air mixed with R-134a forms a combustible vapor. • The vapor can burn or explode causing serious injury. • Never use compressed airto pressure test R-134a service equipment or vehicle air conditioning systems.


4. Test conditions: • • • •

Avoid direct sunlight. Open the hood. Open the front doors. Set the temperature control dial on Max Cool, the mode control switch on Vent and the recirculation control switch on Recirculate. • Turn the AlC switch on and the fan switch on Max. • Run the engine at 1,500 rpm. • No driver or passengers in vehicle.

The performance test will help determine if the air conditioner system is operating within specifications. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air.

5. After running the air conditioning for 10 minutes under the above test conditions, read the delivery temperature from the thermometer in the dash vent, the intake temperature near the blower unit behind the glove box and the high and low system pressure from the AlC gauges.

Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recover/recycling/ charging station to the high-pressure service port and the low-pressure service port, following the equipment manufacturer's instructions. 2. Determine the relative humidity and air temperature.

21-44

BACK

6. To complete the charts: • • • • • • • •

Mark the delivery temperature along the vertical line. Mark the intake temperature (ambient air temperature) along the bottom line. Draw a line straight up from the air temperature to the humidity. Mark a point 10 % above and 10 % below the humidity level. From each point, draw a horizontal line across the delivery temperature. The delivery temperature should fall between the two lines. Complete the low-side pressure test and high-side pressure test in the same way. Any measurements outside the line may indicate the need for further inspection.

kPa (kgf/cm2)

psi 2900 (30) [430]

80% HUMIDITY LEVEL

2500 (25) [360] 2000 (20) [280]

DELIVERY PRESSURE

30%

kPa (kgf/cm2)

psi Of (CC)

1500 (15) [210]

400 (4) [57]

86 (30)

980 (10) [140]

300 (3) [43]

77

80% HUMIDITY 80% LEVEL

(25)

DELIVERY 200 (2) PRESSURE [28]

68 (20)

100 (1) [14]

59 (15)

0

50 (10)

30% HUMIDITY LEVEL

INTAKE PRESSURE 30%

INTAKE PRESSURE

DELIVERY TEMPERATURE

41 (5)


I

I

68 (20)

77 (25)

I

86 (30)

I

I

95 (35)

104 (40)

Of (CC)

INTAKE TEMPERATURE

BACK

21-45

Air Conditioning Evaporator Removal and Installation 1. Recover the refrigerant with a recovery/recycling/ charging station (see page 21-54). 2. Disconnect the suction (A) and the receiver (B) lines from the evaporator. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination. A

5. Disconnect the connector (A) from the evaporator temperature sensor, then remove the self-tapping screws, the mounting nut, the mounting bolts and the evaporator (B).

31 N·m (3.2 kgf.m, 23 Ibf·ftl

B

B

13 N·m (1.3 kgf.m, 9.4Ibf·ftl

3. Remove the glove box (see page 20-87).

6x 1.0 mm 9.8 N·m (1.0 kgf·m, 7.2Ibf·ftl

4. Remove the bolt, the screws and the glove box frame (A). Remove the self-tapping screw, the bolts and the passenger's knee bolster (B).

6. Install the evaporator in the reverse order of removal, and note these items:

B

• If you're installing a new evaporator, add refrigerant oil (DENSO ND-OIL8) (see page 21-32). • Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for HFC-134a (R-134a) to avoid leakage. • Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. • Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. • Make sure that there is no air leakage. • Charge the system (see page 21-56).

21-46

BACK

Evaporator Components Replacement 1. Remove the filter lid (A), then pull out the dust and pollen filters (B). 9th fin from inlet side

D

113±5mm (4.45±O.2 in.)

B

2. Pull out the evaporator temperature sensor (C) from the evaporator fins. 3. Remove the screws, carefully separate the upper housing (D) from the lower housing (E), then remove the evaporator core (F). 4. If necessary, remove the expansion valve (G). Use a second wrench to hold the other fitting on the valve so the evaporator line won't twist. Leave the first fitting loosely connected so you can use it to hold the valve while you loosen the second fitting. 5. Reassemble the evaporator in the reverse order of disassembly, and note these items: • Replace all O-rings with new ones at each fitting and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for HFC-134a (R-134a) to avoid leakage. • Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. • Install the capillary tube (H) directly against the outlet line, and wrap it with electrical tape (I). • Reinstall the evaporator temperature sensor in its original location. • Make sure no air is leaking from the upper housing and the lower housing fitting.

BACK

21-47

Air Conditioning Compressor Replacement 1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes, then shut the engine off.

7. Disconnect the compressor clutch connector (A), then remove the mounting bolts and the compressor(B).

2. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 3. Disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station (see page 21-54). 5. Loosen the Ale compressor belt (see page 4-39). 6. Remove the nuts, then disconnect the suction line (A) and discharge line (B) from the compressor. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination. &x1.0mm 9.8 N·m (1.0 kgf·m, 7.2Ibf.ftl

8x1

mm 22 N·m 12.2 kgf·m, 16 Ibf·ftl

8. Remove the bolts, the suction service valve (A) and the O-ring (B) from the compressor. 25.5 N·m 12.& kgf·m, 18.8Ibf·ftl

A

A

21-48

BACK

9. If necessary, remove the mounting bolts, mounting nuts and the compressor bracket. A(

(

10. Install the compressor in the reverse order of removal, and note these items.

f'/YI-

/~!( /~

. "/~/

10x 1.25mm 49 N·m (5.0 kgf.m, 36 Ibf·ft)

BACK

• If you're installing a new compressor, you must calculate the amount of refrigerant oil to be removed from it (see page 21-32). • Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for HFC-134a (R-134a) to avoid leakage . • Use refrigerant oil (OENSO NO-OILS) for HFC-134a OENSO piston type compressors only. • To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. • Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. • 00 not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint. wash it off immediately. • Adjust the AlC compressor belt (see page 4-39). • Charge the system (see page 21-56). • Enter the anti-theft code for the radio, then enter the customer's radio station presets.

21-49

Air Conditioning Compressor Clutch Check 1. Check the plated parts of the pressure plate for color changes, peeling or other damage. If there is damage, replace the clutch set (see page 21-51).

4. Check resistance of the field coil. If resistance is not within specifications, replace the field coil (see page 21-51).

2. Check the pulley bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag (see page 21-51).

3. Measure the clearance between the pulley (A) and the pressure plate (8) all the way around. If the clearance is not within specified limits, remove the pressure plate (see page 21-51) and add or remove shims as needed to increase or decrease clearance.

Clearance:

O.S±O.1S mm (O.020±O.006 in.'

NOTE: The shims are available in three thicknesses: 0.1 mm, 0.3 mm and 0.5 mm. B

21-50

BACK

Field Coil Resistamce: 3.4 - 3.8 ohms at 68°F (20°C)

Compressor Clutch Overhaul Special Tool Required

AlC clutch holder, Robinair 10204, Kent-Moore J37872, or Honda Tool and Equipment KMT-J33939, commercially available

3. If you are replacing the field coil, remove the snap ring (A) with snap ring pliers, then remove the pulley (B). Be careful not to damage the pulley and compressor.

1. Remove the center bolt while holding the pressure plate with a commercially available AlC clutch holder. 13.2 N·m (1.35 kgf.m, 9.76Ibf·ftl

I

2. Remove the pressure plate (A) and shim(s) (B), taking care not to lose the shim(s). If the clutch needs adjustment, increase or decrease the number and thickness of shims as nesessary, then reinstall the pressure plate, and recheck its clearance (see page 21-50).

(cont'd)

BACK

21-51

Air Conditioning Compressor Clutch Overhaul (cont'd)

Compressor Relief Valve Replacement

4. Remove the screw from the field coil ground terminal (A). Remove the snap ring (8) with snap ring pliers, then remove the field coil (C). 8e careful not to damage the field coil and compressor.

1. Recover the refrigerant with a recover/recycling/ charging station (see page 21-54). 2. Remove the relief valve (A) and the O-ring (8). Plug the opening to keep foreign matter from entering the system and the compressor oil from running out.

A

13.2 N·m (1.35 kgf·m, 9.76Ibf·ft)

3. Clean the mating surfaces.

5. Reassemble the clutch in the reverse order of disassembly, and note these items: • Install the field coil with the wire side facing down, and align the boss on the field coil with the hole in the compressor. • Clean the pulley and compressor sliding surfaces with contact cleaner or other non-petroleum solvent. • Install new snap rings, note the installation direction, and make sure they are fully seated in the groove. • Make sure that the pulley turns smoothly after it's reassembled. • Route and clamp the wires properly or they can be damaged by the pulley.

21-52

4. Replace the O-ring with a new one at the relief valve, and apply a thin coat of refrigerant oil before installing it. 5. Remove the plug, and install and tighten the relief valve.

6. Charge the system (see page 21-56).

BACK

Condenser Replacement 1. Recover the refrigerant with a recovery/recycling/ charging station (see page 21-54). 2. Remove the coolant reservoir, but do not disconnect the reservoir hose from the coolant reservoir and the radiator.

5. Remove the bolts and the upper mount brackets (A), then remove the condenser (8) by lifting it up. Be careful not to damage the radiator and condenser fins when removing the condenser. A

~

3. Remove the bolts, then remove the upper mount brackets from the radiator.

i~~~o

4. Remove the bolts, then disconnect the discharge line (A) and condenser line (B) from the condenser. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

\

6x 1.0mm 9.8 N·m (1.0 kgf·m, 7.2Ibf·ftl

A

6. Install the condenser in the reverse order of removal, and note these items: • If you're installing a new condenser, add refrigerant oil (OENSO NO-OIL 8) (see page 2132). • Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for HFC-134a (R-134a) to avoid leakage. • Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. • Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. • Be careful not to damage the radiator and condenser fins when installing the condenser. • Charge the system (see page 21-56).

6x1.0mm 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft)

BACK

21-53

Air Conditioning Refrigerant Recovery 1. Connect a R-134a refrigerant recovery/recycling/ charging station (A) to the high-pressure service port (8) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions.


Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J221 0 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service.

i i i

(1

i

Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.

../

./

/

/ \

".

2. Measure the amount of refrigerant oil removed from the AlC system after the recovery process is completed. Be sure to put the same amount of new refrigerant oil back into the AlC system before charging.

21-54

BACK

System Evacuation 2. Connect a R-134a refrigerant recovery/recycling/ charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. Evacuate the system.


Use only service equipment that is U.L.-Iisted and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. When an AlC System has been opened to the atmosphere, such as during installation or repair, it must be evacuated using a R-134a refrigerant recovery/recycling/charging station (If the system has been open for several days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.)

3. If the low-pressure does not reach more than 93.3 kPa (700 mm Hg, 27.6 in.Hg) in 15 minutes, there is probably a leak in the system. Partially charge the system, and check for leaks.

BACK

21-55

Air Conditioning System Charging 2. Evacuate the system (see page 21-55).

ACAUTION

3. Add the same amount of new refrigerant oil to the system that was removed during recovery. Use only OENSO NO-OIL 8 refrigerant oil.

• Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. • Be careful when connecting service equipment. • Do not breathe refrigerant or vapor.

4. Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system; the compressor will be damaged.

Use only service equipmentthat is U.L.-Iisted and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system.

Select the appropriate units of measure for your refrigerant charging station.

Refrigerant capacity: 600 to 650 g 0.60 to 0.65 kg 1.3 to 1.4 Ibs 21.2 to 22.9 oz

If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.

5. Check for refrigerant leaks (see page 21-57). 1. Connect a R-134a refrigerant recovery!recycling! charging station (A) to the high-pressure service port (B) and the low-pressure service port (Cl. as shown, following the equipment manufacturer's instructions.

./

(

\

21-56

---

6. Check for system performance (see page 21-44).

./

."

BACK

Refrigerant Leak Test Special Tool Required Leak detector, Honda Tool and Equipment YGK-H-10PM, commercially available

AWARNING

1. Connect a R-134a refrigerant recovery/recycling/ charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions.

0~I~f?;:" .._______A ,~m

• Compressed air mixed with R-134a froms a combustible vapor. • The vapor can burn or explode causing serious injury. • Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning system.

~"

./


Use only service equipment that is U.L.-listed and is certiified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system.

2. Open high pressure valve to charge the system to the specified capacity, then close the supply valve, and remove the charging system couplers.

If accidental system discharge occurs, ventilate work area before resuming service.

Select the appropriate units of measure for your refrigerant charging station.

R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air.

Additional health and safety information may be obtained from the refrigerant and lulbricant manufacturers.

Refrigerant capacity: 600 to 650 g 0.60 to 0.65 kg 1.3 to 1.41bs 21.2 to 22.9 oz 3. Check the system for leaks using a R-134a refrigerant leak detector with an accuracy of 14 g (0.5 oz) per year or better. 4. If you find leaks that require the system to be opened (to repair or replace hoses, fittings, etc.), recover the system. 5. After checking and repairing leaks, the system must be evacuated.

BACK

21-57

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If electrical maintenance is required) The Accord Sedan/Coupe (L4) SRS includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensioners ('01-02 models) in the front seat belt retractors, and side airbags ('00-02 models) in the front seat-backs. Information necessary to safely service the SRS is included in this Service Manual. Items marked with an asterisk ( * ) on the contents page include or are located near SRS components. Servicing, disassembling, or replacing these items will require special precautions and tools, and should be done only by an authorized Honda dealer.

• To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all SRS service work must be performed by an authorized Honda dealer. • Improper service procedures, including incorrect removal and installation ofthe SRS, could lead to personal injury caused by unintentional deployment of the airbags and side airbags. • Do not bump the SRS unit. Otherwise, the system may fail in a collision, or the airbags may deploy when the ignition switch is ON (II). • SRS electrical connectors are identified by yellow color coding. Related components are located in the steering column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats, and around the floor. Do not use electrical test equipment on these circuits.

BACK

Body Electrical Body Electrical Special Tools ......................... 22-2 General Troubleshooting Information .................... 22-3 Rel~y and Control

Unit Locations ....... Connectors and Harnesses .............. Fuse/Relay boxes ....... Power Distribution Ground Distribution ........... Battery ......................... Relay:s .......................... *Igmtion Switch

22-7

22-11 22-43 22-46 22-49 22-51 22-52

Test ......................................... 22-55 Replacement .......................... 22-56

*Gauges Component Location Index ............................... Circuit Diagram ..................... Gauge Assembly Replacement .................. VSS Replacement ................. VSS Circuit Troubleshooting ............ Maintenance Required Indicator Reset Procedure .......................

22-57 22-60 22-68 22-68 22-69 22-72

22-73 22-74 22-76

Circuit Diagram ..................... 22-79 Control Unit Input Test ......... 22-80

Exterior Lights

*Turn Signal/Hazard Flasher

Component Location Index ............................... Circuit Diagram ..................... Turn Signal/Hazard Relay Input Test ........................ Hazard Warning Switch Test .................................

Interior Lights

Component Location Index ............................... Circuit Diagram ..................... Spotlight Test ........... ............. Trunk light Test ..................... Latch Switch Test ..................

Entry Light Control System Component Location Index ............................... Circuit Diagram ..................... Control Unit Input Test ......... Ignition Key Switch Test ....... Ignition Key Light Test ..........

22-115 22-116 22-117 22-120 22-120

*~t~;~;iSh~~~d System

22-121

Component Location Index ............................... Circuit Diagram ..................... Audio Unit Removal ............. Audio Unit TerminallD ......... Speaker Replacement .......... Window Antenna Test .......... Window Antenna Repair ...... Window Antenna Coil Test .................................

22-122 22-123 22-124 22-124 22-125 22-126 22-126 22-127

Clock Circuit Diagram ..................... 22-128 Replacement .......................... 22-129 Component Location Index ............................... 22-130 Circuit Diagram ..................... 22-131 Horn Test/Replacement ........ 22-131

Accessory Power Socket Circuit Diagram ..................... 22-132 Test/Replacement ................. 22-133

Multiplex Control System 22-78

Lights-on, Key-in, Seat Belt Reminder, Key Light Timer, Engine Oir Pressure Indicator Systems

Component Location Index ............................... Circuit Diagram ..................... Back-up Lights Circuit Diagram .......................... Brake Lights Circuit Diagram .......................... Automatic Lights Off Feature Circuit Diagram .............. Control Unit Input Test ......... Combination Light Switch Test/Replacement .......... DRL Control Unit Input Test ................................. Headlight Replacement ........ Taillight Replacement ........... High Mount Brake Light Replacement .................. License Plate Light Replacement .................. Rear Side Marker LiQttt Replacement ........

Circuit Diagram ..................... 22-112 Control Unit Input Test ......... 22-113 Controller Test ....................... 22-114

*Horns

Safety Indicator System Component Location Index ............................... Circuit Diagram ..................... Safety Indicator Input Test ... Brake Light Failure Sensor Test .................................

Power Windows

Dash Lights Brightness Control

22-82 22-84 22-90 22-91

Component Location Index ............................... Circuit Diagram ..................... System Descriptions ............. Troubleshooting .................... Power and Ground Test .......

22-134 22-135 22-136 22-137 22-141

Power Mirrors Component Location Index ............................... Circuit Diagram ..................... Function Test ......................... PowerMirrorSwitchTest .... Power Mirror Actuator Test ................................. Power Mirror Actuator Replacement ..................

22-145 22-146 22-148 22-149

22-95 22-96 22-98 22-100 22-102 22-103 22-103

22-104 22-105 22-106 22-107 22-108 22-109 22-110 22-111 22-111

Component Location Index ............................... Circuit Diagram ..................... Switch Test ............................ MotorTest .............................

Power Seat

Component Location Index ............................... Circuit Diagram ..................... Switch Test ............................ Motor Test ............................. Component Location Index ............................... Circuit Diagram ..................... Switch Test ............................ Heater Test .............................

Immobilizer System

Component Location Index ............................... Circuit Diagram ..................... System Description .............. Troubleshooting .................... Immobilizer Receiver Unit Replacement .................. Component Location Index ............................... Circuit Diagram ..................... System Descriptions ............. Control Unit Input Test ......... Front Door Lock Actuator Test ................................. Rear Door Lock ActuatorTest .................. Driver's Door Lock Knob Switch Test ..................... Passenger's Door Lock Knob Switch Test ..................... Door Key Cylinder Switch Test ................................. Door Lock Switch Test .......... Trunk Lid Opener/Latch Switch Test ..................... Trunk Key Cylinder Switch Test ................................. Security Indicator Test .......... Hood Switch Test .................. Transmitter Test .................... Transmitter Programming ...

22-158 22-159 22-160 22-160

22-179 22-179 22-180 22-180

22-181 22-182 22-184 22-187 22-188 22-188 22-189 22-190 22-190 22-191

22-192 22-193 22-195 22-197

Seat Heaters - Canada

22-151

Rear Window Defogger Component Location Index ............................... Circuit Diagram ..................... Function Test ......................... Defogger Wire Repair ...........

Component Location Index ............................... Circuit Diagram ..................... Control Unit Input Test ......... Wiper/Washer Switch Test/Replacement .......... WiperMotorTest .................. Wiper Motor Replacement ... Washer Motor Test ............... Washer Reservoir Replacement .................. Washer Level Switch Test (Canada) ......................... Washer Tube Replacement ..................

Keyless Entry/Security Alarm System

22-155 22-156 22-157 22-157

22-161 22-162 22-174

Wiper/Washer

22-150

Moonroof 22-92 22-93

Component Location Index ............................... Circuit Diagram ..................... Control Unit Input Test ......... Master Switch Replacement .................. Passenger's Window Switch Replacement .................. Driver's Window Motor Test ................................. Passenger's Window Motor Test .................................

Power Door locks

22-199 22-200 22-201 22-201 22-202 22-203 22-204 22-206 22-207

22-208 22-210 22-215 22-216 22-225 22-225 22-226 22-226 22-227 22-227 22-228 22-228 22-229 22-229 22-230 22-230

Component Location Index ............................... 22-231 Circuit Diagram ..................... 22-232

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Body Electrical Special Tools Ref. No.

CD (])

Tool Number 07LAJ-PT3020A 07WAZ-001010A

Description Test Harness MPCS Short Switch

.

CD

22-2

BACK

aty

1 1

r::-:, I.!!!!.I General Troubleshooting Information Tips and Precautions Before Troubleshooting

1. Check applicable fuses in the appropriate fuse/relay box.

• Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a pull type lock. • Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A).

2. Check the battery for damage, state of charge, and clean and tight connections.

INOTICE I • Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator diodes . • Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring. 3. Check the alternator belt tension. Handling Connectors

• Make sure the connectors are clean and have no loose wire terminals. • Make sure multiple cavity connectors are packed with grease (except watertight connectors). • All connectors have push-down release type locks (A).

A

• Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. • Always reinstall plastic covers.

• Before connecting connectors, make sure the terminals (A) are in place and not bent.

A

(cont'd)

BACK

22-3

Body Electrical General Troubleshooting Information (cont'd) Handling Wires and Harnesses • Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. • Remove clips carefully; don't damage their locks (A).

• Check for loose retainer (A) and rubber seals (8).

A

B

• The backs of some connectors are packed with grease. Add grease if necessary. If the grease is contaminated, replace it.

• Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip.

• Insert the connector all the way and make sure it is securely locked. • Position wires so thatthe open end of the cover faces down.

22-4

• After installing harness clips, make sure the harness doesn't interfere with any moving parts. • Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts. • Seat grommets in their grooves properly (A). Do not leave grommets distorted (8).

BACK

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I..:!!..I Testing and Repairs • Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape. • After installing parts, make sure that no wires are pinched under them. • When using electrical test equipment, follow the manufacturer's instructions and those described in this manual. • If possible, insert the probe of the tester from the wire side (except waterproof connector).

• Use a probe with a tapered tip.

• Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals.

(cont'd)

BACK

22-5

Body Electrical General Troubleshooting Information (cont'd) Five-step Troubleshooting

Wire Color Codes

1. Verify The Complaint Turn on all the components in the problem circuit to verify the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power feed through the circuit components to ground. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit operation, identify one or more possible causes of the problem.

The following abbreviations are used to identify wire colors in the circuit schematics: WHT.................................... White VEL...................................... Vellow BlK...................................... Black BlU ..................................... Blue GRN..................................... Green RED ..................................... Red ORN..................................... Orange PNK..................................... Pink BRN..................................... Brown GRV..................................... Gray PUR ..................................... Purple l T BLU ................................ Light Blue Light Green l T GRN ............................... The wire insulation has one color or one color with another color stripe. The second color is the stripe.

3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified. make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on the fuse. Make sure no new problems turn up and the original problem does not recur.

22-6

BACK

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Relay and Control Unit Locations Engine Compartment UNDER-HOOD FUSE/RELAY BOX

SEAT HEATER RELAY (Canada]

lWire colors: BlK/YEl. BlK. LWHT/BlK and WHT/GRN

BLOWER MOTOR RELAY ABS PUMP MOTOR RELAY [Wire colors: YEL/RED. LBRN/BlK. WHT/BLU and WHT CONDENSER FAN RELAY

MULTI-RELAY BOX U - - - - t - - - RADIATOR

FAN RELAY

AIC COMPRESSOR CLUTCH RELAY

ABS FAIL-SAFE RELAY [Wire colors: YEL/GRN. BlK. LBRN/BlK and WHT/GRN

INTERMITTENT WIPER RELAY

Wire colors: GRN/BlK. [ WHT. BlK. GRN/RED and BLU/WHT

BACK

22-7

Relay and Control Unit Locations Dashboard

PGM-FI MAIN RELAY

CRUISE CONTROL UNIT

MOONROOF OPEN RELAY

DAYTIME RUNNING LIGHTS CONTROL UNIT

(Canada)

[ Wire colors: WHTNEl, BlK, GRYNEl, GRN and GRNNEl MOONROOF CLOSE RELAY

[ Wire colors: WHTNEl, BlK. GRN/RED. GRN and GRN/RED


~

SRSUNIT STARTER CUT RELAY

AfT REVERSE RELAY

TURN SIGNAL/HAZARD RELAY DRIVER'S UNDER-DASH FUSE/RELAY BOX

22-8

BACK

r--:'I I.!!:..I

IMMOBILIZER CONTROL UNIT

PASSENGER'S UNDER-DASH FUSE/RELAY BOX


ACCESSORY SOCKET RELAY

REAR WINDOW DEFOGGER RELAY

-~

'"

~: /---------. Gl£~ ~ -------~) o -1.__ // ~---~ , to. o // //-------:::--------=--/----, c-----; - . ~ ~

I

'I (

--/

~~, )/~ ,I..-

/;;I/)~)

"~'#/ TAILLIGHT RELAY [ Wire colors: RED/GRN RED/VEL, RED/GRN and RED/BLK

17~

CANADA: HIGH BEAM CUT RELAY

]

[ Wire colors: BLU, BLU!RED ORN and ORN/WHT '

]

CALIFORNIA: HEATED OXYGEN SENSOR RELAY ]

[ Wire colors: GRN/RED BLK/YEL, WHT and RED/BLU

BACK

22-9

Relay and Control Unit Locations Door and Seat

MULTIPLEX CONTROL UNIT (DOOR)

OPDSUNIT

FRONT PASSENGER'S SEAT

22-10

BACK

r-:'I t=!..I

Connectors and Harnesses Connector Index

Identification numbers have been assigned to in-line connectors. The number is preceded by the letter "c" for connectors, "G" for ground terminals or "T" for non-ground terminals. Location Dashboard

Harness Engine Compartment Starter cable

T1, T2 and (+ I

Battery ground cable

T3 G1 and (-I T4 G2 C101 and C102 T101 and n02 G101 C101 and C102 G201 and G202 G301 through G303

Engine ground cable Engine wire harness

Right engine compartment wire harness Left engine compartment wire harness Dashboard wire harness B lIeft branch I Dashboard wire harness B (right branchl Dashboard wire harness A

Others (Aoor, Door, Trunk, and Roofl

Notes (see page 22-121 (see page 22-121 (see page 22-121 (see page 22-141 (see page 22-161 (see page 22-181 (see page 22-201

C201 through C204 C301 and C302 G304 and G30S C301, C401, C402 and C404 G401 C201 through C203 and C403 C204, C302 and C401 GS01 and GS02

Left side wire harness

Right side wire harness

Rear wire harness Moonroof wire harness

CS01 through CSOS andCS82 GS03 and GS04 C501 and C5S1 through CS57 G551 and G552 C581 through CS86 and C851 G581 C554 and C601 G601 C502

Roof wire harness Driver's power seat wire harness

C551

Driver'S door wire harness

C631 and C632

Passenger's door wire harness Left rear door wire harness

C553

Right rear door wire harness

C581

Ignition switch lead Clutch switch sub-harness (MITI

C404

SRS main harness

C503

SRS floor harness (Sedanl OPOS wire harness (with side airbags) Rear window defogger wire harness

C556, C557, C583 and C 584 G801 C505 and C851 C851

BACK

(see page 22-201 (see page 22-221 (seepage 22-24) (see page 22-261 (see page 22-281 (see page 22-301 (see page 22-301 (seepage 22-311 (seepage 22-321 (see page 22-341 (see page 22-361 (see page 22-371 (see page 22-38) (see page 22-381 (see page 22-391 (see page 22-39) (see page 22-42) (see page 22-42)

22-11

Connectors and Harnesses Connector to Harness Index Starter Cable Connector or Terminal T1 T2

Ref 2 3

Cavities

Location Right side of engine compartment RiQht side of enQine compartment Battery

Connects to Under-hood fuse/relay box Starter motor Battery positive terminal

Notes

Ref

Cavities

Location Rioht side of enoine compartment Right side of engine compartment

Connects to Transmission housino Body ground via battery Qround cables Battery neQative terminal

Notes

Connects to Cylinder head cover Body ground via engine Qround cable

Notes

(+)

Battery Ground Cable Connector or Terminal

6

T3 G1

1

Battery

(-)

Engine Ground Cable Connector or Terminal T4 G2

22-12

Ref 4

5

Cavities

Location Middle of enQine compartment Left side of engine compartment

BACK

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ENGINE GROUND CABLE

STARTER CABLE

5 2

\+) (-)

6

BATTERY GROUND CABLE

BACK

22-13

Connectors and Harnesses Connector to Harness Index (cont'd) Engine Wire Harness Ref 23 36 35 42

Cavities 4 2 2 10

Location Left side of engine compartment Under the battery Under the battery Right side of engine compartment

32 31 41 39 38

1 1 2 4 1

Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment

37

2

Right side of engine compartment

14

2

Middle of engine

9

6

Middle of engine

10 15 12 13 27

3 2 14 1 2

Middle of engine Middle of engine Middle of engine Middle of engine Right side of engine compartment

34 8 17 19 20 21 11 4 5 6 26

2 3 2 2 2 2 1 25 31 16 4

Under the battery Middle of engine Middle of engine Middle of engine Middle of engine Middle of engine Middle of engine Under middle of dash Under middle of dash Under middle of dash Middle of engine

40 43 28 30 29 18 7 33 44 25 24 2

2 1 2 2 1 4 3 1 3 2 1 10

C102

3

14

C102

3

8

C102

3

10

T101 T102 G101

1 22 16

Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Left side of engine compartment Middle of engine Under the battery Right side of engine compartment Right side of engine compartment Right side of engine compartment Under the under-hood fuse/relay box Under the under-hood fuse/relay box Under the under-hood fuse/relay box Under the under-hood fuse/relay box Under-hood fuse/relay box Alternator Middle of engine compartment

Connector or Terminal Alternator AfT clutch pressure control valve A AfT clutch pressure control valve B Transmission range switch (AfT gear position switch) Back-up light switch connector A (+) Back-up light switch connector B (-) Countershaft speed sensor Distributor Coolant temperature gauge sending unit Engine coolant temperature (ECT) sensor EVAP canister purge valve (EVAP purge control solenoid valve) Exhaust gas recirculation (EGR) valve Idle air control (lAC) valve Intake air temperature (lAT) sensor C103 (Junction connector) Knock sensor Torpue converter clutch solenoid valve (Lock-up control solenoid valve) and shift control solenoid valve A Mainshaft speed sensor MAP sensor Fuel injector No.1 Fuel injector No.2 Fuel injector No.3 Fuel injector No.4 Engine oil pressure switch PCM/ECM connector B PCM/ECM connector C PCM/ECM connector 0 Primary heated oxygen sensor (Primary H02S) Radiator fan switch Second clutch pressure switch Shift control solenoid valve B Shift control solenoid valve C Starter solenoid TDC/CKP sensor Throttle position (TP) sensor Third clutch pressure switch Vehicle speed sensor (VSS) VTEC pressure switch VTEC solenoid valve C101

* 1: * 2: * 3:

98-99 models '98-99 models, '00-02 model (except California) '00-02 model (California)

22-14

BACK

Connects to

Notes

MfT MfT

AfT

*1

AfT

AfT

AfT AfT AfT

AfT MfT Right engine compartment wire harness (see page 22-16) Right engine compartment wire harness (see page 22-16) Right engine compartment wire harness (see page 22-16) Right engine compartment wire harness (see page 22-16) Engine ground via engine wire harness

AfT

* 2 (MfT) * 3 (MfT)

~ ~

32

31

30

29

28

27

BACK

26

25

24

23

22-15

Connectors and Harnesses Connector to Harness Index (cont'd) Right Engine Compartment Wire Harness Location Right side of engine compartment Right side of engine compartment Right side of engine compartment Left side of engine compartment Middle of engine compartment Behind right kick panel Into under-hood fuse/relay box Right side of engine compartment Behind right kick panel Behind right kick panel Behind middle of front bumper Behind right kick panel

Ref 7 6 34 23 22 1 13 20 2 2 24 4

Cavities 4 4 2 1 2 2 3 2 4 4 1 18

5

3

Behind right kick panel

27 29 32 28 30 26 8 21

2 2 3 2 2 1 4 4

Middle of engine compartment Behind right headlight Behind right of front bumper Behind right headlight Behind right headlight Behind middle of front bumper Right side of engine compartment Right side of engine compartment

25 3 33 12

2 4 2 18

Under hood latch Behind right kick panel Right side of engine compartment Right side of engine compartment

11

7


10

3


9

16


19

10


C102

18

14


C102

18

8


C102

18

10


C201

14

16

Under right side of dash

C202

15

7


C203

17

5


C204

16

22


G201

31


G202

35


Connector or Terminal ABS fail-safe relay ABS pump motor relay ABS right front wheel sensor AlC compressor clutch Condenser fan motor Diode (Lighting) ELD unit Engine mount control solenoid valve Heated oxygen sensor relay High beam cut relay Left horn Passenger's under-dash fuse/relay box connector C (see page 22-45) Passenger's under-dash fuse/relay box connector D (see page 22-45) Radiator fan motor Right front parking light Right front side marker light Right headlight (High beam) Right headlight (Low beam) Right horn Seat heater relay Secondary heated oxygen sensor (Secondary H02S) Security hood switch Taillight relay Test tachometer connector Under-hood fuse/relay box connector A (see page 22-43) Under-hood fuse/relay box connector B (see page 22-43) Under-hood fuse/relay box connector C (see page 22-43) Under-hood fuse/relay box connector D (see page 22-43) C101

" 1: * 2:

98-99 models, '00-02 model (except California) '00-02 model (California)

22-16

BACK

Connects to

Notes

Canada

AfT California Canada

Canada

Engine wire harness (see page 22-14) Engine wire harness (see page 22-14) Engine wire harness (see page 22-14) Engine wire harness (see page 22-14) Dashboard wire harness B (see page 22-20) Dashboard wire harness B (see page 22-20) Dashboard wire harness B (see page 22-20) Dashboard wire harness A (see Daoe 22-22) Body ground via right engine compartment wire harness Body ground via right engine compartment wire harness

AfT "1 (MIT) "2 (MIT)

r--:'I

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UNDER-HOOD FUSE/RELAV BOX

PASSENGER'S UNDER-DASH FUSE/RELAV BOX

22

2

23

24

25

RIGHT ENGINE COMPARTMENT WIRE HARNESS

BACK

22-17

Connectors and Harnesses Connector to Harness Index (cont'd) Left Engine Compartment Wire Harness Connector or Terminal ABS control unit connector A ABS control unit connector B ABS left front wheel sensor ABS modulator unit ABS pump motor Brake fluid level switch connector A ( + ) Brake fluid level switch connector B (-) Cruise control actuator Driver's under-dash fuse/relay box connector C (see page 22-44) Driver's under-dash fuse/relay box connector E (see page 22-44) Intermittent wiper relay Left front parking light Left front side marker light Left headlight (High beam) Left headlight (Low beam) Power steering pressure (PSP) switch Washer level switch Windshield washer motor Windshield wiper motor C301

Ref 12 13 14 22 21 5

Cavities 12 22 2 10 2 1

Location Behind left kick panel Behind left kick panel Left side of engine compartment Left side of engine compartment Left side of engine compartment Left side of engine compartment

6

1

Left side of engine compartment

15 10

4 5

Left side of engine compartment Behind left kick panel

11

20

Behind left kick panel

4 24 16 25 23 26 17 18 7 8

6 2 3 2 2 2 2 2 5 20

Left side of engine compartment Behind left headlight Behind left of front bumper Behind left headlight Behind left headlight Left side of engine compartment Behind left of front bumper Behind left of front bumper Left rear of engine compartment Under left side of dash

C302

9

8

Under left side of dash

G301

20


G302

1


G303

19


G304

3


G305

2


22-18

BACK

Connects to

Notes

Canada Dashboard wire harness B (see page 22-20) Dashboard wire harness A . (see page 22-22) Body ground via left engine compartment wire harness Body ground via left engine compartment wire harness Body ground via left engine compartment wire harness Body ground via left engine compartment wire harness Body ground via left engine compartment wire harness

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1 2

3

DRIVER'S . / UNDER-DASH

/

FUSE/RELAY BOX

;/;1.1..._--- 10

12 13 LEFT ENGINE COMPARTMENT WIRE HARNESS

26

15

25

19

20

BACK

22-19

Connectors and Harnesses Connector to Harness Index (cont'd) Dashboard Wire Harness B (Left Branch) Ref

Cavities

6 6 14 5

2 4 4 2

Under left side of dash Under left side of dash Under left side of dash Under left side of dash

17

3


13 18 15 1

14 16 14 20

In the steering column covers

3

7


2

22


12 11 10 7 9 8

7 5 2 7 8 20

In the steering column covers Under left side of dash In the steering column covers Under left side of dash In the steering column covers Under left side of dash

C401

16

22


C402

4

8


C402

4

4


C404 (with clutch wire harness)

20

10


G401

19

Connector or Terminal

Brake switch Brake switch Cable reel Clutch interlock switch (Without clutch wire harness) Clutch switch (Without clutch wire harness) Combination light switch Data link connector (DLC) Daytime running lights control unit Driver's under-dash fuse/relay box connector 0 (see page 22-44) Driver's under-dash fuse/relay box connector P (see page 22-44) Driver's under-dash fuse/relay box connector Q (see page 22-44) Ignition switch Immobilizer control unit Intermittent dwell time controller PGM-FI main relay Windshield wiper/washer switch C301

* 1.

Location

Connects to

Notes

CRUISE

* 1 (MfT) * 1 (MfT)

Under left side of dash Under left side of dash Behind left kick panel


Left engine compartment wire harness (see page 22-18) Dashboard wire harness A (see page 22-22) Security system wire harness (Optional) Security system wire harness (Optional) Clutch wire harness (see page 22-38) Body ground via dashboard wire harness B

USA MIT

98-99 models


to Right Branch

~~~~---10

.... r~·' /

1Ih.-,~"""'

11

17 or20

22-20

Canada

BACK

r--:'I ~

Dashboard Wire Harness B (Right Branch) Connector or Terminal

Ref 14 10 11 4 2 3 1

Cavities 7

8

16

Under right side of dash Under right side of dash Under right side of dash Under middle of dash Under middle of dash Under middle of dash Under middle of dash Behind right kick panel

9

16


5 6

7 16

Under middle of dash Under right side of dash

C202

13

7


C203

12

5


C403

7

2


Air mix control motor Blower motor Blower resistor Evaporator temperature sensor Heater fan switch Heater control panel Mode control motor Passenger's under-dash fuse/relay box connector J (see page 22-45) Passenger's under-dash fuse/relay box connector K (see page 22-45) Recirculation control motor C201

Continues to Left Branch

2 5 2

7 22

7

Location

Notes

Connects to

Right engine compartment wire harness (see page 22-16) Right engine compartment wire harness (see page 22-16) Right engine compartment wire harness (see page 22-16) Security system wire harness IOotionall'

DASHBOARD WIRE HARNESS B (right branch)


1 8

11

BACK

22-21

Connectors and Harnesses Connector to Harness Index (cont'd) Dashboard Wire Harness A Location

Connects to


Ref

Cavities

Accessory socket AfT gear position console light/parking pin switch Audio unit Clock Cruise control unit Cruise control main switch Driver's seat heater switch Driver's under-dash fuse/relay box connector I (see page 22-44) Driver's under-dash fuse/relay box connector K (see page 22-44) ECM/PCM connector A Gauge assembly connector A Gauge assembly connector B Gauge assembly connector C Glove box light Hazard warning switch Left tweeter Moonroof switch Multiplex control unit (driver's) connector B MUltiplex control unit (passenger's) connector B Parking brake switch Passenger's seat heater switch Passenger's under-dash fuse/relay box connector H (see page 22-4S) Passenger's under-dash fuse/relay box connector I (see page 22-4S) Right tweeter Shift lock solenoid SRS memory erase signal (MES) connector SRS unit C204

23 26

2 4

Behind middle of dash Behind console panel

11 10 31 2 2S 37

20 S 14 S 6 18

Behind audio unit Behind middle of dash Behind left side of dash Behind instrument panel Behind middle of dash Behind left kick panel

38

18


22 6 S 7 21 9 4 3 40

32 14 22 16 2 10 2 6 22

Behind middle of dash Behind gauges Behind gauges Behind gauges Behind glove box Behind middle of dash Behind instrument panel Behind instrument panel Behind left kick panel

17

22


30 24 1S

1 6 18

Behind center console Behind middle of dash Behind right kick panel

16

18


14 28 39

2 2 2

Behind instrument panel Behind console panel Behind left kick panel

27 20

8 22

Middle of floor Behind right side of dash

C302

32

8

Behind left side of dash

C401

33

22


CS01 CS01 CS02

3S 3S 1

18 20 7

Behind left kick panel Behind left kick panel Behind instrument panel

CS03

8

3

Under middle of dash

Right engine compartment wire harness (see page 22-16) Left engine compartment wire harness (see page 22-18) Dashboard wire harness B (see page 22-20) Left side wire harness (see page 22-24) Left side wire harness (see page 22-24) Moonroof wire harness (see page 2230) SRS main harness (see page 22-39)

CS03

8

2


SRS main harness (see page 22-39)

CS03

8

8


SRS main harness (see page 22-39)

CS04

34

2


CSOS CS82

29 19

6 16

Middle offloor Behind right kick panel

CS82

19

6


GS01

12


GS02

13


GS03

36


GS04

18


Security system wire harness (Optional) SRS floor harness (see page 22-39) Right side wire harness (see page 2227). Right side wire harness (see page 2226). Body ground via dashboard wire harness A Body ground via dashboard wire harness A Body ground via dashboard wire harness A Body ground via dashboard wire harness A

* 1: * 2: * 3: * 4:

00-02 Sedan, 01-02 Coupe All '98-99 models, '00-02 Coupe, '00-02 Sedan without seat heater '00-02 Sedan with seat heater '00 Sedan with side airbags

22-22

BACK

Notes

AfT '01-02 models * 1

*2 *3 '98-99 models '00-02 Sedan '00-02 Coupe USA *4 '00 Coupe '01-02 models

13

DASHBOARD WIRE HARNESS A

6

7


15

~~____~~~~~~~___ 16 17

30 36

-1-_-

BACK

18

22-23

Connectors and Harnesses Connector to Harness Index (cont'd) Left Side Wire Harness (Sedan) Connector or Terminal ABS left rear wheel sensor Driver's door switch Driver's seat belt switch

Ref 12 23 6

Cavities 2 1 2

Driver's seat belt switch Driver's side airbag inflator

6 20

3 2

Under driver's seat Under driver's seat

Driver's side impact sensor

24

2

Under driver's seat

Driver's side seat belttensioner

21

2

Left B-pillar

Driver's under-dash fuse/relay box connector A (see page 22-44) Driver's under-dash fuse/relay box connector B (see page 22-44) EVAP bypass solenoid valve EVAP control canister vent shut solenoid valve Fuel pump/Fuel gauge sending unit Fuel tank pressure sensor High mount brake light Left rear door switch Left rear speaker Trunk light C501

2

10


3

14


10 9

2 2

Left side of trunk Left side oftrunk

18 11 16 13 15 17 1

5 3 2 1 2 2 18

Fuel tank Left side of trunk Middle of rear shelf Left quarter panel Left quarter panel Middle of rear shelf Behind left kick panel

C501

1

20


C551

5

10

Under driver's seat

C551

5

4

Under driver's seat

C553

22

10

Left B-pillar

C554

19

12

Left quarter panel

C555

4

2


C556

7

4

Under center console

C557

8

4


G551

25

Under driver'S seat

14

Left side of trunk

G552 * 1: * 2: * 3:

Location Under left side of trunk Left B-pillar Under driver's seat

,

Connects to

'98-99 models *1 '01-02 model '01-02 models '01-02 models

Dashboard wire harness A (see page 22-22) Dashboard wire harness A (see page 22-22) Driver's power seat wire harness (see page 22-31) Driver's power seat wire harness (see page 22-31) Left rear door wire harness C (see page 22-36) Rear wire harness (see page 2228) Security system wire harness (Optional) SRS main harness (see page 2239). SRS main harness (see page 2239). Body ground via left side wire harness Body ground via left side wire harness

00-02 models Without B-way power seat All '98-99 models, '00-02 model without seat heater '00-02 model with seat heater

14

2

17

19 LEFr SIDE WIRE HARNESS

22-24

BACK

Notes

*2 *3 8-way 2-way

'01-02 models '01-02 models

r:'I I.!!!:..I ICoup_~ Connector or Terminal ABS left rear wheel sensor Driver's door switch Driver's seat belt switch

Left Side Wire Harness

17 20 5

Cavities 2 1 2

Driver's seat belt switch

21

3

Under driver's seat

Driver's side airbag inflator

5

2

Under driver's seat

Driver's side impact sensor

19

2

Under driver's seat

Driver's under-dash fuse/relay box connector A (see page 22-44) Driver's under-dash fuse/relay box connector B (see page 22-44) EVAP bypass solenoid valve EVAP control canister vent shut solenoid valve Fuel pump/Fuel gauge sending unit Fuel tank pressure sensor High mount brake light Left rear speaker Left side seat belt tensioner

2

10


3

14


9 8

2 2

Left side of trunk Left side of trunk

14 10 12 15 18

5 3 2 2 2

Fuel tank Left side of trunk Middle of rear shelf Left quarter panel Left B-pillar

Trunk light C501

13 1

2 18

Middle of rear shelf Behind left kick panel

C551

22

10

Under driver's seat

C551

22

4

Under driver's seat

C554

16

12

Left quarter panel

C555

4

2


C556

6

4


C557

7

4


G551

23

Under driver's seat

G552

11

Left side of trunk

Ref

Connects to

Location Under left side of trunk Left B-pillar Under driver's seat

Notes

'98-99 models '00-02 models '00-02 models '00-02 models

'01-02 models Dashboard wire harness A (see page 22-22) Driver's power seat wire harness (see page 22-31) Driver's power seat wire harness (see page 22-31) Rear wire harness (see page 22-29) Security system wire harness (Optical) SRS main harness (see page 22-39) SRS main harness (see page 22-39) Body ground via left side wire harness Body ground via left side wire harness

8-way 2-way

'01-02 models

11

23

LEFT SIDE WIRE HARNESS

BACK

22-25

Connectors and Harnesses Connector to Harness Index (cont'd) Right Side Wire Harness (Sedan) Ref 16 2 13 4 3 3 11 7

Cavities 2 2 1 3 3 4 2 20

8

3


15 14 18 1

1 2 2 1 10

Right quarter panel Right quarter panel Right B-pillar Middle of rear shelf Right side of floor

C582

9

6


C583

5

4

C584

6

4

C851

12

4

Connector or Terminal ABS right rear wheel sensor Front passenger's side airbag inflator Passenger's door switch Passenger's seat belt switch Passenger's seat heater Passenger's seat heater Passenger's side impact sensor Passenger's under-dash fuse/relay box connector A (see page 22-45) Passenger's under-dash fuse/relay box connector G (see page 22-45) Right rear door switch Right rear speaker Right side seat belt tensioner Window antenna coil connector A C581

10

G581 * * * *

1. 2: 3: 4:

17

Location Under right side of rear seat Under passenger's seat Right B-pillar Under passenger's seat Under passenger's seat Under passenger's seat Under passenger's seat Behind right kick panel

Connects to

Notes

*4 *1 *2 *3 *4 Canada

*4 Right rear door wire harness (see page 22-37) Dashboard wire harness A (see page 22-22) SRS main harness (see page 22-39) SRS main harness (see page 22-39) OPDS wire harness (see page 22-421 Body ground via right side wire harness

Under passenger's seat

,

00-02 model without seat heater '98-99 model '00-02 model with seat heater '00-02 models

5

6

1

10

18

22-26

17

16

BACK

*4 *4 *4 *4

~

t=!!..I Riaht Side Wire Harness (Coupe) Connector or Terminal ABS right rear wheel sensor Passenger's door switch Passenger's seat belt switch Passenger's seat heater Passenger's seat heater Passenger's side airbag inflator Passenger's side impact sensor Passenger's seat belt tensioner Passenger's under-dash fuse/relay box connector A (see page 22-45) Passenger's under-dash fuse/relay box connector G (see page 22-45) Right rear speaker Window antenna coil connector A C582

Ref 16 13 12 10 10 15 14 9 5

Cavities 2 1 3 3 4 2 2 2 20

6

3


17 18 7

2 1 16

Right quarter panel Middle of rear shelf Behind right kick panel

C582

7

6


C583

2

4

C584

3

4

C585 (Connects to C586) C586 (Connects to C585) C851

4 8 11

1 1 4

G581

1

* * * * * *

1. 2: 3: 4: 5: 6:

Location Under right side of rear seat Right B-pillar Under passenger's seat Under passenger's seat Under passenger's seat Under passenger's seat Under passenger's seat Right B-piller Behind right kick panel

Connects to

*1 *2 *3 *5 *5 Canada

Dashboard wire harnessA (see page 22-22) Dashboard wire harnessA (see page 22-22) SRS main harness (see page 22-39) SRS main harness (see page 22-39)

Under passenger's seat Under passenger's seat


,

Notes

OPDS wire harness (see page 22-42) Body ground via right side wire harness

*4 *5 *6 *6 *6 *6 *6

00-02 model without seat heater '98-99 models '00-02 model with seat heater '00 model '01-02 models '00-02 models

RIGHT SIDE WIRE HARNESS

2

7

9

18 17

BACK

22-27

Connectors and Harnesses Connector to Harness Index (cont'd) Rear Wire Harness (Sedan) Ref 15 13 12 17 16 9 5 6 3 4 2 7 8 10 1

Cavities

6 3 2 2 4 2 3 2 2 4 6 6 2 2 12

Left side of trunk Left side of trunk lid Left side of trunk lid Left side of trunk Left side of trunk Middle oftrunk Right side oftrunk lid Right side of trunk lid Right side of trunk Right side of trunk Left side oftrunk Right side of trunk Middle of trunk Middle oftrunk Left side of rear shelf

C601

11

1

Middle oftrunk

G601

14


Brake light failure sensor Left back-up light Left inner taillight Left rear turn signal light Left taillight License plate light Right back-up light Right inner taillight Right rear turn signal light Right taillight Trailer lighting connector Trunk actuator Trunk key cylinder switch Trunk latch switch C554

1

Connects to

Location

Security Security Left side wire harness (see page 22-24) Security system wire harness (OotionaJ) Body ground via rear wire harness

Left side of trunk

2

j,.'1......-_-- 3

-----4

::..\9......

5 6

7 8 9 10 11

22-28

BACK

Notes

r:-:'I

~

Rear Wire Harness (Coupe) Connector or Terminal

Ref

Cavities

Brake light failure sensor Left back-up light Left inner taillight Left rear side marker light Left taillight License plate light License plate light Right back-up light Right inner taillight Right rear side marker light Right taillight Trailer lighting connector Trunk actuator Trunk key cylinder switch Trunk latch switch (Without keyless entry/security alarm system) C554

16 4 3 18 2 12 13 11 10 8 9 17 6 7 14

6 2 3 2 6 2 2 2 3 2 6 6 6 2 2

Left side of trunk Left side of trunk lid Left side of trunk lid Left side of trunk Left side oftrunk Middle oftrunk Middle of trunk Right side of trunk lid Right side of trunk lid Right side of trunk Right side of trunk Left side of trunk Middle of trunk Middle of trunk Middle of trunk

1

12

Left side of rear shelf

C601

5

1

Middle of trunk

G601

15

* 1:

Location

Left side of trunk

Connects to

Notes

*1

Security Security Left side wire harness (see page 22-24) Security system wire harness (OPtional)· Body ground via rear wire harness

01-02 models

5

BACK

22-29

Connectors and Harnesses Connector to Harness Index (cont'd) Moonroof Wire Harness Connector or Terminal Moonroof close relay Moonroof motor Moonroof open relay Moonroof position switch C502

7

Cavities 5 2 5 4 7

Location Behind left kick panel Roof area Behind left kick panel Roof area Behind left kick panel

Ref

Cavities

3

3

5 10

2 4

Location Roof area Roof area Behind right kick panel

4 6

3

Ref

8 1 9 2

Connects to

Notes

Dashboard wire harness A (see paQe 22-22)

Roof Wire Harness Connector or Terminal Ceiling light Driver's vanity mirror light Passenger's under-dash fuse/relay box connector B (see page 22-45) Passenger's vanity mirror light SpotliQht

2

1

Connects to

Roof area Roof area

2

3

4 MOONROOF WIRE HARNESS

7 8 'l'fJJl~-----9

ROOF WIRE HARNESS

10


22-30

BACK

Notes

r--:'I --=:.I Driver's Power Seat Wire Harness IS-way adjustable) Connector or Terminal Driver's power seat switch connector A Driver's power seat switch connector B Driver's recline motor Driver's seat belt switch Driver's seat belt switch Driver's seat heater Driver's seat heater Power seat front up-down motor Power seat rear up-down motor Power seat slide motor C551

* * * *

1. 2: 3: 4:

Ref

Cavities

9

6

11 12 5 5 3 3 4 2 1 10

6 2 2 3 3 4 2 2 2 10

Connects to

Location Left side of driver's seat

Left side of driver's seat Under driver's seat Under driver's seat Under driver's seat Under driver's seat Under driver's seat Under driver's seat Under driver's seat Under driver's seat Left side of driver's seat

Notes

*1 *2 *3 *4

Left side wire harness (see oaoe22-241

,

98-99 models '00-02 models '98-99 models (Canada) '00-02 models (Canada)

Driver's Power Seat Wire Harness 12-way adjustable) Ref 6 8 7

Connector or Terminal Driver's power seat up-down motor Driver's power seat up-down switch C551

Cavities 2 5 4

Connects to

Location Under driver's seat Left side of driver's seat Under driver's seat

Notes

Left side wire harness (see nane 22-241

DRIVER'S POWER SEAT WIRE HARNESS IS-way adjustable)

1

6

12

11

10

9

DRIVER'S POWER SEAT WIRE HARNESS 12-wayadjustable)

BACK

22-31

Connectors and Harnesses Connector to Harness Index (cont'd) Driver's Door Wire Harness (Sedan) Connector or Terminal

Ref

Cavities

Driver's door courtesy light Driver's door key cylinder switch Driver's door lock actuator Driver's door lock knob switch Driver's door lock switch Driver's door speaker Driver's power window motor Driver's under-dash fuse/relay box connector F (see page 22-44) Driver's under-dash fuse/relay box connector G (see page 22-44) Left power mirror Left power mirror Multiplex control unit (door) connector A Multiplex control unit (door) connector B Power mirror switch Security indicator light C631

16 3 1 2 6 11 14 8

2 3 2 3 3 2 4 6

Driver's door Driver's door Driver's door Driver's door Driver's door Driver's door Driver's door Behind left kick panel

9

18


7 7 15

6 3 20

Driver's door Driver's door Driver's door

5

2

Driver's door

12 4 10

10 2 2


C631

10

3

Driver's door

C632

13

2

Driver's door

3

4

Connects to

Location

Canada

Canada USA

Security system wire harness (Optional) Security system wire harness (Optional) Security system wire harness IOotional)

USA Canada Canada

7

6

5

Notes

8

9 - - - DRIVER'S UNDER-DASH FUSE/RELAY

2

BOX

10

11

1

DRIVER'S DOOR WIRE HARNESS

22-32

16

15

14

BACK

13

12

r--:'I

~

Driver's Door Wire Harness (Coupe) Ref 13 16 14 15 4 10 6 7

Cavities 2 3 2 3 3 2 4 6

8

18


5 5 2

6 3 20


3

2

Driver's door

11 1 9

10 2 2


C631

9

3

Driver's door

C632

12

2

Driver's door

Connector or Terminal Driver's door courtesy light Driver's door key cylinder switch Driver's door lock actuator Driver's door lock knob switch Driver's door lock switch Driver's door speaker Driver's power window motor Driver's under-dash fuse/relay box connector F (see page 22-44) Driver's under-dash fuse/relay box connector G (see page 22-44) Left power mirror Left power mirror Multiplex control unit (door) connector A Multiplex control unit (door) connector B Power mirror switch Security indicator light C631

Location Driver's door Driver's door Driver's door Driver's door Driver's door Driver's door Driver's door Behind left kick panel

5

Connects to

Notes

Canada

Canada USA

Security system wire harness (Optional) Security system wire harness (Optional) Security system wire harness (Ootional)

USA Canada Canada

6 DRIVER'S UNDER-DASH FUSE/RELAY BOX

16

7

8

9

14

13

BACK

22-33

Connectors and Harnesses Connector to Harness Index (cont'd) Passenger's Door Wire Harness (Sedan) Connector or Terminal Passenger's door courtesy light Passenger's door key cylinder switch Passenger's door lock actuator Passenger's door lock knob switch Passenger's door lock switch Passenger's door speaker Passenger's power window motor Passenger's power window switch Passenger's under-dash fuse/relay box connector E (see page 22-45) Passenger's under-dash fuse/relay box connector F (see page 22-45) Right power mirror Riaht Dower mirror

Ref

Cavities 2

2

Location Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Behind left kick panel

2

20


3 3

6 3

Passenger's door Passenaer's door

9 6 8 7 4 11 10 5 1

3 2

3 3 2 2

6

Connects to

Notes

Security

Canada

Canada USA

PASSENGER'S DOOR WIRE HARNESS

2 1

7

k;..I.L.I--I---- 8


/

11

22-34

10

BACK

9

r--:'I I.!!:..I Passenger's Door Wire Harness (Coupe) Connector or Terminal Passenger's door courtesy light Passenger's door key cylinder switch Passenger's door lock actuator Passenger's door lock knob switch Passenger's door lock switch Passenger's door speaker Passenger's power window motor Passenger's power window switch Passenger's under-dash fuse/relay box connector E (see page 22-45) Passenger's under-dash fuse/relay box connector F (see page 22-45) Right power mirror RiQht power mirror

Ref 9 6 7 4 11 10 5 1

Cavities 2 3 2 3 3 2 2 6 2

Location Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Behind right kick panel

2

20


3 3

6 3

Passenger's door PassenQer's door

8

4

3

Connects to

Notes

Canada

Canada

USA

5

6

2

7 1

8

11

10

9 PASSENGER'S DOOR WIRE HARNESS

BACK

22-35

Connectors and Harnesses Connector to Harness Index (cont'd) Left Rear Door Wire Harness (Sedan) Connector or Terminal Left rear door courtesy light Left rear door lock actuator Left rear door lock knob switch Left rear power window motor Left rear power window switch C553

Ref 4 5

6 3

1 2

Cavities 2 2

3 2 6 10

Location Left rear door Left rear door Left rear door Left rear door Left rear door Left rear door

22-36

5

4

Notes Security

Left side wire harness (see pa!:!e 22-24)

2

1

6

Connects to

3

BACK

LEFT REAR DOOR WIRE HARNESS

~ ~

Right Rear Door Wire Harness (Sedan) Right Right Right Right Right C581

Connector or Terminal rear door courtesy light rear door lock actuator rear door lock knob switch rear power window motor rear power window switch

Ref 5

4 3 6 2 1

Cavities 2 2 3 2 6 10

Right Right Right Right Right Right

rear rear rear rear rear rear

Connects to

Location door door door door door door

Notes

Security

Right side wire harness (see page 22·26)

RIGHT REAR DOOR WIRE HARNESS

5

6

BACK

4

22-37

Connectors and Harnesses Connector to Harness Index (cont'd) Ignition Switch Lead Connector or Terminal Driver's under-dash fuse/relay box connector M (see a e 22-44)

Location Behind left kick panel

Connects to

Location Under left side of dash Under left side of dash Under left side of dash

Connects to

Clutch Switch Sub-Harness (MIT) Connector or Terminal Clutch interlock switch Clutch switch C404

Ref 2 3 4

Cavities 2 3 10

Dashboard wire harness B (see oaoe 22-20)

IGNITION SWITCH LEAD

1


22-38

2

3 CLUTCH SWITCH SUB·HARNESS IM/TI

BACK

Notes

r--:'I

~

SRS Main Harness ('98-99 models) Connector or Terminal Cable reel Driver's under-dash fuse/relay box connector N (see page 22-44) Front passenger's airbag assembly SRS memory erase signal (MES) connector SRS unit C503

Ref 5

Cavities 2 2

Location Under left side of dash Behind left kick panel

6

2 2

Behind glove box Under left side of dash

4 2

18 3

Middle offloor Under middle of dash

7 1

3

G801

Middle of floor

Connects to

Notes

Dashboard wire harness A (see paCle 22-22) Body ground via SRS main harness

SRS MAIN HARNESS

7

2 6

DRIVER'S UNDER-DASH FUSE/RELAY

BOX

(cont'd)

BACK

22-39

Connectors and Harnesses Connector to Harness Index (cont'd) SRS Main Harness ('00 Sedan) Connector or Terminal Cable reel Driver's under-dash fuse/relay box connector N (see page 22-44) Front passenger's airbag assembly SRS memory erase signal (MES) connector SRS unit C503

Ref 13 11

Cavities 2 2

15 12

4 2

Behind glove box Behind left kick panel

10 14

18 2

Middle offloor Under middle of dash

Connects to

Notes

Dashboard wire harness A (see oaoe 22-22) Body ground via SRS main harness

Middle of floor

1

GB01

Location Under left side of dash Behind left kick panel

SRS Floor Harness ('00 Sedan with Side Airbags) Connector or Terminal Driver's side airbag inflator Driver's side impact sensor Front passenger's seat belt switch Front passenger's side airbag inflator Front passenger's side impact sensor SRS unit C505 CB51

6 7 5 3 2 9 8

Cavities 2 2 3 2 2 14 6

Location Under driver's seat Left side of floor Under front passenger's seat Under front passenger's seat Right side of floor Middle of floor Under middle of dash

4

4

Under front passenger's seat

Ref

Connects to

Notes

Dashboard wire harness A (see page 22-22) OPDS wire harness (see page 22-421

SRS MAIN HARNESS

1 DRIVER'S UNDER-DASH FUSE/RELAY BOX

12

9 5

8 SRS FLOOR HARNESS

6

22-40

BACK

r:-:'I L=!..I SRS Main Harness ('00-02 Coupe, '01-02 Sedan) Ref 11 11 12

Cavities 2 4 2

2 13

4 2

Behind glove box Behind left kick panel

8 10 1

8 14 18 8

Middle of floor Middle offloor Middle of floor Under middle of dash

C556

6

4

Middle offloor

C557

7

4

Middle of floor

C583

3

4

Middle of floor

C584

4

4

Middle offloor

G801

5

Connector or Terminal Cable reel Cable reel Driver's under-dash fuse/relay box connector N (see page 22-44) Front passenger's airbag assembly SRS memory erase signal (MES) connector SRS unit SRS unit SRS unit C503

* 1. * 2: * 3:

9

Connects to

Location Under left side of dash Under left side of dash Behind left kick panel

Notes *1 *2

*1 * 1 Dashboard wire harness A (see page 22-22) Left side wire harness (see page 22-25) Left side wire harness (see page 22-24) Right side wire harness (see page 22-27) Right side wire harness (see Daoe 22-27) Body ground via SRS main harness

Middle of floor

,

*1

*3

00 Coupe '01-02 models With seat belt tensioner

,

SRS MAIN HARNESS

5

BACK

22-41

Connectors and Harnesses Connector to Harness Index (cont'd) OPDS Wire Harness (With Side Airbags) Ref 1 2

Cavities B 4

CB51

2

4


CB51

2

4


Connector or Terminal OPDS unit CB51

Connects to

Location Left side offront passenger's seat Under front passenger's seat

Notes

SRS floor harness (see page 22-39) Right side wire harness (see page 22-26) Right side wire harness (see paQe 22-26)

'00 Sedan Coupe '01-02 Sedan

Rear Window Defogger Wire Harness Connector or Terminal Rear window defogger connector A ( + ) Rear window defogger connector B (- ) Window antenna coil

Ref 3

Cavities 1

1

1

Left C-pillar

2

2

Middle of rear shelf

Connects to

Location

1

OPDS WIRE HARNESS

1

2

22-42

Notes

Right C-pillar

REAR WINDOW DEFOGGER WIRE HARNESS

BACK

2

3

~

I.!!!.J

Fuse/Relay Boxes Connector to Fuse/Relay Box Index Under-hood Fuse/Relay Box Socket

Ref 15 3 14 11 13 1 12 9 4 10 7 8 2 6 5

A

NC compressor clutch relay B Blower motor relay C Condenser fan relay D Diode ELD Unit Horn relay Headlight relay 1 Headlight relay 2 Radiator fan relay T1 T101 1

11

2

Terminal 18 4 7 4 3 4 16 2 3 4 4 4 4

Connects to Right engine compartment wire harness (see page 22-16) Right engine compartment wire harness (see page 22-16) Right engine compartment wire harness (see page 22-16) Right engine compartment wire harness (see page 22-16) Not used Right engine compartment wire harness (see page 22-16)

Battery positive cable (see page 22-12) Engine wire harness (see page 22-14)

3

Q~tD~

00

4

12

13 5 6

9 14 ro ro ro

464748 L..J L..J L..J 15

ro ro ro

8

434445 L..J L..J L..J

7

BACK

22-43

Fuse/Relay Boxes Connector to Fuse/Relay Box Index (cont'd) Driver's Under-dash Fuse/Relay Box Socket A B C D Diode Diode

E F G H I

J K L M Multiplex control unit connector A N

0 P Q R Reverse relay S Starter cut relay T Turn signal/hazard relay

U

Ref 11 3 10 7 1 2 4 9 8 5 13 12 14 23 15 6 22 21 16 17 26 19 27 18 24 20 25

Terminal 10 14 5

--

Connects to Left side wire harness (see page 22-24) Left side wire harness (see page 22-24) Left engine compartment wire harness (see page 22-18) Not used

--20 6 18 6 18 2 18

-6 24 2 20 7 22 1 4 1 4 1 4 1

Left engine compartment wire harness (see page 22-18) Driver's door wire harness (see page 22-32) Driver's door wire harness (see page 22-32) Not used Dashboard wire harness A (see page 22-22) Service check connector Dashboard wire harness A (see page 22-22) Not used Ignition switch lead (see page 22-38) (Plugs directly into the fuse box) SRS main harness (see page 22-39) Dashboard wire harness B (see page 22-20) Dashboard wire harness B (see page 22-20) Dashboard wire harness B (see page 22-20) Optional connector Optional connector Optional connector Ootional connector

27

26

12

14

15

16

17

7

22-44

6

20

BACK

19

18

~ ~

Passenger's Under-dash Fuse/Relay Box Socket A Accessory relay B C 0 Diode Diode Diode E

Ref 10 15 4

9

F G H I

J K Multiplex control unit connector A Power window relay Rear window defogger relay

5 1 2 3 8 7 6 18 12 17 13 11 14 16

Terminal 20 4 4 18 3

--

Connects to Right side wire harness (see page 22-26) Roof wire harness (see page 22-30) Right engine compartment wire harness (see page 22-16) Right engine compartment wire harness (see page 22-16) Not used

--

-2 20

Passenger's door wire harness (see page 22-34) Passenger's door wire harness (see page 22-34) Right side wire harness (see page 22-26) Dashboard wire harness A (see page 22-22) Dashboard wire harness A (see page 22-22) Dashboard wire harness B (see page 22-20) Dashboard wire harness B (see page 22-20) (Plugs directly into the fuse box)

3 18 18 16 16 24 4 4

1 2 3

:J

a

11

4

12

18 5

13

16

7

BACK

15

14

22-45

Power Distribution Fuse to Components Index Under-hood Fuse/Relay Box Fuse Number 41 42 43 44 45 46 47

48 49 50 51 52 53 54 55 56 57 58 59

Amps

Wire Color

Component(s) or Circuit(s) Protected

100A 50A 20A

-WHT RED/GRN

20A

RED/YEL

15A 20A

WHT/GRN WHT/YEL

Battery, Power distribution Ignition switch (BAT) Right headlight, Daytime running lights control unit (Canada) Not used Left headlight, Daytime running lights control unit (Canada), High beam indicator, High beam cut relay (Canada) PGM-FI main relay, Data link connector (DLC) Ignition key light and key interlock solenoid, ABS control unit (BLS), Cruise control unit, ECM/PCM, Horn relay, High mount brake light, Brake failure sensor, Trailer lighting connector Multiplex control unit (driver's)

--

20A 15A 30A 40A

-40A 40A 40A 40A 20A 20A 20A

--

Fuse/relay box socket WHT/GRN ABS control unit WHT/GRN Turn signal/hazard relay WHT ABS pump motor No. 14 fuse (in passenger's under-dash fuse/relay box) WHT/BLU No.1 fuse (in passenger's under-dash fuse/rela'Lbox), Power window relay - - Not used WHT/GRN Rear window defogger relay_ YEL No.9, 10, 11, 12 and 13 fuses (in passenger's under-dash fuse/relay box) YEL/GRN No.2, 3, 4, 5 and 6 fuses (inpassenger's under-dash fuse/relay box) YEL/BLK Blower motor BLU/BLK Radiator fan motor BLU/YEL Condenser fan motor RED AlC compressor clutch WHT/GRN Driver's and front passenger's seat heaters (Canada) 1

2

3

4

5 6

7

22-46

BACK

r--:'I L=.!..I Driver's Under-dash Fuse/Relay Box Fuse Number 1

Amps

Wire Color

15A

2

10A

3

7.5A

RED/WHT RED/BLU (or GRN) BLK/WHT (or GRN) BLK/YEL

4

7.5A

5 6

7.5A 15A

7

7.5A

8

7.5A

9

7.5A

10 11 12

7.5A 15A 30A

13

7.5A


PGM-FI main relay SRS unit (VA) SRS unit (VB) Heater control panel, Recirculation control motor, Rear window defogger relay, Seat heaters (Canada) ABS control unit, Power mirror actuators, Power mirror defoggers (Canada) Optional connector

VEL/BLK Fuse/relay box socket VEL/RED Daytime running lights control unit (Canada) BLK/YEL Alternator, Cruise control unit, Cruise main switch indicator, ECM/PCM, ELD unit, Engine mount control solenoid valve (A!T), Evaporative emission bypass solenoid valve, Evaporative emission purge control solenoid valve, Gauge assembly, Heated oxygen sensor relay, Primary and secondary heated oxygen sensors, Vehicle speed sensor (VSS) (MIT), Vent shut solenoid valve VEL/GRN Multiplex control unit (driver's) (All '98-99 models and '00 Sedan), OPDS unit (with side airbags), Windshield washer motor (All '98-99 models and '00-02 Sedan) VEL/BLK Accessory socket relay Fuse/relay Optional connector box socket VEL Back-up lights, Brake failure sensor, Clock, DRL indicator light (Canada), Gauge assembly, Multiplex control unit (passenger's), Shift lock solenoid, Trailer lighting connector Fuse/relay Multiplex control unit (driver's) box socket VEL/RED Turn signal/hazard relay Ignition coil BLK/YEL GRN/BLK Windshield wiper intermittent relay, Windshield wiper motor, Windshield washer motor ('00-02 Coupe), Multiplex control unit (driver's) ('00-02 Coupe) BLU/ORN ECM/PCM, PGM-FI main relay

2

3

11

4

9

5 8

7

6

(cont'd)

BACK

22-47

Power Distribution Fuse to Components Index (cont'd) Passenger's Under-dash Fuse/Relay Box Fuse Number 1 2

Amps

Wire Color


30A 20A

GRN RED

3 4 5 6

--

-BLU

Moonroof motor Power seat up-down motor (2-way adjustable), Power seat rear up-down motor, Recline motor (a-way adjustable) No used Power seat front up-down motor, Slide motor (a-way adjustable) Not used Daytime running lights control unit (Canada) Heated oxygen sensor (California) Moonroof open relay, Moonroof close relay, Left rear power window motor (Sedan), Multiplex control unit (passenger's) Passeng_er's power window motor Audio unit Audio unit, Accessory socket Heater control panel, AfT gear position console light, Driver's seat heater switch light (Canada), Audio unit, Gauge lights, Cruise main switch light Moonroof switch light, Clock, Hazard warning switch light, Glove box light Vanity mirror lights, Front parking lights, Front side marker lights, Rear side marker lights, License plate light(s), Taillights, Trailer lighting connector Multiplex control unit (driver's)

20A

--

--

7

10A 20A 20A

RED/BLU RED/BLU WHT/YEL

a 9

20A 20A

10

10A (Sedan) 15A (Coupe)

BLU/BLK WHT/GRN WHT/RED RED/GRN

11 12

7.5A 20A

13

7.5A

14 15 16

7.5A 20A 20A

Fuse/relay box socket WHT/BLU Courtesy lights, Trunk light, Ceiling light, Spotlights Fuse/relay Multiplex control unit (passenger's) box socket WHT/YEL ECM/PCM, Heater control panel, Security indicator, Multiplex control unit (door), Gauge assembt~ Clock Fuse/relay Multiplex control unit (driver's), Multiplex control unit (passenger's) box socket GRN ABS control unit GRN/WHT Multiplex control unit (door), Driver's power window WHT/BLK Right rear power window motor (Sedan)

1

2 3 4 5 7

6

22-48

BACK

r--:'I

t=:.I

Ground Distribution Ground to Components Index Ground Gl G2 Gl0l

G201 G202 G301 G302 G303 G304 G305 G401

G501

-- G502G503 G504 G551

G552 G581

G601 G801

Component or circuit grounded Battery, Transmission housing Engine block ECM/PCM (PGl and PG2 are BLK; LGl and LG2 are BRN/BRK), Idle air control solenoid valve, Radiator fan switch, PGM-FI main relay, EGR control solenoid valve, Shift control solenoid valve assembly (AfT), Vehicle speed sensor (MIT), AfT gear position switch Shielding between the ECM/PCM (all have braided wires) CKPITDC sensor, CYP sensor, Primary and secondary heated oxygen sensors, Knock sensor, Mainshaft speed sensor (AfT), Countershaft speed sensor (AfT). VTEC~ressure switch, Data link connector (DLC), Immobilizer control unit Condenser fan motor, Radiator fan motor, Right headlight (low beam), Right front parking light. Right front side marker light, Right front turn signal light. Hood switch (security) Seat heater relay (Canada). Blower motor relay, ELD unit, ABS fail-safe relay Washer level switch (Canada), Windshield washer motor, Left headlight (low beam), Left front parking light, Left front side marker light, Left front turn signal light Brake fluid level switch, Windshield wiper motor, Intermittent wiper relay, Power steering pressure switch, Cruise control actuator ABS pump motor ABS control unit (2 wires) ABS control unit (2 wires) Multiplex control unit (driver's), Turn signal/hazard relay, Power window master switch, Driver's door key cylinder switch, Driver's door lock switch, Driver's door lock knob switch, Ignition key switch, Daytime running lights control unit (Canada), Clutch switch (MIT). Data link connector (DLC). Combination light switches, Heater control panel (2 wires), Windshield wiper/washer switch Moonroof switch, Moonroof open relay, Moonroof close relay, Driver's seat heater switch (Canada), Front passenger's seat heater switch (Canada), Glove box light. Clock, Audio unit, Accessory socket, Gauge assembly, Cruise control unit, Cruise main switch, OPDS unit ('00 Sedan with side airbags), Fuel gauge sending unit ('00 Coupe), Front passenger's seat belt switch ('OO Sedan). Memory erase signal (MES) connector ('01-02 models). ParkQin switch Audio unit Multiplex control unit (driver's) Multiplex control unit (passenger's) Power mirror switch, Left power mirror defogger (Canada), Driver's power window motor, Power window master switch (2 wires), High mount brake light, Driver's seat belt switch, Left rear door lock knob switch, Driver's power seat switch (2 wires), Driver's seat heater (Canada) Fuel pump (FP), Fuel gauge sending unit (All '98-99 models and '00-02 Sedan) Multiplex control unit (passenger's), Power window relay, Accessory relay, Vanity mirror lights, Spotlight, Passenger's door key cylinder switch, Passenger's door lock switch, Passenger's door lock knob switch, Front passenger's seat heater (Canada). Right power mirror defogger (Canada), Right rear door lock knob switch, OPDS unit (Coupe with side airbags, '01-02 Sedan with side airbags), Front Passenger's seat belt switch ('00 Coupe, '01-02 models) Taillights (right. left). License plate light, Trunk latch switch, Trunk key cylinder switch (security), Trunk actuator (security), Brake failure sensor, Trailer lighting connector SRS unit (2 wires), Memory erase signal (MES) connector ('00 model)

BACK

22-49

Under-dash Fuse/Relay Box Removal and Installation SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-28).

6. Disconnect the driver's or pasHenger's under-dash fuse/relay box connectors, and remove the driver's or passenger's under-dash fuse/relay box. NOTE: The SRS main harness connector is a springloaded lock type (see page 23-28).

Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least three minutes.

Installation 1. Connect the connectors to the driver's or passenger's under-dash fuse/relay box, then install the driver'S or passenger's under-dash fuse/relay box in the reverse order of removal. 2. Install the left or right kick panel and access panel, and the door sill molding.

3. Remove the driver's dashboard lower cover (see page 20-84) or the passenger's dashboard lower cover (see page 20-85).

3. Install the dashboard lower cover.

4. Remove the door sill molding, left or right kick panel (see page 20-74) and fuse box cover (see page 20-84).

4. Connect both the negative cable and positive cable to the battery, enter the anti-theft code for the radio, then enter the customer's radio station presets.

5. Remove the mounting bolt, and pull the driver's under-dash fuse/relay box (A) or passenger's under-dash fuse/relay box (B) away from the body.

5. Confirm that all systems work properly.

22-50

BACK

r:'I

a.=:..J

Battery Battery Test

AWARNING A battery can explode if you do not follow the proper procedure, causing serious injury to anyone nearby. Follow all procedures carefully and keep sparks and open flames away from the battery. Use either a JCI or Bear ARBST tester, and follow the manufacturer's procedures. If you don't have one of these computerized tester, follow this conventional test procedure: 1. Be sure the temperature of the electrolyte is between 70°F (21°C) and 100°F (38°C). 2. Inspect the battery case for cracks or leaks. • If the case is damaged, replace the battery .• • If the case looks OK, go to step 3. 3. Check the indicator EYE. • If the EYE indicates the battery is charged, go to step 4. • If the EYE indicates a low charge, go to step 7. 4. Apply a 300 amp load for 15 seconds to remove the surface charge. 5. Wait 15 seconds, then apply a test load of 280 amps for 15 seconds. 6. Record battery voltage. • If voltage is above 9.6 volts, the battery is OK.• • If voltage is below 9.6 volts, go to step 7. 7. Charge the battery on High (40 amps) until the EYE shows the battery is charged, plus an additional 30 minutes. If the battery charge is very low, it may be necessary to bypass the charger's polarity protection circuitry. • If the EYE indicates the battery is charged within 3 hours, the battery is OK.• • If the EYE indicates the battery is not charged within 3 hours, replace the battery.•

BACK

22-51

Relays Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE (see page 22-106) for the turn signal/hazard relay input test. 2

Relay ABS fail-safe relay Accessory socket relay AlC compressor clutch relay Condenser fan relay Headlight relay 1 Headlight relay 2 Heated oxygen sensor relay (California) High beam cut relay Horn relay Power window relay Radiator fan relay Reverse relay Seat heater relay Starter cut relay Taillight relay ABS pump motor relay Blower motor relay, type 1 Blower motor relay, type 2 Rear window defogger relay Windshield wiper intermittent relay Moonroof open and close rela,{s

Test Normally-open type A

DE] 1

type 1:

Normally-open type B

Five-terminal type A Five-terminal type B

Normally-open type A: type 2: Check for continuity between the terminals . • There should be continuity between the No.1 and No. 2 terminals when power and ground are connected to the No.3 and No.4 terminals . • There should be no continuity between the No.1 and No.2 terminals when power is disconnected.

22-52

3

BACK

4

r--:'I l!!!!!..I Normally-open type B:

ABS pump motor relay

Check for continuity between the terminals . • There should be continuity between the No.1 and No.3 terminals when power and ground are connected to the No.2 and No.4 terminals . • There should be no continuity between the No.1 and No.3 terminals when power is disconnected.

1

2

1+·················.. ···· Blower motor relay, type 1: 3

4

Rear window defogger relay

Blower motor relay, type 2:

(cont'd)

BACK

22-53

Relays Power Relay Test (cont'd) Five-terminal type A:

Five-terminal type B:

Check for continuity between the terminals .

Check for continuity between the terminals.

• There should be continuity between the No.1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals. • There should be continuity between the No.2 and No.4 terminals when power is disconnected.

• There should be continuity between the No. 1 and No.2 terminals when power and ground are connected to the No.3 and No.5 terminals . • There should be continuity between the No.1 and No.4 terminals when power is disconnected.

3

~ 5

2

Windshield wiper intermittent relay

22-54

. . . . . . .1:J 2

5

Moonroof open and close relays

BACK

4

1

~ ~

Ignition Switch Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-28).

5. Check for continuity between the terminals in each switch position according to the table.

1\

2 3 5 Terminal WHT! BlK! BlK WHT VEL Position (ACC) (BAT) (lG1)

\


o (lOCK) I (ACC) II (ON) III (START)

2. Disconnect the battery negative cable.

0

,....

,.... ,.... ~

0

4

VEL

(lG2)

6 BlK! WHT (ST)

,.... r-.

,.,.

~

~

3. Remove the dashboard lower cover (see page 2084).

6. If the continuity checks do not agree with the table, replace the electrical switch.

4. Disconnect the 6P connector from the driver's under-dash fuse/relay box.

7. After reconnecting the battery, enter the anti-theft code for the radio, then enter the customer's radio station presets.


BACK

22-55

Ignition Switch Replacement SRS components are located in this area. Review the SRS components locations, precautions, and procedures in the SRS section before performing repairs of service (see page 23-28). 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable. 3. Remove the steering column covers (see page 1725). 4. Insert the ignition key, and turn it to "0". 5. Remove the 3 screws (A), and replace the electrical switch (B).

B

6. Install the switch in the reverse order of removal. 7. After reconnecting the battery, enter the anti-theft code for the radio, then enter the customer's radio station presets.

22-56

BACK

r--:'I I..!:!..I

Gauges Component Location Index VEHICLE SPEED SENSOR (VSS) (MIT) Troubleshooting, page 22-69 Replacement, page 22-68

GAUGE ASSEMBLY Replacement, page 22-68 Bulb Locations, page 22-59

COOLANT TEMPERATURE GAUGE SENDING UNIT page 10-5

BRAKE FLUID LEVEL SWITCH page 19-9 ENGINE OIL PRESSURE SWITCH page 8-4

(cant'd)

BACK

22-57

Gauges Component Location Index (cont'd)

o

C1

B1

- - - - - -- C7

X~L( II~I ~

\.Jl

=

rL"\

~~~

~

CONNECTORC

------ B10

CONNECTOR A

CONNECTORB

AfT GEAR POSITION INDICATOR page 14-136

TACHOMETER

COOLANT TEMPERATURE GAUGE

FUEL GAUGE

page 10-5

page 11-128

SAFETY INDICATOR page 22-73

22-58

BACK

r--:'I I..:!:..I Gauge Bulb Replacement HIGH BEAM INDICATOR L1GHT(1.4 W) ABS INDICATOR LIGHT (1.4 WI

IMMOBILIZER INDICATOR LIGHT (1.4 WI

CRUISE INDICATOR LIGHT (1.4 WI

WASHER LEVEL INDICATOR LIGHT (1.4 W) (Canada) DRL INDICATOR LIGHT (1.4 W) (Canada)

SIDEAIRBAG INDICATOR LIGHT (1.4WI (With side airbags)

GAUGE LIGHT (3.4W) RIGHT TURN SIGNAL INDICATOR LIGHT (1.4 WI

MALFUNCTION INDICATOR LAMP (MIl) (1.4WI

LOW FUEL INDICATOR LIGHT (3.0 WI

LCD BACK LIGHT (1.4 WI

LOW ENGINE OIL PRESSURE INDICATOR LIGHT (1.4WI

MAINTENANCE REQUIRED INDICATOR LIGHT (1.4WI

GAUGE LIGHTS (1.4Wx2) AfT GEAR POSITION INDICATOR LIGHTS (1.12 W x 71

BACK

22-59

Gauges Circuit Diagram '98-99 models UNDER·HOOD FUSEIRELAV BOX BATIERV

(±)+ BLK

No.41 (100A)

-QIGNITION SWITCH

No.42 (SOA)

BAT

~-
No.54 (40A)

BLKlYEL - - - - . ,

IGI

YEL PASSENGER'S UNDEFl·DASH FUSEIRELAV BOX


No.9 (7.SA)

No.13 (7.5A)

VEL (Canada)

(MIT)

(Canada)

(USA)

I~~~~ RUNNING :

--I

LIGHTS

!yi~! l:.~DiT i

-:~

WHTNEL

I.

I ~EDNEL :

A13

~: SPEE~

ODOITRIPI MAINTENANCE! WASHER CIRCUIT (To page 22·61)

VEHICLE SENSOR (VSS) (To page 22:,6!)

WHTNEL

BLKlYEL

B20

B9

YEL

YEL Bl1

GAUGE ASSEMBl V

A4

I I

HIGH BEAM INDICATOR LIGHT (1.4W)

A12 BLU/RED

ORNlWHT

7

• COMBINATION LIGHT SWITCH (USA) • DAYTIME RUNNING LIGHTS CONTROL UNIT (Canada)

IMMOBILIZER

~o/'TOR

~~mOR CIRCUIT

I

CHARGING

E~WM

(1.4W)

(1.4W)

B19

B8

7

GRNlRED

ALTERNATOR

11

(~~I~~~l

BLK

1. G401

22-60

I

BACK

BRAKE

II :

(E1= ~~ )

I

BLK:

:

.,.\;.".~

~-- ¢:>:I Euorr

--

down )

~~a~)

...

:

OFF: Aoatup

I' I

8SkROL UNIT

~

G~"'""'" r~~~

I

:9 : I J

• MULTiPlEX CONTROl UNIT (Driver'S) (USA) • ABS CONTROl UNIT

r-,,-


m&CATOR LIGHT (1.4W)

I~ i

C14

PNK

ECM/PCM

I, I

I_~ _ ~

I

GRNlWHT

~ PARKING

l'

BRAKE

I I :

L:_:J

r--:'I

~

ECMlPCM

Y BLU

No.13 (7.SA)

PASSENGER'S FUSE (From page 22-60)

r


WHTJVEL

BLU

B21

Bl

GAUGE ASSEMBLY

SPEEDOMETER

TACHOMETER

TRIP/MAINTENANCE REQUIRED INDICATOR RESET SWITCH

ODorrRIP/MAINTENANCElWASHER CIRCUIT

B16

B2 • MULTIPLEX CONTROL UNIT (Driver's) • CRUISE CONTROL UNIT • ECM (MIT)

BLUIWHT

Y

BLUlWHT

_~-' t'~y""

[&1 __

PNK

BLK.

No.6 (lSA) DRiVER'S FUSE

I

B12

, _ 1

~~" I~!

BLK

1

~1_01

t

1

I'-~

I I

I&K

:1

:

_J

WASHER LEVEL SENSOR

G501

~---(Canada)

(MIT)

(cant'd)

BACK

22-61

Gauges Circuit Diagram (cont'd) '98-99 models

TURN SIGNAlIHAZARD RELAY LEH

RIGHT

YY

GRNlBW

GRNlYEL

GRNlBW

I

LEFT TURN SIGNAL LIGHTS

BW

GAUGE ASSEMBLY

Cl LT GRNlRED

C9

FUEL GAUGE

LOW FUEL INDICATOR LIGHT (3.0W)

C2

YElIBLU

YEUGRN

3

Cl0

ABSCONTROL UNIT

2

LOW

FUEL GAUGE UNIT

~UEL

SENSOR

ENGINE COOLANT TEMPERATURE SENDING UNIT

FUEL GAUGE SENDING UNIT

BLK

1 G552

22-62

BACK

RIGHT

TURN SIGNAL LIGHTS

GRNlBLU

GRNlYEL

A14

C8

LEFT TURN SIGNAL INDICATOR LIGHT (1.4W)

RIGHT TURN SIGNAL INDICATOR LIGHT (1.4W)

ARS INDICATOR LIGHT (1.4W)


Cl1

GRNlYEL

VV

SRSUNIT

~

I.!!!:.I

• COMBINATION LIGHT SWITCH (DX,LX) • TAILLIGHT RELAY


lOy

(EX)y

REDIBLK GAUGE ASSEMBLY

REDlWHT

B22

B4

AlTGEAR POSITION INDICATOR DIMMING CIRCUIT

SEAT BELT REMINDER LIGHT (1.4W)

MALFUNCTION INDICATOR LAMP (MIL) (1.4W)

CRUISE INDICATOR LIGHT (1.4W)

LOW ENGINE OIL PRESSURE INDICATOR LIGHT (1.4W)

C3

B6

A6

B7

REDIBLU

GRN/ORN

BLUlBLK

YEURED

MULTIPLEX CONTROL UNIT (Drive(s)

y

~ ~

ECMlPCM

REDIBLU

YEURED

B5

RED

WHT/RED

~

~


MULTIPLEX CONTROL UNIT IDrive(s)

YEURED

REDIBLU

~


BID


CRUISE CONTROL UNIT

GAUGE LIGHTS 1.4Wx2) ( 3.0W 3.4Wx3

DRIVER'S SEAT BELT SWITCH ( ON ; Unbuckled ) OFF; Buckled

ENGINE OIL PRESSURE SWITCH ( ON ; Engine slOPped) OFF; Engine running

BLK

1. 6551

BACK

22-63

Gauges Circuit Diagram (cont'd) '00-02 models UNDER-HOOD FUSE/RELAY BOX

e±r +

BATIERY

No.4l (l00A)

BLK

-QIGNITION SWITCH

No.42 (SOA) -C"-l>--i-WHT No.54 (40A)

-+-<::r"....t>-....

BAT

BLKIVEL - - - - - ,

IGl

YEL PASSENGER'S UNDER·DASH FUSE/RELAY BOX

NO.6 (1 SA)

No.13 (7.5A)


NO.9 (7.5A)

BLKlVEL

YEL (Canada)

(Mfr)

(canada)

I ~~~ilI

(USA)

:

I 8~WROL ¢>, :

LIGHTS i

'Y , L~~DrT i I.~EDIVEL

" :

A13


A12 BLUIRED

• COMBINATION LIGHT SWITCH (USA) • DAYTIME RUNNING LIGHTS CONTROL UNIT (Canada)

11

t: SPEE~

001

,:


-:~

WHTIVEL

ODOrrRIPI MAINTENANCE/ WASHER CIRCUIT (To page 22·65)

VEHICLE SENSOR (VSS! (To page 22:.6~

WHTIVEL

YEL

B20

Bll

SAFETY IMMOBILIZER INDICATOR INDICATOR CIRCUIT LIGHT (1.4W)

CHARGING SYSTEM LIGHT (1.4W)

B19

B8

C14

PNK

WHTIBLU

GRNlRED

ECMlPCM

ALTERNATOR

~

G401

22-64

A4

DRL INDICATOR LIGHT (1.4W)

AS

~:

~

~ROL

UNIT

• MULTIPLEX CONTROL UNIT (Drivefs) (USA) • ASS CONTROL UNIT

1-._,

!

BACK

J (Canada)

r-~ GRNlRED,

(USA)

l'(i~l~~td~n T ) OFF: Float up

r

GAUGE ASSEMBLY

,.1'-'\., PARKING ,'\n/, BRAKE SWITCH ) ( ON : Lever up OFF: Lever down

DAYTIME RUNNING LIGHTS CONTROL UNIT

GRNIWHT

.J L ,,

i. __

I

.

~ ~_

, ,

PARKING BRAKE SWITCH:

I

r--:'I a..=.J

ECM/PCM

Y BLU

BLU

V

No.13 (7.SA) PASSENGER'S FUSE (From page 22-64)


I

WHTIYEL

BLU B1


TACHOMETER

GAUGE ASSEMBLY

B21

SPEEDOMETER

TRIP/MAINTENANCE REQUIRED INDICATOR RESET SWITCH

ODOrrRIP/MAINTENANCEIWASHER CIRCUIT

C2 YEUGRN

~

ECMlPCM

B16

B2 • MULTIPLEX CONTROL UNIT (Drive(s) BLUIWHT • CRUISE CONTROL UNIT • ECM (MfT)

?

BLUIWHT

B12

BLK

PNK

No_6 (1SA) DRIV~R'S FUSE (From page 22-64)

y

BLUlWHT

: I

BLK/YEL

.<:::>:

'"

i

1 G101

:

---

J

BLUiHT-

~:

I_~

GS01

I I:1~, , ,

WASHER LEVEL SENSOR

~'-----' (Canada)

(MfT)

(cont'd)

BACK

22-65

Gauges Circuit Diagram (cant'd) '00-02 models TURN SIGNAUHAZARD RELAV LEFT

RIGHT

GRNlBLU

GRNlYEL

YY

SRSUNIT

I


BLU

GAUGE ASSEMBL V

""--r-'

(1.4W)

SIDE AIRBAG INDICATOR LIGHT (1.4W)

CIO

B17

Cl1

VEUBLU

I

3

OPDS : UNIT

2

~

I

I

__ --.J

(WIJh side airbags)

FUEL GAUGE UNIT

LOW FUEL SENSOR


I G552 (Sedan, '01·02 Coupe) G501 rOO Coupe)

22-66

GRNlYEL

A14

C8



ABS INDICATOR LIGHT

SRS INDICATOR LIGHT (1.4W)

LTGRNlRED

GRNlBLU

C9

FUEL GAUGE

RIGHT TURN SIGNAL LIGHTS

BACK

ABSCONTROl UNIT

r--:'I I..=:J

• COMBINATION LIGHT SWITCH (DX, LX) • TAIlliGHT RELAY


(EX)?

(Dry

REDIBLK GAUGE ASSEMBLY

REDIWHT

B4

B22

AfT GEAR POSITION INDICATOR DIMMING CIRCUIT

SEAT BELT REMINDER LIGHT

MALFUNCTION INDICATOR LAMP (MIL)

CRUISE INDICATOR LIGHT

(1.4W)

(1.4W)

(1.4W)

LOW ENGINE OIL PRESSURE INDICATOR LIGHT

GAUGE LIGHTS 1.4Wx2) ( 3.0W 3.4Wx3


(1.4W)

C3

B6

A6

B7

REDIBLU

GRNlORN

BLUIBLK

YEURED

MULTIPLEX CONTROL UNIT (Drivefs)

y

~ ~

ECMJPCM

REDIBLU

I'

MULTIPLEX CONTROL UNrr (Drivefs)

CRUISE CONTROL UNIT

YEURED

B5

RED

WHTIRED

~

~



YEURED

REDIBLU

~

Bl0

DRIVER'S SEATBELT SWITCH ( ON : Unbuckled ) OFF: Buckled

ENGINE OIL PRESSURE SWITCH ( ON : Engine stopped) OFF: Engine running

BLK

.1 G551

BACK

22-67

Gauges Gauge Assembly Replacement

VSS Replacement (MIT)

1. Remove the instrument panel (see page 20-84).

1. Disconnect the 3P connector (A) from the VSS (vehicle speed sensor) (8).

2. Remove the screws (A) from the gauge assembly (8), and spread a protective cloth (C) on the upper column cover. D

:::::::::::==:~~~-'~~--l~ _--_.- --.--"...... .. -...

----

2. Remove the mounting bolt (C), then remove the VSS. 3. Disconnect the connectors (D), and remove the gauge assembly.

3. Install in the reverse order of removal.

4. Install in the reverse order of removal.

22-68

BACK

r--:'I I.!!!:..I Vehicle Speed Signal Circuit Troubleshooting (MIT) 5. Connect the WHT test harness clip (C) to the positive probe of a voltmeter, and connect the RED test harness clip (B) to the negative probe.

Special Tools Required: Test harness 07LAJ-PT3020A

Before testing, inspect the No.6 (15A) fuse in the driver's under-dash fuse/relay box.

07LAJ.PT302OA~

1. Disconnect the 3P connector from the VSS (vehicle speed sensor) (A).

c .7LAJ.PT302~


Is there battery voltage? YES-Go to step 7. 2. Connect the test harness only to the engine wire harness.

NO- Repair open in the BLK/YEL wire between the VSS and the driver's under-dash fuse/relay box.•

3. Connect the RED test harness clip (B) to the positive probe of an ohmmeter. Cover the white (C) and green (D) test harness with protective tape (E).

7. Disconnect the WHT test harness clip (C). 8. Connect the GRN test harness clip (D) to the positive probe of a voltmeter.

4. Check for continuity between the RED test harness clip and body ground.


YES - Go to step 5. NO- Repair open in the BLK wire between the VSS and G101 .•

Is there 5 V or more? YES-Go to step 9. NO- Repair short in the BLU/WHTwire between the VSS and the ECM, cruise control unit, or the driver's multiplex control unit.•

(cont'd)

BACK

22-69

Gauges Vehicle Speed Signal Circuit Troubleshooting (MIT) (cont'd) 9. Turn the ignition switch OFF.

14. Disconnect the 22P connector "8" from the gauge assembly.

10. Connect the other test harness connector (A) to the VSS (8).

DASHBOARD WIRE HARNESS 22P CONNECTOR B

B1 619 620 621 622


15. Touch a probe to the 8LU/WHTwire, and connect it to body ground through a voltmeter.

B


16. Slowly rotate one wheel with the other wheel blocked.

12. Put the vehicle in neutral with the ignition switch ON (II).

Does the meter indicate pulsing voltage? YES- Replace the speedometer..

13. Slowly rotate 1 wheel with the other wheel blocked.

Does voltage pulse from 0 to approx. 5 V or more? YES-Go to step 14. NO- Replace the VSS .•

22-70

BACK

NO- Repair open in the 8LU/WHT wire between the VSS and the speedometer..

~

I..!::..I Vehicle Speed Signal Circuit Troubleshooting (AfT) Before Testing: • Check to see if diagnostic trouble code P0720 (9) is indicated. If it is, troubleshoot the DTC (see page 1475). • Inspectthe No.9 (7.5A) fuse in the driver's underdash fuse/relay box. • Check for continuity between the 816 terminal and body ground (G501).

6. Connect the No.9 terminal of the 32P PCM connector to the positive probe of a voltmeter, and connect the negative probe to body ground. PCM 32P CONNECTOR (Connected)

BLU/WHT

VI2 3 4 5 6 V 8 9 10 112113 14 15 V 17 18 19 20 21 V 23 32 25 26 27 28 29 30 /


/1 24 I

-

2. Disconnect the 22P connector from the gauge assembly.

'::L

3. Connect the 82 terminal to the positive probe of a voltmeter, and connect the negative probe to body ground. To prevent damage to the gauge assembly, lay the gauge assembly on a shop rag. DASHBOARD WIRE HARNESS 22P CONNECTOR B


7. Putthe vehicle in neutral with the ignition switch ON (II). 8. Slowly rotate (over 3 mph (2 km/h)) 1 wheel with the other wheel blocked.

Does voltage pulse from 0 to about 5 V or more? YES- Repair open in the 8LU/WHTwire between the PCM and the gauge assembly .• NO- Check for loose connections at the PCM connector. If necessary; substitute a known-good PCM, and recheck .•


4. Put the vehicle in neutral with the ignition switch ON (II). 5. Slowly rotate (over 3 mph (2 km/h)) 1 wheel with the other wheel blocked.

Does voltage pulse from 0 to about 5 V or more? YES-Replace the gauge assembly .• NO-Go to step 6.

BACK

22-71

Gauges Maintenance Required Indicator Reset Procedure How to Reset: Push the select switch and reset switch at the same time, turn the ignition switch ON (II), and hold them more than 10 seconds.

srInk"Ing Pattern: Miles (km) At 5,900 (9,440) to 6,100 (9,760) At 7,400 (11,840) to 7,600 (12,160)

22-72

Maintenance Reminder Light Blinks for 10 seconds when the ignition switch is turned ON (II). Comes on and stays on while the ignition switch is ON (II).

BACK

r--:'I

~

Safety Indicator System Component Location Index

SAFETY INDICATOR Input Test, page 22-76

I BRAKE

LAMP

I FRONT PASSENGER'S DOOR SWITCH

RIGHT REAR DOOR SWITCH

TRUNK LIGHT Test, page 22-111

DRIVER'S DOOR SWITCH BRAKE PEDAL POSITION SWITCH (BRAKE SWITCH) Test, page 4-49 Pedal Height Adjustment, page 19-5

LEFT REAR DOOR SWITCH

BRAKE LIGHT FAILURE SENSOR Test, page 22-78

BACK

22-73

Safety Indicator System Circuit Diagram UNDER-HOOD FUSE/RELAY BOX BATTERY

No.47 (20A) WHTNEL-----D-R-IVE~R-'S------------------------

(±)-BLK

UNDER-DASH FUSEJRELAY BOX

IGNITION SWITCH No.41 (IOOA)

No.42 (SOA)

WHT

--E5-

No.9 (7.5A)

BLKNEL

IGI

----+--or:r""'-'l ....O-....--~,,....- YEL - - - - - - - YEL BlI

SAFETY INDICATOR (In the gauge assembl~)

SAFETY INDICATOR CIRCUIT

II:I,.NG I~ tiil::rM:i

~

--I

,r

,

,,

YI

-

-

~

"

"

"

,

,r

-"

,r

r--

"

,r

,

,r All WHT/GRN - -

BLKIWHT

,

'AID

:: BLKIWHT

~

MULTIPLEX CONTROL

UN,~....."._.\

,,

::-

::....

I,,

A7

A2

I

~~a~

GRNIORN

AI

GRNNEL

GRN

A9

A8

GRNIWHT

B8

BI6

BLK

CAN

(Withoul keyless ) \enrrysyslem • MULTIPLEX CONTROL UNIT (Driver's) • COURTESY LIGHT

• MULTIPLEX CONTROL UNIT (Passenger's) • COURTESY LIGHT

Y Y

GRNIORN

GRN

DRIVER'S DOOR SWITCH

• MULTIPLEX CONTROL UNIT (Driver's) , COURTESY LIGHT

, MULTIPLEX

CONTROl

UNIT (Passenger's) , COURTESY LIGHT

Y Y

GRNNEL

FRONT PASSENGER'S DOOR SWITCH

GRNNEL

LEFT REAR DOOR SWITCH (Sedan)

ALTERNATOR TRUNK LIGHT

Y ORN

RIGHT REAR DOOR SWITCH (Sedan)

TRUNK LATCH SWITCH BLK

1 G601

22-74

BACK

G501

~

I.!!!!!..I

[ ) : Coupe

I

YEL

WHTIYEL

+

BRAKE PEDAL POSITION SWITCH (BRAKE SWITCH)

WHTIBLK

1-~'~'17

5(6)

---WHTlGRN

~'~l

6[1)

4[2)

BRAKE LIGHT FAILURE SENSOR

• MULTIPLEX CONTROL UNIT (Driver'S) • ECMlPCM • CRUISE CONTROL UNIT • ABS CONTROL UNIT • TRAILER LIGHTING CONNECTOR

GRNIWHT

3[5)

BLK

2[3)

GRN

h

GRN

GAN

LEFT BRAKE LIGHT (27W)

BLK

RIGHT BRAKE LIGHT (27W)

BLK

HIGHMOUNT BRAKE LIGHT (21W)

BLK

BLK

1 G551

GSOl

BACK

22-75

Safety Indicator System Safety Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-28). 1. Remove the gauge assembly (A) from the dashboard (see page 22-68), and disconnect the 22P connector (B) and the 14P connector (e) from the gauge assembly. *Without keyless entry system

WHT/BLU

t

~oooo~

MM~

~4--*~~+-~~~~~~-+--~+-4

B19 B20 B21 B22

All A12 A13 A14

+

ORN

+

WHT/GRN



c B

A

2. Inspect the connector and socket terminals to be sure they are all making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. • If the terminals look OK, go to step 3. 3. Make these input tests at the connectors. • If any test indicates a problem, find and correct the cause, then recheck the system. • If all the input tests prove OK, the printed circuit board must be faulty; replace it.

22-76

BACK

r-:'I I..!!!!..I Cavity B16

Wire BLK

B11

VEL

Test condition Under all conditions Ignition switch ON (II)

Test: Desired result Check for continuity to ground: There should be continuity. Check for voltage to ground: There should be battery voltage.

Ignition switch ON (II) and brakes applied Ceiling light switch in middle position (Without keyless entry system)


ORN

Trunk lid open

A7

GRN

Front passenger's door open

A2

GRN/ORN

Driver's door open

Check for continuity to ground: There should be continuity. NOTE: Before testing, remove No. 11 (7.5 A) fuse from the passenger's under-dash fuse/ relay box.

A1

GRN/YEL

A8

GRN/WHT

B8

WHT/BLU

Left rear door open (Sedan) Right rear door open (Sedan) Engine running

A11

WHT/GRN

A10

BLK/WHT

A9

Connect to ground: The ceiling light should come on.


BACK

Possible cause if result is not obtained • Poor ground (G501) • An open in the wire • Blown No.9 (7.5 A) fuse in the driver's under-dash fuse/relay box • An open in the wire • Blown brake light bulbs • Faulty sensor • A short to ground in the wire • Faulty ceiling light • An open in the wire • Blown No. 11 (7.5 A) fuse in the passenger's under-dash fuse/ relay box • Blown ceiling light bulb • Faulty trunk latch switch • An open in the wire • Faulty front passenger's door switch • An open in the wire • Faulty driver's door switch • An open in the wire • Faulty left rear door switch • An open in the wire • Faulty right rear door switch • An open in the wire • Faulty charging system • An open in the wire

22-77

Safety Indicator System Brake Light Failure Sensor Test Coupe:

1. First make sure the brake lights come on when the brake pedal is pressed. • If all the brake lights come on, go to step 2. • If one of the brake lights does not come on, check whether the bulb is blown. If the bulb is OK, go to step 2. • If none of the brake lights come on, check the brake light circuit (see page 22-91). 2. Open the trunk lid, and remove the left trunk side trim (see page 20-78). Sedan:

WHT/GRN

3. Make sure the BRAKE LAMP light in the safety indicator does not come on and stay on when the 6P connector is disconnected and the engine is running. If the BRAKE lAMP light in the safety indicator comes on and stays on, check for: • a short to body ground in the WHT/GRN wire between the safety indicator and the No.4 (Sedan) or 2 (Coupe) terminal ofthe failure sensor. • a faulty safety indicator circuit (printed circuit board) in the gauge assembly.


4. Reconnect the 6P connector. Make sure the BRAKE lAMP light in the safety indicator comes on and goes off when the No.3 (Sedan) or 5 (Coupe) terminal ofthe 6P connector is grounded, the brake pedal is pressed, and the engine is running. • If the BRAKE lAMP light does not go off, replace the failure sensor. • If the BRAKE lAMP light goes off, check for: - a poor ground (G601). - an open in the BlK wire.

22-78

BACK

Lights-on, Key-in, Seat Belt Reminder, Key Light Timer, and Engine Oil Pressure Indicator Systems

r--:'I I.!!:.I

Circuit Diagram

UNDER·HooD FUSEIRELAY BOX BAnERV

c±:>-

No.42 (SOA)

No,41 (100A) BlK

DRIVER'S UNDER· DASH FUSE/RELAY BOX

IGNITION SWITCH

~ BAT

WHT

~

-+--<"..0---11-"1

BlKIYEL

\..:!!T I

No.54 (40A) .-::1"'\ No.47 ~ (20A)

WHTlYEl

YEl

I

7

~

No.13 (7.SA)

IGNITION KEY LIGHT (lED)

LlGHTS·ON PASSENGER'S SIGNAL UNDER·DASH FUSE/RELAY BOX

I

6 WHTlBlK

Al

Ig

,.. '"

i

:>

!:.

WHTIYEl

REDlBlK

A12

A6

A24

MULTIPLEX CONTROL UNIT (Driver's)

Bll

B17

BS

lOW ENGINE Oil PRESSURE INDICATOR LIGHT

A13

A16

BlUIWHT

GRNlORN

Al8

CHARGING SYSTEM LIGHT

"~',,""", :l(' YEURED

[

ENGINE Oil PRESSURE SWITCH Closed: Engine Slapped ]

IGNITION KEY SWITCH

DRIVER'S

DRIVER'S SEAT BELT SWITCH

DOOR SWITCH

ALTERNATOR

Open:

Engine running

BlK

1 G503

BlK

BLK

1

1

G401

G551

BACK

22-79

Lights-on, Key-in, Seat Belt Reminder, Key Light Timer, and Engine Oil Pressure Indicator Systems Control Unit Input Test 1. Before testing these systems, troubleshoot the multiplex control system (see page 22-137). Multiplex Control Unit, Driver's: 2. Remove the driver's multiplex control unit from the driver's under-dash fuse/relay box. 3. Inspect the connector and socket terminals to be sure they are all making good contact. o o

If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. If the terminals look OK, go to step 4.

Al

A2

A3

IV.

AS

1>£

A7

ASI

/>S

A10 All Al2

Al3 Al4 Al5 AlB I-- Al7 Al8 Al9 A20r- A21 A22 A23 A24

81 811

Fuse/relay box socket

BU<

VEL/RED RED/GRN Wire side of female terminals

4. Make these input tests at the connector and fuse/relay box socket. o

o

If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, the control unit must be faulty; replace it.

L'.Iglh R ' d er: emln ts-on Wire Cavity BLK B11 A6

A16

Test condition Under all conditions Fuse/relay Combination box socket light switch ON Jump battery voltage to B16 (RED/GRN) on automatic lights off feature only Fuse/relay Driver's door box socket open

Seat Belt Reminder' Cavity Wire BLK B11 A24

A18

22-80


Check for voltage to ground: There should be 1 V or less.

Test condition Under all conditions Fuse/relay Ignition switch box socket ON (II)




Driver's seat belt is not buckled.

BACK

Possible cause if result is not obtained Poor ground (G503) o An open in the wire o Blown No. 10 (10 or 15A) fuse in the passenger's under-dash fuse/ relay box o Faulty combination light switch o An open in the wire

o

o o

Faulty driver's door switch An open in the wire

Possible cause if result is not obtained Poor ground (G503) o An open in the wire o Blown No.9 (7.5A) fuse in the driver's under-dash fuse/relay box o Faulty driver's under-dash fuse/ relay box o Faulty seat belt switch o Poor ground (G551) o An open in the wire o

~

l!::.I Englne . O'IP I ressure Ind'Icat or FI ash er: Cavity B11

Wire BlK

A24


B5

WHT/BlU

B17

VEL/RED



Engine running Ignition switch OFF Ignition switch ON (II)

Start the engine.

Check for voltage to ground: There should be battery voltage. Check for continuity to ground: There should be continuity. Check light operation. If the light does not come on, attach the VEL/RED terminal to ground: Light should come on as the ignition switch is turned ON (II). Check for voltage to ground: There should be battery voltage.

Test: Desired result Check for continuity to ground: There should be continuity Check for voltage to ground: There should be battery voltage.

Possible cause if result is not obtained • Poor ground (G503) • An open in the wire • Blown No.9 (7.5A) fuse in the driver's under-dash fuse/relay box • Faulty driver's under-dash fuse/ relay box • Faulty charging system • An open in the wire • Faulty engine oil pressure switch • An open in the wire • Blown bulb • An open in the wire

• • • •

Insufficient oil Improper lubrication Faulty engine oil pressure switch A short in the wire

Key L'Iglt h l'Imer: Cavity B11

Wire BlK

A12


Test condition Under all conditions Under all conditions

A1



A16


Driver's door open

Attach to ground: Ignition key light should come on. Check for voltage to ground: There should be 1V or less.



Driver's door open Ignition key is inserted into the ignition switch.

Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 1 V or less.

Key-m . Remm • d er: Cavity Wire B11 BlK A24


A16

Fuse/relay box socket Fuse/relay box socket

A13

BACK

Possible cause if result is not obtained • Poor ground (G503) • An open in the wire • Blown No. 13 (7.5A) fuse in the passenger's under-dash fuse/ relay box • An open in the wire • Blown No. 47 (20A) fuse in the under-hood fuse/relay box • An open in the wire • Faulty driver's door switch • An open in the wire

Possible cause if result is not obtained • Poor ground (G503) • An open in the wire • Blown No.9 (7.5A) fuse in the driver's under-dash fuse/relay box • Faulty driver'S under-dash fuse/ relay box • Faulty driver's door switch • An open in the wire • Faulty ignition key switch • Poor ground (G401) • An open in the wire

22-81

Exterior Lights Component Location Index • BRAKE PEDAL POSITION SWITCH (BRAKE SWITCH) DRL INDICATOR LIGHT (Canada)

Test, page 4-49 Adjustment, page 19-5

HIGH BEAM CUT RELAY (Canada)

Test, page 22-52

TAILLIGHT RELAY

Test, page 22-52 COMBINATION LIGHT SWITCH

DAYTIME RUNNING LIGHTS CONTROL UNIT (Canada) DASH LIGHTS BRIGHTNESS CONTROLLER


Input Test, page 22-96


UNDER HOOD FUSE/RELAY BOX

HEADLIGHT RELAY 2 1:~~~d-k~::=::In~~r\ Test, page 22-52

HEADLIGHT RELAY 1

Test, page 22-52

HEADLIGHTS/FRONT PARKING LIGHTS

Replacement, page 22-98 FRONT TURN SIGNAL/FRONT SIDE MARKER LIGHT

22-82

BACK

~

l!!!..J Sedan: REAR TURN SIGNAL LIGHT HIGH MOUNT BRAKE LIGHT Replacement, page 22-102

LICENSE PLATE LIGHT Replacement, page 22-103

TAILLIGHT and BRAKE LIGHT Replacement, page 22-100

INNER TAILLIGHT Replacement, page 22-100

Coupe:

REAR TURN SIGNAL LIGHT and TAILLIGHT Replacement, page 22-101

BACK-UP LIGHT Replacement, page 22-101

LICENSE PLATE LIGHTS Replacement, page 22-103

BRAKE LIGHT and INNER TAILLIGHT Replacement, page 22-101

HIGHMOUNT BRAKE LIGHT Replacement, page 22-102

BRAKE LIGHT and TAILLIGHT Replacement, page 22-101 REAR SIDE MARKER LIGHT Replacement, page 22-103

BACK

22-83

Exterior Lights Circuit Diagram - USA with Automatic Lights-off Feature MULTIPLEX CONTROL UNIT (Oriver's)

y

UNDER HOOD FUSE/RELAY BOX BATIERY

NO.55 (40A)

No.41 (IDOA)

@- r---'

)

HEADLIGHT RELAY 2

UIWHT BL ",

L

J.

)

I~ ~~------

I~ ~~-----1

1

~

~

No.45 ~ (20A)

HEADLIGHT RELAY 1 MULTIPLEX CONTROL

UNIT~~S)

No.43 (2OA)

;>

I

MULTIPLEX CONTROL UNIT (Drivel's)

yY

MULTIPLEX CONTROL UNIT (Passenger's)

BLUIRED REDlYEL


No.IO .1 !'OAI .2 ISA

TAILLIGHT RELAY

BLU/RED

RIGHT HEADLIGHT

;>

REDlGRN RED/GRN

I I

REDIWHT

lEFT HEADLIGHT

YEL PASSENGER'S UNDER-OASH FUSEIRELAY BOX

REDIYEL

3

REDlYEl 6

4

REOIBlK

PASSING LOW (SIW)

HIGH (&OW)

HIGH (60W)

REOIBLK

/ HIGH

LOW (SIW)

DIMMER

10

11 ORNIWHT

ORNIWHT

ORNlWHT

BlK

REDIBLK

1

REDlBlK

LEFT FRONT SIDE MARKER LIGHT (aw)

1

REDIBLK

RIGHT FRONT SIDE MARKER LIGHT (&W)

, REDIBLK

1

REDlBlK

lEFT RIGHT FRONT FRONT PARKING r~:NG LIGHT (SW) (5W)

.2

G301

22-84

.1 : Sedan .2 :Coupe

I

,

REOIBLK

TAILLIGHTS .1 (5WIC2)

I

1

REDlBLK

I

BLK

BLK

7 BlK

I

j I


ORNlWHT

(7Wx4)

REDlBlK

INNER TAILLIGHTS

:~=l

G&OI

0001

BACK

G201

LIGHTS (5Wx2)

I

1

G201

G201

.2 REAR SIDE MARKER

BLK

BlK

I

G301

REDIBLK

liCENSE PLATE liGHTS .1 (SW) .2 (SWIC2)

111111 G401

~

MULTIPLEX CONTROL UNIT (Ilrivef'S)

r--:'I

~

Circuit Diagram - USA without Automatic Lights-off Feature *! :Sedan *2 : Coupe

UNDER·HooD FUSE/RELAY BOX BAlTERY

NO.4! (!OOA)

@- r--v

HEADLIGHT RELAY 2

1

1 I~ ~~-----.{~

1

1

~f-----~

HEADLIGHT RELAY!

J No.4S (20A)

No.43 (20A)

NO.54 (40A)

m- rI REDIYEl

Blu/RED

YEl

No.!O *1 (IDA! *2(15A

RED/GRN

REDIYEl

lEFT HEADLIGHT

H!GHBEAM INDICATOR LIGHT (1.4W)

PASSENGER'S UNDER·DASH fUSEIRElAY BOX

REDlGRN RIGHT HEADLIGHT


(Not used)

4

6

PASSING lOW (SIW)

HIGH

I

HIGH (&OW)

DIMMER

10 ORNlWHT

ORNIWHT

ORNlWHT

11

OF1N1WHT

REOIBlK

REOIBLK

REDlBlK

~

MULTIPLEX CONTROL UNIT (Driver'S)

lEFT FRONT SIDE MARKER liGHT

RIGHT FRONT SIDE MARKER LIGHT

(ew)

(aw)

lEFT fRONT PARKING lIGHT (SW)

TAilLIGHTS * 1 (SWx21 *2 (7Wx4

RIGHT FRONT PARKING liGHT (SW)

BlK

I

BlK

BlK

BlK

BlK

BLK

BlK

INNER TAILLIGHTS *1 (SWx2) *2 (7Wx2)

BlK

I

LICENSE PLATE LIGHTS *1 (SW) *2 (5Wx2)

BlK

f

11 1 1 1 1

1

G301

G201

G601

G301

G201

G301

BACK

G201

BlK

I

BlK

I

G401

*2 REAR SIDE MARKER LIGHTS (SWx2)

22-85

Exterior Lights Circuit Diagram - Canada with Automatic Lights-off Feature UNDER·HOOD FUSEIRELAY BOX BATIERY

+

No.41 (100A)

I I

.L

..

~~-----~ No.42 (50A)

WHT

No.55 (40A)

YEUGRN

DRIVER'S UNDER· DASH FUSEJRELAY BOX

~ No.5 (7.5A)

Y 9

REDLr

(51W)

BLK

3

(&OW)

ORNlWHT

-1

2

I

REtlRN

"I

,

REDIBLU

12

RED~

~

I~ ~ow ~ ~IGH ~~

:) No.6 (IDA)

REDlYEL

YEURED

BLUIRED

/

BLUIWHT

BLU

RIGHT HEADLIGHT

lEFT HEADLIGHT


DRL INDICATOR LIGHT

REDlGRN

~I

REDlYEl

t

REDIYEl


ORNlWHT

I~ ~IGH ~ ~ow (&OW)

ORjHT

(51~

BLK

Y-0RNIWHT ORNlWHT

1 G301

10

- ....

REDIORN REDlGRN

G201

11

DAYTIME RUNNING LIGHTS CONTROL UNIT 13

4

6

• BRAKE SYSTEM LIGHT

.W~~~~'


GRNlWHT

GRNlWHT3

1

P I

G302

G401

GRNlRED

~ BlK

22-86

BRAKE FLUID lEVEL SWITCH

HEADLIGHT RELAY 1

No.43 (2OA)

REDIYEl

MULTIPLEX CONTROL UNIT (Drivers)

YfL

-;T

~~------

HEADLIGHT RELAY 2

REDIYEl

A

IGNITION BAT SWITCH IG2

~

No.45 (lOA)

BLUIWHT

I

I

,6

~

N : Flail down (8FF : Flail up

BACK

BLUIRED

r--:,

I.!!!..I ., : Sedan *2 :Coupe

No.54 (4OA)

BLUIRED ----BLU------------~

VEL

I

MULTIPLEX

CONTRO~ UNIT (~ivefS)

~ ;>

yy MULTIPLEX CONTROL UNIT (Driver's)


REDIWHT

BLUIRED

yy

HIGH BEAM CUT RELAV

.a>m

ORN-----"'I

PASSENGER'S UNDER·DASH FUSEIRELAV BOX

'~r::iF REDIYEL

REDlBlK

h

- - BlUiRED """T-U!.lllol:r1r--

--ORNIWHT

No.l0 *1 (10AI *2(15A

10

3

""'" '~

4


(:0)

DIMMER

(m)


11

BLK

BLK

REDIBLK

lEFT FRONT SIDE MARKER LIGHT (8Wl

RED/BLK

REDlBlK

RIGHT FRONT SIDE MARKER LIGHT (8W)

LEFT

REDlBLK

FRONT PARKING LIGHT (SW)

REDlBLK

RIGHT FRONT PARKlNG LIGHT (5W)

FlED/BlK

REDlBlK

INNER TAILLIGHTS *1 (5Wx2) *2 (7Wx2)

TAILLIGHTS ., !5Wx2) *2 7Wx4)

BLK

BlK

I

I

LICENSE PLATE UGHTS *1 !5W) *25Wic2)

BlK

I

BlK

BLK

BLK

BLK

BlK

1.

1.

1.

1.

1.

.!.

G401

G301

G201

G301

G201

G601

BACK

REDIBLK

*2 REAR SIDE MARKER LIGHTS (5Wx2)

BLK

I

BLK

22-87

Exterior Lights Circuit Diagram - Canada without Automatic Lights-off Feature UNDER-HOOD FUSE/RELAY BOX BArrERY

+

No.41 (100A)

1

I

6

,J

~~-----1

I~

'1

No.42 (50A)

WHT

NO.55 (40A)

No.45 (20A)

YEUGRN

!

REDIYEl

REDIYEl REDLHT

l DRIVER'S UNDER-DASH FUSE/RELAY BOX

~ NO.5 (7.5A)

Y

lOW (51W)

YEURED

(f::>

HIGH (60W) ~

RED/YEl

BlK

~-1

REDlBlU

BlUIWHT

3

12

~I

REDLHT

r~ P .~P

No.6 (IDA)

DRL INDICATOR LIGHT

No.43 (20A)

BLU

RIGHT HEADLIGHT

LEFT HEADLIGHT



BLUIRED

REDIGRN

r~ ~ ::> HIGH (60W)

"4"-..0A1

BLK

REDIORN ~

10

lOW (SIW) ..)

ORNlWHT

1 G301

....

BlUiRED

REDIGRN

G201

11

8

DAYTIME RUNNING LIGHTS CONTROL UNIT 13

4

6

• BRAKE SYSTEM LIGHT

'~y::~" -=r


GRNIWHT

GRNIWHT3

$

GRNJRED

BLK

BRAKE FLUID lEVEL SWITCH (ON : Floal down1 BlK lOFF: Floal up )

22-88

HEADLIGHT RELAY 1

RED/GRN REDIYEl

IGNITION BAT SWITCH IG2

,J

~~------

HEADLIGHT RELAY 2

~

1

I

G302

G401

BACK

BlK

~ ~

*1 : Sedan

*2 : Coupe

NO.54 (40A)

BLUIRED

VEL

--BLU

4---+-..J

HIGH BEAM CUT RELAY

~ No.l0


*1 (10Al

~ *2 (15A

ORN

RED/GRN

10

6 PASSING

/ HIGH

/ I

-

t--------...---.I

BLUIRED

11 -

ORNIWHT

6

(=0)

DIMMER

(000:)


----...,j

RED/BLK

RED/BLK


lEFT FRONT SIDE MARKER LIGHT (8W)

RIGHT FRONT SIDE MARKER LIGHT (8W)

lEFT FRONT PARKING LIGHT (5W)

RIGHT FRONT PARKING LIGHT (5W)

TAILLIGHTS *1 ~5WX21 *2 7Wx4

BLK

I

INNER TAilliGHTS *115WX2 *2 7Wx2l

BLK

1

liCENSE PLATE LIGHTS *1 (5W) *2 (5Wx2)

BLK

11 1 1 1

I 1

G401

G601

BlK

BLK

G301

BLK

G201

BLK

G301

BACK

BLK

G201

*2 REAR SIDE MARKER LIGHTS (5Wx2) BlK

I

BlK

22-89

Exterior Lights Circuit Diagram - Back-up Lights UNDER-HOOD FUSE/RELAY BOX

IGNITION SWITCH

BATTERY No.41 (IOGA)

(±)

No.42 (SOA)

_

l-o(cr"V::J.D---(l~

WHT~ ~

BLKlYEL - - - - ,

(MIT) I

BlKIYEL

BLKlYEL

No.9 (7.SA)

DRIVER'S UNDER-OASH fUSE/RELAY BOX

No.9 (7.5A) DRIVER'S UNDER-DASH FUSE/RELAY BOX

VEL

2

I

~~--------------------18 BACK-UP LIGHT SWITCH Ihe ) lIans.mission housing (Closed: In position

(On

1]]) :

GRNlBLK

I

GRNlBLK

I

GRNlBLK

LEFT BACK-UP LIGHT (21W)

BLK

Y I I

L - ..

22-90

REVERSE RELAY

fliGHT BACK-UP LIGHT (21W)

BLK

BLK

1

GRNlBLK

I

GRNlBLK

~

I

I

GRNIBlK

I

GRNlBLK

LEFT BACK-UP LIGHT (21W)

TRAILER LIGHTING CONNECTOR BlK

Y

G601

BACK

RIGHT BACK-UP LIGHT (21W)

WHT

I

GRNlBLK

~

TRANSMISSION RANGE SWITCH (AITGEAR ) POSiTION SWITCH

(Back-UP

TRAILER LIGHTING CONNECTOR

)

lighl swilch (Closeci : In position

lID )

BLK

BLK

BLK

1

1

G601

GI01

I I

.. ~

r--:'I I.!:..I Circuit Diagram - Brake Lights IGNITION SWITCH

UNDER-HOOD FUSE/RELAY BOX

I J : Coupe

BATTERY

YEl

WHTNEl BRAKE PEDAL POSITION SWITCH (BRAKE SWITCH) IClosed : Pedal depressed]


I ~

No_9 (7.5A)

SAFETY INDICATOR

WHT/BlK

-~-1 WHTlBlK • ABS CONTROL UNIT • CRUISE CONTROL UNIT • ECMlPCM • TRAilER LIGHTING CONNECTOR


YEl

611J

516J

7

WHTIGRN

412J

BRAKE LIGHT FAilURE SENSOR

213J

WHT/BlK

315J

GRN

r--1

GRN HIGH MOUNT BRAKE LIGHT (21W) BLI(

GRN

P

~p :> lEFT ~,~ ~ :1 :> (27W)

BlK

I

RIGHT BRAKE LIGHT (27W)

i

BlK

I

BlK

G55!

1 G601

BACK

22-91

Exterior Lights Circuit Diagram - Auto-off Headlights Automatic Light Off Feature


UNDER-HOOD FUSEIRELAY BOX BATTERY

No_41 (IOOA)

No_l D11 DA : Sedan! 15A: CoIJpe

No_S4(40A)

+>-+-C'-'_....-+.....-YEl __I-....c:'""'-'o--+-------------__. No_13 (7_5A) YEl--+---
IGNITION SWITCH

~

No_42 (SOA) '-C-t--WHT _ _ _ _ _ _ _.....

~T IGI BlKlYEl

WHTIYEl

NO.9 (7.5A)


iIII i

1;"

]!

~ MULTIPLEX CONTROL UNIT (Door)

A15

>-- BRN

A24

A12

A2

A6


A7

AI3

PNK

BLUIWHT

A16

A14

GFINIOfIN

\l I

(NG/used)

I lOCK

DRIVER'S DOOR lOCK KNOB SWITCH

3

IGNITION KEY SWITCH

A22


lOW

OR~~

\l I

RELAYS

B.LUoQ~'

PASSINGo-RE.DIW ... 3H... T. .

I HIGH

..

I

(:0)

REOIYEL

_ _,

11 BlK

f

BlK

BlK

BlK

1

1

1

G401

G401

G401

G401

BACK

t-

REDlBLK REDlBLK

~ EXTERIOR LIGHTS

I

6

--~----~(~)

22-92

B16

BlK • HEADLIGHTS (HIGH) • HIGH BEAM INDICATOR LIGHT

0,

AID

B13

BLK

I

~

I.!!:..I Control Unit Input Test 1. Before testing exterior light control functions, troubleshoot the multiplex control system (see page 22-137). Multiplex Control Unit, Driver's: 2. Remove the driver's multiplex control unit from the driver's under-dash fuse/relay box. 3. Inspect the connector and socket terminals to be sure they are all making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. • If the terminals look OK, go to step 4.

Wire side of female ,e,minals

4. Make these input tests at the connector or fuse/relay box socket. • If any test indicates a problem, find and correct the cause, then recheck the system. If ate II h InPut . tests prove OK,goto step 5. Possible cause if result is not obtained Test condition Test: Desired result Cavity Wire Check for voltage to ground: • Blown No.9 (7.5A) fuse in the driver's Fuse/relay Ignition switch A24 under-dash fuse/relay box box socket ON (II) There should be battery voltage. • An open in the wire • Faulty driver's under-dash fuse/relay box • Blown No. 13 (7.5A) fuse in the passenger's Check for voltage to ground: Under all A12 under-dash fuse/relay box There should be battery conditions voltage. • An open in the wire A13 Ignition key is in Check for voltage to ground: • Faulty ignition switch the ignition There should be 1 V or less. • An open in the wire switch • Poor ground (G401) Driver's door Check for voltage to ground: • Faulty driver's door switch A16 There should be less than 1 V. • An open in the wire o~en A14 Under all Check for continuity to ground: • Poor ground (G401) There should be continuity. conditions • An open in the wire Combination light The headlights should come on. • Poor ground (G401) A10 switch (ON) and • An open in the wire jumpbanery • Faulty headlight relay voltage to A10 • Faulty combination light switch A22 Combination Check for continuity to ground: • Poor ground (G401) light switch (ON) There should be continuity. • An open in the wire • Faulty combination light switch Combination light • Blown No. 10 (10 or 15A) fuse in the A6 Check for voltage to ground: switch (ON) and passenger's under-dash fuse/relay box There should be battery Jumpbanery voltage. • Faulty combination light switch voltage to B16 • Faulty taillight relay. (RED/GRN) • An open in the wire. B16 RED/GRN Combination Check for continuity to ground: • Poor ground (G401) light switch (ON) There should be 75 Q • An open in the wire resistance. • Faulty combination light switch • Faulty taillight relay B13 RED/WHT Passing switch Check for continuity to ground: • Poor ground (G401) ON there should be continuity. • An open in the wire • Faulty combination light switch

·

(cont'd)

BACK

22-93

Exterior Lights Control Unit Input Test (cont'd) Multiplex Control Unit, Door: 5. Remove the driver's door panel, and disconnect the 20P connector from the door multiplex control unit. 6. Inspect the connector and socket terminals to be sure they are all making good contact . • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system . • If the terminals look OK, go to step 7. PNK

Al

A2

All

A12

V V VV A4

A15

~

.J

L

A6

A7

A8

V

A16

A17

A18

A19

Al0

V


7. Reconnect the connectors to the unit, and make this input test. • If a test indicates a problem, find and correct the cause, then recheck the system . • If all the input tests prove OK, go to step 8.

Cavit A7

Wire

PNK

Test condition Driver'S door lock knob locked

Test: Desired result Check for voltage to ground: There should be less than 1 V.

Possible cause if result is not obtained • Faulty driver's door lock actuator • Poor ground (G401) • An open in the wire

8. If all the input tests prove OK, one of the control units must be faulty. Substitute a known-good control unit for the one that is most likely at fault, then recheck the system. Ifthe system works properly, the original control unit is faulty; replace it. If there is still a malfunction, substitute a known-good control unit for the next most likely unit to be at fault, and recheck. If the system works properly, the original unit is faulty; replace it.

22-94

BACK

~

I..!!!:..I Combination Light Switch Test/Replacement 1. Remove the dashboard lower cover (see page 20-84) and steering column covers (see page 17-25). 2. Disconnect the 14P connector (A) from the combination light switch (8). 3. Remove the two screws (e), then pull out the switch (8). 4. Inspect the connector terminals to be sure they are all making good contact . • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system . • If the terminals look OK, check for continuity between them in each switch position according to the tables. - If there is no continuity, replace the switch. A

B

-1

((

------,,~c

,~ Light switch: Terminal

\

\

Position

3

11

4

(*)

10

6

7

OFF

,....

:00: Headlight switch

sD

LOW

,....

,....

'"'

'"'

HIGH

'"'

'"'

,....

,....

-v

v

'"'

""

....

OFF Passing switch

ON

,....

,....

'"'

''-'

,....

-v

0

'"'

-0

-

,....

,....

*: With auto-off headlight feature Turn signal switch:

1\

Terminal

Position LEFT

\

12

13

,....

,....

14

NEUTRAL RIGHT

'"'

'"'

BACK

22-95

Exterior Lights Daytime Running Lights Control Unit Input Test (Canada) 1. Remove the driver's dashboard lower cover (see page 20-84). 2. Disconnect the 14P connector (A) from the control unit (8). 3. Inspect the connector and socket terminals to be sure they are all making good contact. • If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system . • If the terminals look OK, go to step 4.

B

RED/BLU

BlK

RED/VEL

RED/WHT

BLK

RED/GRN

2

3

8

9

BLU/WHT

BLU/RED

GRN/RED

RED/ORN

ORN/WHT

GRN/WHT

VEL/RED


4. Make these input tests at the disconnected connector. • If any test indicates a problem, find and correct the cause, then recheck the system . • If all the input tests prove OK, the control unit must be faulty; replace it.

22-96

BACK

r--:'I I.!!:.I Cavity

Wire

1 11 10 2

RED/WHT RED/ORN ORN/WHT RED/BLU


Test: Desired result Check for continuity between each terminals: There should be continuity. Check for voltage to ground: There should be battery voltage.

Possible cause if result is not obtained • • • • •

BLK

4 7 6

GRN/WHT

8

BLU/RED

Under all conditions Parking brake lever up With automatic lights OFF: Combination light switch ON(§D) Without automatic lights OFF: Under all conditions Ignition switch ON

Check for continuity to ground: There should be continuity. Check for continuity to ground: There should be continuity. Check for continuity to ground: There should be continuity.

• • • • • • • •


• Faulty headlight relay 1 and 2 • An open in the wire

• Faulty DRL indicator light • An open in the wire • Blown No. 45 (20 A) fuse in the under-hood fuse/relay box • Faulty combination light switch • Faulty headlight relay 2 • An open in the wire • Blown No. 43 (20 A) fuse in the under-hood fuse/relay box • Faulty combination light switch • Faulty headlight relay 1 • An open in the wire • Blown No.5 (7.5 A) fuse in the driver's under-dash fuse/relay box • An open in the wire • Faulty brake fluid level switch • An open in the wire

3

REDNEL

Combination light switch ON @D)

Connect to ground: The indicator light should come on. Check for voltage to ground: There should be battery voltage.

5

RED/GRN

Combination light switch ON (~D)


12

VEL/RED

Ignition switch ON


9

BLU/WHT

(II)

(II)

13

GRN/RED

Brake fluid reservoir float in down J~osition

Blown headlight bulb (High beam) Blown high beam indicator light. An open in the wire Blown No. 55 (40 A) fuse in the under-hood fuse/relay box Blown No.6 (10 A) fuse in the passenger's under-dash fuse/ relay box An open in the wire Poor ground (G401) An open in the wire Faulty parking brake switch An open in the wire Faulty combination light switch Faulty headlight relay 1 and 2 An open in the wire


BACK

22-97

Exterior Lights Headlight Adjustment

Headlight Replacement 1. Remove the front bumper (Coupe (see page 20-140), Sedan (see page 20-142)). 2. Disconnect the connectors (A). 3. Remove the 5 mounting bolts (8), then remove the headlight assembly (C). A

Before adjusting the headlights:

• Park the vehicle on level ground. • Make sure the fuel tank is full. • The driver or someone who weight the same should sit in the driver'S seat. • Load the trunk with the items you usually carry. • Push down on the front and rear bumpers several times to make sure the vehicle is sitting normally.

'98-00 models: 1. Open the hood. 2. Check the horizontal adjustment indicator. The "0" mark (A) on the horizontal adjustment indicator gear should be aligned with the mark (8) on the horizontal indicator.

A

B HEADLIGHT: 60/51 W FRONT PARKING LIGHT: 5 W

L-R

4. Install the headlight in the reverse order of removal. 5. After replacement, adjust the headlights to local requirements.

3. Check the vertical adjustment indicator. The bubble (A) should be centered underneath the longest scribe mark (the "0" mark) on the gauge.

A

4. If either indicator is not aligned with its "0" mark as described above, adjust it to "0" with a Phillips screwdriver.

22-98

BACK

r--:'I I.!!!!.I '01-02 models:

5. Adjust the headlights to local requirements by turning the adjusters. 6. After headlight assembly replacement, it may be necessary to readjust the horizontal indicator gear

1. Clean the outer lens so that you can see the center ofthe headlights (A).

(A).

A

• First install the headlight, and adjust its horizontal and vertical aimings according to local requirements . • Then check that the arrow on the horizontal indicator gear is aligned with the mark on the horizontal indicator.

B

/

7.5 mm (25 tt)

2. Align the center ofthe headlights to 7.5 m (25 ft) from the wall or a screen (B), and park the vehicle. 3. Turn the low beams on. 4. Measure the height of the headlights (A) and the lights should reflect 52 mm (2.1 in.) below headlight height (B).

I

(cont'd)

BACK

22-99

Exterior Lights Headlight Adjustment (cont'd) 5. If necessary, adjust the headlights to local requirements by turning the vertical adjuster.

Taillight Replacement - Sedan Taillights 1. Open the trunk lid and pull back the trunk side trim (see page 20-78). 2. Disconnect the connectors from the taillight.

3. Remove the three mounting nuts, then pull out the taillight. 4. Install the taillight, and note these items: • Inspect the gasket; replace it if it is distorted or stays compressed . • After installing the taillights, run water over them to make sure they do not leak. BRAKE/TAILLIGHT BULB: 21/5 W TURN SIGNAL LIGHT BULB: 21 W

22-100

BACK

~

I.!!:..I Taillight Replacement - Coupe Inner Taillights

Taillights

,. Open the trunk lid.

,. Open the trunk lid and pull back the trunk side trim (see page 20-78).

2. Disconnect the connectors (A) from the inner taillight.

2. Disconnect the 6P connector (A) from the taillight (8).

A

B

3. Remove the three mounting nuts (8) and a clip (C), then pull out the inner taillight.

TAILLIGHT BULB: BACK-UP LIGHT BULB:

5W 21 W

B

3. Remove the four mounting nuts (C), then pull out the taillight (8). NOTE: • Inspect the gasket: replace it if it is distorted or stays compressed . • After installing the taillights, run water over them to make sure they do not leak.

TURN SIGNAL/TAILLIGHT BULB: BRAKE/TAILLIGHT BULB:

27/7 W 27/7 W

(cont'd)

BACK

22-101

Exterior Lights High Mount Brake Light Replacement

Taillight Replacement - Coupe (cont'd) Inner Taillights

1. Push the light rearward to release the clips.

1. Open the trunk lid. 2. Remove the screw (D) and taillight lid cover (E).

E

D

3. Disconnect the connectors from the inner taillight 2. Pull the light out, then disconnect the 2P connector from the light.

(F).

4. Remove the mounting nuts then pull out the inner taillight (F).

BRAKE/TAILLIGHT BULB: BACK-UP LIGHT BULB:

22-102

3. Clean the rear window glass, and install the light in the reverse order of removal.

27/7 W 21W

HIGH MOUNT BRAKE LIGHT BULB: 21 W

BACK

~

a=!:..I License Plate Light Replacement

Rear Side Marker Light Replacement - Coupe

Sedan 1. Pull the license plate light assembly (A) out, and disconnect the 2P connector (B) from the light.

1. Remove the screw from the rear side marker light assembly (A).

LICENSE PLATE LIGHT BULB: 5 W B

B

2. Carefully pry the light (A) out of the rear bumper, and disconnect the 2P connector (B) from the light. Be careful not to damage the rear bumper. 3. Remove the bulb socket (A) by turning it 45° counterclockwise, then replace the bulb (B). 2. Take the lens off, then replace the bulb (C).

REAR SIDE MARKER LIGHT BULB: 5 W

Coupe 1. Pull the license plate light assembly (A) out, and disconnect the 2P connector (B) from the light.

LICENSE PLATE LIGHT BULB: 5 W

A

2. Take the lens off, then replace the bulb (C).

BACK

22-103

Turn Signal/Hazard Flasher Component Location Index TURN SIGNAL INDICATOR LIGHTS (In the gauge assembly) Bulb Replacement, page 22-59 HAZARD WARNING SWITCH Test, page 22-107

COMBINATION LlGHT/TURN SIGNAL SWITCH Test, page 22-95

TURN SIGNAL/HAZARD RELAY Input Test, page 22-106


22-104

BACK

r--:'I

~

Circuit Diagram

IGNITION SWITCH

UNDER·HOOD FUSE/RELAV BOX BATIERV

No.42(~A)

No.41 (100A)


WHT

(±r-BlK

~ BAT

BlKIYEL

' COMBINATION LIGHT SWITCH (OX, LX) • TAilLIGHT RELAY

-""'"-CT""""O-..--... (EX)

IGl

No.49 (15A) WHTiGRN - - - - - - - - - - - - - . VEURED

RED/BLK

_ - - - - - GRNlBLU - - - - - - . . . . ,

GRNlYEl

HAZARD WARNING 6 [61 SWITCH

TURN SIGNAL SWITCH ON 12

lEFT \

I

RIGHT

LIGHT (O.84W)

14

13

--1I-_ _

L-_ _ _

1 [41

5(2]

GRNlBLU (GRNlREDI

GRNlWHT

RED

GRNlBlU (GRNlRED] 2

3 TURNSIGNAU HAZARD RELAY

GRNIYEl

GRNlBlU

7(5)

MULTIPLEX CONTROl UNIT

REAR Sedan (21W) Coupe (27W) BLK

FRONT (27W)

BlK

(~river's)

RIGHT TURN SIGNAL LIGHT

LEFT TURN SIGNAL LIGHT

INDICATOR (1.4W)

BlK

I

. lHT

RIGHT

TRAilER LIGHTING CONNECTOR

INDICATOR (1.4W)

BLK

I 1

FRONT (27W)

REAR Sedan(21~

Coupe (27

BLK

BlK

BLK

G201

G601

G401

BLK

G601

G301

GSOI

BACK

22-105

Turn Signal/Hazard Flasher Turn Signal/Hazard Relay Input Test 1. Remove the turn signal/hazard relay (A) from the driver's under-dash fuse/relay box (B). 2. Inspect the relay and fuse/relay box socket terminals to be sure they are all making good contact. • If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system . • If the terminals look OK, go to step 3.

B

3. Make these input tests at the fuse/relay box . • If any test indicates a problem, find and correct the cause, then recheck the system . • If all the input tests prove OK, the turn signal/hazard relay must be faulty; replace it.

CavLtv 1

Test condition Under all conditions

2


3

22-106


Hazard warning switch


Hazard warning switch ON; connect the No.2 terminal to the No.3 terminal. Ignition switch ON (II) and turn signal switch in Right or Left; connect the No.2 terminal to the No.3 terminal.

Hazard lights should come on.

Right or left turn signal lights should come on.

BACK

Possible cause if result is not obtained • Poor ground (G401) • An ooen in the wire • Blown No. 10 (7.5 A) fuse in the driver's under-dash fuse/relay box • An open in the wire • Faultv hazard warning switch • Blown No. 49 (15 A) fuse in the under-hood fuse/relay box • An open in the wire • Faultv hazard warning switch • Poor ground (G201, G301, G501, G601) • Faulty hazard warning switch • An open in the wire • Faulty turn signal switch

~

l.!!:.I Hazard Warning Switch Test 1. Carefully pry the clock (A) out of the center panel (8).

D

l[ffi]mmJl


'98-00 models

1[ffi]tt?W11


'01-02 models

2. Pull the hazard warning switch (C) out from the clock. 3. Disconnect the 10P connector (D) from the hazard warning switch. 4. Check for continuity between the terminals in each switch position according to the table.

\

Terminal 6 Position \ [6]

OFF ON

7 1 2 10 9 3 5 [5] [4] [7] [1 ] [3] [10] [2]

0 ~ -D 0 0 ~ -D 0 -0

[l : '01-02 models

D D 0 r- ~

BACK

22-107

Interior Lights Component Location Index SPOTLIGHTS Test, page 22-110


PASSENGER'S VANITY MIRROR LIGHT

-:::::;;z$~_


RIGHT REAR DOOR SWITCH TRUNK LIGHT Test, page 22-111

22-108

BACK

r:-:'I I.!!!:..I Circuit Diagram PASSENGER'S UNDER-DASH FUSEIRELAY BOX

UNDER-HOOD FUSEIRELAY BOX BATIERY

~

No.4l (100A)

No.l0 (lOA: Sedan! (l5A:Coupe

No.54 (40A)

~BlK--~~~o---~~~~~YEl--~~~~~--~----------' No.ll (7.SA)

WHTIBLU

1

WHTlBlU

WHT/BlU

DRIVER'S

OOOR COURTESY LIGHT (3.BW)

TRUNK LIGHT (5W)

ORN

YEUBlU

1

WHT/BlU

1

WHTlBlU

lEFT REAR DOOR COURTESY LIGHT (3.8W)

YELlGRN

VEL

,(Driver~)

DRIVER'S DOOR SWITCH ( Closed: ) Door open

Y

PASSENGER'S DOOR COURTESY LIGHT (3.8W)

I

REDIBLK

YEl.JWHT

T RED/BlK

I

REDlBlK

3 SPOTLIGHTS (6.2Wx2)


TRUNK LATCH SWITCH ( Closed: ) Lid open

, COMBINATION LIGHT SWITCH (DX,LX) - tAilLIGHT RELAY (EX)

WHTIBLU

MULTIPLEX CONTROL UNIT (Passe!'ger's)


GRNlORN

V

I

I

WHTIBLU

RIGHT REAR DOOR COURTESY lIGHT (3.8W)

RED/GRN

GRNlYEl


( Closed: ) Oooropen

PASSENGER'S UNDER-DASH FUSEIRELAY BOX

GRN

GRNIWHT

PASSENGER'S

DOOR

SWITCH ( Closed: ) Oooropen

PASSENGER'S VANITY MIRROR LIGHT (1.lWx2)

BlK


( Closed: ) Oooropen

BlK

2 GLOVE BOX LIGHT

DRIVER'S VANITY MIRROR LIGHT (1.lWx2) BlK

BlK

BlK

BlK

1 G58l

G60l

BACK

G50l

22-109

Interior Lights Spotlight Test 1. Carefully pry off the lens (A) with a small screwdriver.


1\

Terminal

\

Position

LEFT RIGHT

ON

OFF

2. Remove the four mounting screws (8). 3. Disconnect the 3P connector (C) from the housing (D).

22-110

BACK

0

r.-.

0

r.-.

OFF ON

3

1

"'" ""

-0 -0

r--:'I I..!!!!..I Trunk Light Test

Trunk Lid Latch Switch Test

1. Open the trunk lid.


2. Pry out the trunk light assembly.

2. Disconnect the 2P connector (without keyless entry/ security alarm system), or 6P connector (with keyless entry/security alarm system) from the trunk latch.

3. Disconnect the 2P connector (A) from the housing (B).

Without Keyless Entryl Security Alarm System:

With Keyless EntryI Security Alarm System:

p/


3. Check for continuity between the terminals in each switch position according to the table. Without Keyless Entry/Security Alarm System

1\

Terminal

Position

\

OPEN

4. Open the trunk light cover (C).

1

2

0

D

CLOSED

5. Make sure that the bulb (D) is OK. Check for continuity between the No.1 and No.2 terminals.

With Keyless Entry/Security Alarm System 6. If there is no continuity replace the trunk light assembly.

1\ Terminal Position OPEN

\

1

6

0

-0

CLOSED

4. If the continuity is not as specified, replace the trunk lid latch switch.

BACK

22-111

Dash Lights Brightness Controller Circuit Diagram PASSENGER'S UNDER·DASH FUSEIRELAY BOX

UNDER·HOOD FUSEIRELAY BOX No.41 (100A)

No.S4 (40A)

~-+--~~---o~o--+--YEL---P~--------------------------------~

1:1 No.l0 :sedan\ 110A lSA : Coupe

1:1 No.13 (7.5A) WHTNEL

• COMBINATION LIGHT SWITCH (DX,LX) • TAILLIGHT RELAY (EX)

Y

REDIBLK

r----

RED/BlK

--------t-----

RED/BLK

tAG

A12

-...,

B3

~T

REDIBLK

RED

B22 • AUDIO UNIT LIGHT • AfT GEAR POSITION LIGHT • DRIVER'S SEAT HEATER SWITCH LIGHT • PASSENGER'S SEAT HEATER SWITCH LIGHT • CRUISE CONTROL MAIN SWITCH LIGHT • HAZARD WARNING SWITCH LIGHT • CLOCK • MODNROOF SWITCH LIGHT • HEATER CONTROL PANEL LIGHT

GAUGE LIGHTS

BID

L-_ _ _ _ _

RED-----~'i~D-----

B4

GAUGE ASSEMBLY

DASHUGHTS BRIGHTNESS CONTROllER

!o

-:~


BS

WHT~RED

RED

B4

A20 A14

I G401

22-112

BACK

r--:'I I.!!.I Control Unit Input Test 1. Before testing dash light brightness control functions, troubleshoot the multiplex control system (see page 22137). Multiplex Control Unit, Driver's: 2. Remove the driver's multiplex control unit from the driver's under-dash fuse/relay box. 3. Inspect all connector and socket terminals to be sure they are making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. • If the terminals look OK, go to step 4.



4. With the control unit still disconnected, make these input tests at the connector and fuse/relay box socket. • If any test indicates a problem, find and correct the cause, then recheck the system. • If all the input tests prove OK, the control unit must be faulty; replace it. Cavity A6

A12

Wire Test condition Fuse/relay Combination light box socket switch ON (~OO~) or (~D) (Jump battery voltage to 816 (RED/GRN) on automatic headlights off feature onl}') Under all conditions

A14 A20

RED

B3

RED/WHT and WHT/RED

B4

Under all conditions Combination light switch ON (~OO~) or (~D) (Jump battery voltage to 816 (RED/GRN) on automatic headlights off feature only) Adjusting dial rotated

Test: Desired resuh Check for voltage to ground: There should be battery voltage.


Check for continuity to ground: There should be continuity. Attach to ground: Dash lights should come on full bright.

Check for resistance between the B3 and B4 terminals: There should be 0-20 kQ at all times.

BACK

Possible cause if result is not obtained • Blown No. 10 (10 or 15A) fuse in the passenger's under-dash fuse/relay box • Faulty combination light switch • Faulty taillight relay • An open in the wire • Blown No. 13 (7.5A) fuse in the passenger's under-dash fuse/ relay box • An open in the wire • Poor ground (G401) • An open in the wire • An open in the wire

• Faulty dash light brightness controller • An open in the wire

22-113

Dash Lights Brightness Controller Controller Test 1. Remove the gauge assembly (A) (see page 22-68). RED/WHT

WHT/RED

B

2. Disconnect the 22P connector (B). 3. Measure resistance between the B4 and B5 terminals while rotating the adjusting dial. Resistance should vary from 0 to 20,000 ohms as the dial is rotated.

22-114

BACK

r--:'I I..!!:..I

Entry Light Control System Component Location Index IGNITION KEY SWITCH, KEY LIGHT

Test, page 22-120

CEILING LIGHT

Test, page 22-121 PASSENGER'S DOOR SWITCH




BACK

22-115

Entry Light Control System Circuit Diagram UNDER-HOOD BAITERY

~USEIRELAY

No.41 (100A)


BOX

No_54 (40A)

~-+~--~~--,,-o~~~--YEL------------------------~"--------~

IGNITION SWITCH

No.47 (20A)

No.l1 (7.5A)

No.42 (SOA) &...
WHTIYEL 7

:?-

~~

REDJGRN

BLKlYEL

IGNITION KEY LIGHT (LED)

WHTlBlK

I

~2TI~ ~X,lX)

, AllLiGHT RELAY (EX)

Y

3

DRIVER'S UNO ER·DASH FUS ElRELAY BOX

NO.9 (7.SA)

LIGHT SWITCH

6

WHTIBLU

CEILING LIGHT

l'

if

ti 0

'"

" .8

REDIBLK

BLKlWHT

YEL

~ .,

j

"

!!:.

-

A2 MULTIPLEX AI 5 CONTROL UNIT ~ BRN (Door) A17

BRNIRED

UN- ~ ,0 lOCK L--_+-.....I

2

DRIVER'S DOOR lOCK KNOB SWITCH

A6

AI

A24

Bl B9 C>-PNK __

MULTIPLEX CONTROL UNIT (Driver's) A13

A16

A17

BlUIWHT

GRN/ORN

GRYIYEL

I

IGNITION KEY SWITCH 3 (Closed: Key inserted)

DRIVER'S DOOR SWITCH (Closed: Door open)

BlK

I 1 G401

22-116

G401

BACK

lEFT REAfl DOOR SWITCH (Closed: Door open)

A21

A22

MULTIPLEX CONTROL UNIT (Passenger'5) AI4

AIS

GRNlWHT

GRN

PASSENGER'S

DOOR

SWITCH (Closed: Door open)

RIGHT REAR DOOR SWITCH (Closed: Door open)

r--:'I a.=:J Control Unit Input Test 1. Before testing the entry light control functions, troubleshoot the multiplex control system (see page 22-137). Multiplex Control Unit, Driver's: 2. Remove the driver's multiplex control unit from the driver's under-dash fuse/relay box, and disconnect its connector. 3. Inspect all connector and socket terminals to be sure they are making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. • If all terminals look OK, go to step 4.

Al

A2

A3

A4

A13 A14

A15

A16

-

A5

A6

A7

A8

A17

A18

A19

A20

-

All

A12

A9

Al0

A2l

A22 A23 A24

Fuse/relay box socket 4. With the driver's unit still disconnected, make these input tests at the fuse/relay box socket. • If any test indicates a problem, find and correct the cause, then recheck the system. • If all the input tests prove OK, go to step 5. Cavity A1

A6

A24

A13

A16 A17

Wire Fuse/relay box socket


Test: Desired result Attach to ground: The ignition key light should come on.

Combination light switch ON (Jump battery voltage to B16 (RED/GRN) on automatic headlights off feature only) Ignition switch ON (II)


Ignition key is inserted into the ignition switch Driver's door opened Left rear door opened


Check for continuity to ground: There should be continuity

Check for voltage to ground: There should be less than 1V. Check for voltage to ground: There should be less than 1V.

Possible cause if result is not obtained • Blown No. 47 (20A) fuse in the under-hood fuse/relay box • Blown LED • An open in the wire • Blown No. 10 (10 or 15A) fuse in the passenger's under-dash fuse/ relay box • An open in the wire • Faulty combination light switch

• Blown No.9 (7.5A) fuse in the driver's under-dash fuse/relay box • Faulty driver's under-dash fuse/ relay box • Faulty ignition key switch • Poor ground (G401) • An open in the wire • • • •

Faulty driver's door switch An open in the wire Faulty left rear door switch An open in the wire

(cont'd)

BACK

22-117

Entry Light Control System Control Unit Input Test (cont'd) Multiplex Control Unit, Passenger's: 5. Remove the passenger's multiplex control unit from the passenger's under-dash fuse/relay box, and disconnect its connector. 6. Inspect all connector and socket terminals to be sure they are making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. • If the terminals look OK, go to step 7.

Al

A2

A13 A14

A3

A4

A15 A16

r---

A5

A6

A7

A8

A17

A18

A19

A20

A9

-

A10

All

A12

A2l A22 A23 A24

Fuse/relay box socket 7. With the passenger's mUltiplex control unit still disconnected, make these input tests at the fuse/relay box socket. • If any test indicates a problem, find and correct the cause, then recheck the system. • If all the input tests prove OK, go to step 8.

Cavity

Wire

Test condition


A22




A21

Ceiling light switch in the middle position

Connect to ground: Ceiling light should come on.

A15

Passenger's door opened Right rear door opened

Check for voltage to ground: There should be less than 1 V. Check for voltage to ground: There should be less than 1 V.

A14

22-118

BACK

Possible cause if result is not obtained • Blown No.9 (7.SA) fuse in the driver's under-dash fuse/relay box • An open in the wire • Blown No. 11 (7.SA) fuse in the passenger's under-dash fuse/ relay box • Faulty ceiling light • An open in the wire • Faulty passenger's door switch • An oQen in the wire • Faulty right rear door switch • An open in the wire

r:-:'I I.!:..I Multiplex Control Unit, Door: 8. Remove the driver's door panel, and disconnect the 20P connector from the door multiplex control unit.

9. Inspect all connector and socket terminals to be sure they are making good contact. • Ifthe terminals are bent, loose or corroded, repair them as necessary, and recheck the system. • If the terminals look OK, go to step 10. L

Al

A2

All

A12

/ / / 1/ A4

A15


,J A6

A7

A8

A16

A17

A18

/ A19

AlO

l(

BlK/RED

10. Reconnect the connectors to the door multiplex control unit, and make these input tests at the connector. • If any test indicates a problem, find and correct the cause, then recheck the system. • If all the input tests prove OK, go to step 11. Cavity A17

Wire BlK/RED

Test condition Driver's door lock knob unlocked

Test: Desired result Check for voltage to ground: There should be less than 1 V.

Possible cause if result is not obtained • Faulty driver's door lock actuator • Poor ground (G401) • An open in the wire

11. If all the input tests prove OK, one of the control units must be faulty. Substitute a known-good control unit for the one that is most likely at fault, then recheck the system. If the system works properly, the original control unit is faulty; replace it. If there is still a malfunction, substitute a known-good control unit for the next most likely unit to be at fault, and recheck. If the system works properly, the original unit is faulty; replace it.

BACK

22-119

Entry Light Control System Ignition Key Light Test

Ignition Key Switch Test NOTE: For more key-in beeper information, refer to the circuit diagram (see page 22-79) and input test (see page 22-80).

1. Remove the steering column upper and lower covers (see page 17-25). 2. Disconnect the 7P connector.

When the ignition key is not removed, the key-in beeper in the driver's multiplex control unit senses ground through the closed ignition key switch. When you open the driver's door, the beeper circuit senses ground through the closed door switch. 1. Remove the steering column upper and lower covers (see page 17-25). 2. Disconnect the 7P connector.

111 12 13

J4I

51 6 1 7 11

3. The LED should come on when power is connected to terminal No.7, and ground is connected to terminal No.6.

4. If the LED does not come on, replace the ignition key switch.

3. Check for continuity between terminals No.1 and No.3 . • There should be continuity with the key in the ignition switch . • There should be no continuity with the key removed. 4. If continuity is not as specified, replace the ignition key switch.

22-120

BACK

r--:'I I.!!!!!..I Ceiling Light Test 1. Turn the light switch OFF.

6. If the continuity is not as specified, replace the ceiling light.

2. Carefully pry off the lens (A) with a small screwdriver. D

3. Remove the two mounting nuts (8) and the housing (C).

4. Disconnect the 3P connector (D) from the housing. 5. Check for continuity between the terminals in each switch position according to the table.

\

1

Terminal Position

5

\

0

OFF

0-

MIDDLE ON

0 l'

3

4

or l'

ro 1'"""\

'-'

'-'"

()

'-'" '-'

()

'-'" ......,

()

"""

4

3

BULB (8WI

BACK

22-121

Stereo Sound System Component Location Index DRIVER'S DOOR SPEAKER Replacement, page 22-125

AUDIO UNIT Removal, page 22-124 Connector Replacement, page 22-124

ANTENNA LEAD

REAR SPEAKERS Replacement, page 22-125

WINDOW ANTENNA Test, page 22-126 Repair, page 22-126

22-122

BACK

r--:'I l!:.I Circuit Diagram

BATTERY

No.42 (SOA)

No.41 (100A)

......

C±)-BLK


IGNITION SWITCH

UNDER·HOOD ~USEIRELAY BOX WHT

-§r

WHTiBLK

~O'8(7'5A)

ACC

YEUBLK

NO.54 (40A) YEL

~

I

~ No.9 (20A) ~~---------~

WINDOW ANTENNA • COMBINATION LIGHT SWITCH (OX, LX) • TAILLIGHT RELAY (EX)

WHTIRED

I

REDIBLK

ANTENNA LEAD

WHT/GRN

PASSENGER'S UNDER·DASH FUSEJRELAY BOX ACCESSORY SOCKET RELAY

I

BL

MULTIP~E;I

CONTROL UNIT (Passenge(s)

--l 1 :1 BLU

WHTIRED

ACCESSORY SOCKET

G581

10

4

AUDIO UNIT ('98-00 models)

e 18 GRYIWHT BLUIYEL

BRNIWHT RED/YEL

8

GRYIBLK

17

RIGHT REAR SPEAKER

DRIVER'S

\lj \lj ~

IDOOR SPEAKER

BLK

BLK

RED/GRN

BRN~LK

GRJIBLK

LEFT REA!'! SPEAKER

RED

BRNlBLK

BLU/GRN

BLU/GRN

PASSENGER'S

IDOOR SPEAKER

LEFT TWEETER

RED/GRN


RIGHT TWEETER

I GS02

I

L~

(With SI!QJIny alarm syslem)

BACK

22-123

Stereo Sound System Audio Unit Removal/Installation

Audio Unit Connector Replacement

SRS components are located in this area. Review the SRS component locations, precautions and procedures in the SRS section before performing repairs or service (see page 23-28).

When replacing an audio unit connector, match the wires to the cavities as listed in the following table. Cavities 1,3,11,12, and 13 are not used.

NOTE:

Cavity 2

Wire WHT/RED

4

BlU RED/YEl BLU/YEl RED/GRN

• Put on gloves to protect your hands. • Take care not to scratch the dashboard and related parts.

5 6 7


(+)

8

BlU/GRN

9 10 14* 15 16 17

RED/BlK WHT/GRN BlK BRN/WHT GRY/WHT BRN/BlK

18

GRY/BlK

19

RED

2. Disconnect the negative cable from the battery. 3. Remove the center panel (see page 20-86). 4. Remove the bolts, disconnect the audio unit connectors (A) and the antenna lead (B), then remove the audio unit. Fastener Locations ~:Boh,4

~ .~

5xO.8mm 9N.m

(0.9 kgf·m, 7lbf·ftl

Connects to ACC (Main stereo power supply) Security in Right rear sp_eaker (+) left rear speaker (+) Front passenger's speaker

B

BlK 20 * : '98-00 models

Right tweeter (+ ) Driver's door speaker (+) left tweeter (+ ) Lights-on signal Constant power Security out Right rear speaker (-) left rear speaker (-) Front passenger's door speaker (-) Right tweeter (-) Driver's door speaker (-) left tweeter (-) Multiplex control unit, driver's Ground (G502)

5. Install in the reverse order of removal, and note these items: • Make sure the audio unit connectors are plugged in properly, and the antenna lead is connected properly. • Enter the anti-theft code for the radio, then enter the customer's radio station presets.

22-124

BACK

::--::

1 121314 5 61718 9 10 1 111112113114 15 16117/18 19 20 1

r:-:'I t.=.I Speaker Replacement Rear

Door 1. Remove the front door panel (see page 20-8). 2. Remove the three screws (A), then disconnect the 2P (8) connector from the speaker (C).

1. Remove the two screws from the trunk side, then remove the speaker cover (A). A

----~/

B

c

/ Tweeter Carefully pry the tweeter (A) out of the dashboard, then disconnect the 2P connector (8) from the tweeter. A

/

2. Remove the four screws (8), disconnect the 2P connector (C) from the speaker (D), and remove the speaker.

BACK

22-125

Stereo Sound System Window Antenna Test

Window Antenna Repair

1. Wrap aluminum foil (A) around the tip of the tester probe (8) as shown.

NOTE: To make an effective repair, the broken section must be no longer than 1 inch. 1. Lightly rub the area around the broken section (A) with fine steel wool, then clean it with alcohol.

2. Touch 1 tester probe to the window antenna terminal (A) hear, and move the other tester probe along the antenna wires to check that continuity exists. Repair if continuity does not exist.

A\

I I I

-1

-

- t

c 2. Carefully mask above and below the broken portion ofthe window antenna wire (8) with cellophane tape (C). 3. Mix the silver conductive paint thoroughly. Using a small brush, apply a heavy coat of paint (A) extending about 1/8" on both sides of the break. Allow 30 minutes to dry.

U

[±j 0::

J 4. Check for continuity in the repaired wire. 5. Apply a second coat of paint in the same way. Let it dry 3 hours before removing the tape.

22-126

BACK

~

l!!!..I Window Antenna Coil Test 1. Remove the rear shelf, Coupe (see page 20-59), Sedan (see page 20-77). 2. Disconnect the connectors (A, B) from the window antenna coil (C).

3. Check for continuity between terminal 82 and body ground and between terminals A 1 and 81. If there is no continuity, replace the window antenna coil.

BACK

22-127

Clock Circuit Diagram UNDER-HOOD FUSE/RELAY BOX BATIERY

~

&--

No.4l (100A) No.42 (50A) BLK -+-C'1'"\...I>-....-
~

No.54 (40A)

IGNITION SWITCH

BLKlYEL

YEL

No.13 (7.5A) ~I--_...J

PASSENGER'S UNDER-DASH FUSE/RE~V

No.9 (7.5A)

BOX

-F

~,~, ~'Na~


BOX

• COMBINATION LIGHT SWITCH (OX, LX)

~

.~~,

mm1 1~ GAUGE ASSEMBLY

- ECMlPCM -GAUGE ASSEMBLY

3

CLOCK

S\ h'WJACK

I

<1i!I

LCD DISPLAY

(O.7W)

DRIVE~ 1 ______...._ - - - - - - - -..

CIRCUIT

1

, 4

5

RED

BLK

~


G50l

22-128

BACK

~

I.!!:..I Replacement 1. Remove the clock (A) from the center panel (B). B

\~A

111 I 2

TIT 41 511

2. Disconnect the 5P connector (C) from the clock. 3. Remove the clock. Terminals Cavity 1

Wire VEL

2

4

WHT/ VEL RED/ BLK RED

5

BLK

3

Connect to IG1 (Main clock power supply) Constant power Lights-on signal Multiplex control unit, driver's Ground (G501)

BACK

22-129

Horns Component Location Index UNDER-HOOD FUSE/RELAY BOX

r

000 0 0 [-- D DDD DOD I DOD [J

Cl Cl Cl ClOOD ~. D ~ 0 oc:JDJ

fQCJaL9

HORN SWITCH

page 23-278

HORN RELAY

Test. page 22-52

HORNS

Test. page 22-131

22-130

BACK

~

I..::.J Horn Test/Replacement

Circuit Diagram

1. Open the hood.

BATIERY

~

2. Remove the horn cover (A). C

BLK

i WHTtEL

~


No.47 (20A)

~-- ----------}l1

HORN RELAY

B

• BRAKE LIGHT CIRCU IT • KEY INTERLOCK SOLEN010 'ABSCONTROL UNIT

I

LTGRN/BLU

BLU/RED

BLu/RED

3. Disconnect the 1P connector (B), and remove the horn (e).


CABLE REEL

CRUISE CONTROL SETIRESUME/ CANCEL SWITCH

H

HORN (Low)

H

HORN (High)

4. Test the horn by connecting battery power to the terminal (A) and grounding the bracket (B). The horn should sound. B

HORN SWITCH

A

5. If it fails to sound, replace it.

BACK

22-131

Accessory Power Socket Circuit Diagram BATTERY

~ BlK

No.41 (10GA) UNDER-HOOD FUSE/RELAY BOX No.42 (50A)

NO.54 (40A)

IGNITION SWITCH

WHT/BlK

YEl

NO.8 (7.SA)

No.9 ;) (20A)

I

YEUBlK

~2--------------~

WHT!RED

~

AU DIO UNIT

WHT/RED

-(~ '--

22-132

ACCESSORY SOCKET

-

BlK

BlK

1

1

G501

G581

BACK

DRIVER' S UNDER- DASH .USEJRELAY BOX


PASSENGER'S UNDER-DASH FUSE/RELAY

BOX

r--:'I

~

Test/Replacement 1. Remove the center console (see page 20-83). 2. Disconnect the 2P connector. 3. Inspect the connector terminals to be sure they are all making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. • If the terminals look OK, go to step 4.

8

' 2

~BLK

~ --------.- WHTIRED

4. Turn the ignition switch ACC (I), and check for voltage between the No.1 and No.2 terminals. • There should be battery voltage. • If there is no battery voltage, check for: - blown No.8 (7.5 A) fuse in the driver's underdash fuse/relay box. - faulty accessory socket relay. - poor ground (G501, G581). - an open in the wire. - blown No.9 (20 A) in the passenger's underdash fuse/relay box.

BACK

22-133

Multiplex Control System Component Location Index MULTIPLEX CONTROL UNIT, PASSENGER'S (Has built-in the beeper) IGNITION KEY LIGHT


MULTIPLEX CONTROL INSPECTION CONNECTOR

22-134

BACK

r--:'I I.!:..I Circuit Diagram (Power, Ground, Communication Lines) UNDER·HooD FUSE/RELAY BOX BATTERY

e±>-

NO.41 (I00A) BLK- r---v

IGNITION SWITCH

No.42 (SUA)

BAT

WHT

IGI

NO.51 (40A)

~

WHT/BLU

No.54 (40A)

BLKlYEL

~

VEL

No.47 (20A)

I


~..,.;.

~ No.13 (7.5A)

~ NO.9 (7.5A)


WHTIYEL

r-

7

r-

~~

i. 0

IGNITION KEY LIGHT (LED)

:~

!'j

S>

1:;'

"".'"

'iii

' -~

::J

!:.

6

WH TIYEL

WHTIBLK

AI

AI

WHTIYEL

WHTIYEL

A24

A12

WHTIBLU

YEL

A24

A22

BUZZER A15

MULTIPLEX CONTROLUNIT (Ooor) A12

A'9

A2

R

~BRN--C)

A2

Bll

Bl


A13

A14

B9


>-- PNK--C

= ~

A15

B22

A2

AS I

5\

" 0

S>

1:;'

BLUIWHT

GRiHT

BLK

I.

~~ BLK

BLK

IGNITION KEY SWITCH

~-o

-

r

BLK

11 1 G551

G503

No.15 (20A) ~

,---0

Br

G401

POWER WINDOW RELAY

::J

!:.

BLK

--------~~

BlK

1 G401

BACK


MULTIPLEX CONTROL INSPECTION CONNECTOR

T BlK

BLK

11 G504

Gsal

22-135

Multiplex Control System System Description Wake-up and Sleep

The multiplex Control System has four internal functions: • Multiplexing (send multiple signals over shared wires) • Wake up/sleep (runs at full power only on demand to reduce battery draw) • Fail-safe (fixes or ignores faulty signals) • Self-diagnosis (Mode 1 for the system, Mode 2 for input lines) The system controls the function ofthe following circuits • • • • • • • • • • • • •

Engine Oil Pressure Indicator Seat Belt Reminder Lights-on Reminder Key-in Reminder Key Light Timer Dash Lights Brightness Control Entry Light Control (EX, SE) (ignition key light and ceiling light) Automatic Lights-off (EX) Power Door Locks Power Window (including key-off timer operation) Wiper/Washer (including speed responsive intermittent wiper) Keyless Entry/Security Alarm (EX, SE) Interlock system (see page 14-144).

Multiplex Communication To reduce the number of wire harnesses, digital signals are sent via shared mUltiplex communication lines rather than sending normal electrical signals through individual wires.

The multiplex control system has "wake-up" and "sleep" functions to decrease parasitic draw on the battery when the ignition switch is OFF. • In the sleep mode, the multiplex control unit stops the functions (communication and CPU control) when it is not necessary for the system to operate. • As soon as any operation is requested (for example, door is unlocked), the related control unit in the sleep mode immediately wakes up and begins to function. This control unit also sends a wake-up signal to the other control units via the communication lines. • When the ignition switch is turned OFF, and driver's or front passenger's door opened, there is about a 10 second delay before the control units go from the wake-up mode to the sleep mode. • If any door is open, the sleep mode will not function. • If a key is in the ignition switch, the sleep mode will not function. • When in sleep mode, the current draw is reduced from 70 - 80 mA to less than 10 mAo

Fail-safe To prevent improper operation, the multiplex control system has a fail-safe function. In the fail-safe mode, the output signal is fixed when any part ofthe system malfunctions (for example, a faulty control unit or communication line). Each control unit has a hardware fail-safe function that fixes the output signal when there is any CPU malfunction, and a software fail-safe function that ignores the signal from the malfunctioning control unit and allows the system to operate normally.

• The input signals from each switch are converted to digital signals at the central processing unit (CPU). The digital signals are sent from the transmitter unit to the receiver unit as serial signals. • The transmitted signal is converted to a switch signal at the receiver unit, and it operates the related component. • There are exclusive communication lines between each of the multiplex control units: - Door ~ Driver's (between the door and the driver's multiplex control units) Wire color: BRN - Driver's ~ Passenger's (between the driver'S and the passenger's multiplex control units) Wire color: PNK The control units always communicate via these lines when the system is operating, and they stop communicating when the system is OFF.

22-136

BACK

~

I.!!!!:..I Troubleshooting 5. About 1 second after you go into self-diagnosis Mode 1, the ignition key light and beeper indicate the DTC, and repeat it every 3 seconds. If there is a code, it will blink/beep, pause, then repeat the code as long as the ignition switch is ON (II). If there is more than one DTC, the system will indicate them in ascending order, beginning from the DTC with the lowest numerical value.

Special Tools Required:

SCS Service Connector 07WAZ-001010A 1. Check the No.9 (7.5A) fuse in the driver's underdash fuse/relay box, and the No. 13 (7.5A) fuse in the passenger's under-dash fuse/relay box.

Is the fuses OK? YES - Go to step 2.

Does the ignition key light blink and the beeper beep?

NO-Find and repair the cause of the blown fuse .• YES- There is a DTC. Count the blinks/beeps to find your DTC in the table, then go to step 9 and check the communication lines.

2. Connect the special tool to the multiplex control inspection connector (A). A

DTC

Cause

1

The driver's unit is not able to receive signals from the door unit. The driver's unit is not able to receive signals from the passenger's unit. Malfunction in the driver'S unit. Signals from each unit do not match. (LX and EX control units are not interchangable) The passenger's unit is not able to receive signals from the other units. The door unit is not able to receive signals from the other units.

2 3 4

5

6 3. Turn the ignition switch ON (II). Ifthe driver's seat belt is unbuckled, the seat belt reminder will beep five times.

NO-Ifthe system goes into Mode 1 as described in step 4, and there is not repeating DTC. Go to step 11.

4. Check self-diagnosis function Mode 1 for a diagnostic trouble code (DTC). After about 5 seconds, the ignition key light should come on and the beeper should beep for 2 seconds, then go off for 0.2 seconds, then blink and beep for 0.2 seconds. This means that you are in Mode 1 of the self-diagnosis function.

6. Remove the special tool from the SCS connector. 7. Check for continuity between the No.1 terminal of the inspection connector and the A15 terminal in the driver's multiplex control unit.

Is there continuity? o o

If the system enters Mode 1, go to step 5. Ifthe system does not enter Mode 1, see ifthe SCS circuit is working properly. Go to step 6.

YES- Go to step 8. NO- Replace the driver's under-dash fuse/relay box, and recheck for DTC's.•

0.2 sec.

ON

OFF

2 sec.

0.2 sec.

(cont'd)

BACK

22-137

Multiplex Control System Troubleshooting (cont'd) 8. Check for continuity between the No.3 terminal of the inspection connector and body ground G401.

Is there continuity? YES-Ifthere is still no Mode 1 confirmation, replace the driver's multiplex control unit and try again. After replacing the driver'S multiplex control unit the system confirms Mode 1 and there are no codes, go to step 12. NO- Repair open in the wire, and recheck for DTC's .• 9. With the ignition switch OFF, check for continuity according to the table.

Communication Line Door unit to Driver'S unit Driver's unit to Passenger's unit

Wire BRN PNK

Continuill' YES YES


YES - Go to step 10. NO-Check for an open in the wire .• 10. Turn the ignition switch ON (II), and check for voltage between the communication line and ground.

Communication Line Door unit to Driver's unit Driver's unitto PassenjJer's unit

Wire BRN PNK

VoJta~e

3.5-9.5 3.0-10.0

Does the voltage match the table?

11. Shift to the sleep mode: o Turn the ignition switch OFF and remove the key. o Remove the special tool from the SCS connector. o Cancel the key-off operation timer in the power window system by opening and closing one of the doors. o Make sure that the exterior lights are off. If you do not operate any switches related to the multiplex control units within 1 minute after meeting the above conditions, the system function shifts to the sleep mode. (All of the switches must be turned OFF except door lock knob switches). Go to step 12. 12. Confirm the sleep mode: o Check for voltage to ground on the BRN wire and PNK wire. There should battery voltage in the sleep mode. o Check the parasitic draw at the battery while shifting to the sleep mode. Amperage should change from about 70 to 80 mA to less than 20mA. o If the vehicle does not go into the sleep mode, carefully perform Mode 2 test (see step 14), and check for faulty input for example a key cylinder switch keeping the system awake. 13. Confirm the wake up mode. o When any switch in the multiplex system is turned on, it wakes up its related control unit which, in turns wakes up the other units. After one minute it will return to sleep mode again If the switch is returned to the original position. o When the ignition switch is turned ON (II), all of the multiplex control units wake up at the same time without "talking" to each other through the communication lines.

YES-Communication lines are OK. Go to step 11. NO- Repair the line according to the following .• o If the voltage is too high: - Check for a short to another wire with voltage. - Check for poor contact in the connectors at each control unit connector to the wire. o If the voltage is too low: - Check for a short to ground or to another wire. - Check for poor connections at each control unit connector to the wire. - Faulty circuit in one of the multiplex control units connected to the wire. o If anyone or all the control units are completely inoperative, perform the multiplex control unit input test (see page 22-141).

22-138

BACK

Ifthe wake up mode is confirmed on the first switch tested, and there is no problem with any other switch operation, the system is working correctly. Go to step 14. After confirming a problem in sleep mode, look in the following tables for the switch most closely related to the problem you may be having. Operate that switch and see if its control units wake up. Also use Mode 2 step 14 to confirm switch inputs. NOTE: If any control unit is faulty and will not wake up, several functions (locks, windows, etc.) of the system will malfunction at the same time.

r--:'I

~

In each table below, the control unit is followed by a list of the switches and input signals that can wake it up. Multiplex Control Unit, Passenger's: No.9 (7.5A) driver's fuse No. 13 (7.5A) passenger's fuse Communication lines (BRN, PNK) Front passenger's door lock knob switch (LOCK) Front passenger's key cylinder switch (LOCK) Front passenger's door lock knob switch (UNLOCK)* Front passenger's key cylinder switch (UNLOCK) Front passenger's door lock switch (LOCK/UNLOCK) Front passenger's door switch (OPEN) Right rear door switch (OPEN) Right rear door lock knob switch (UNLOCK)* Keyless transmitter (LOCK) Keyless transmitter (UNLOCK) Keyless transmitter (TRUNK) Security input for the radio. Test by disconnecting and reconnecting the radio connector. *When testing the passenger's door lock knobs, be sure all other passenger lock knobs are in the locked position. Multiplex Control Unit, Driver's: No.9 (7.5A) driver's fuse No. 13 (7.5A) passenger's fuse Communication lines (BRN, PNK) Combination switch Driver's door switch (OPEN) Left rear door switch (OPEN) Left rear door lock knob switch (UNLOCK) Trunk latch switch (OPEN) Trunk key cylinder switch(UNLOCK) Engine hood switch (OPEN)

14. With the system in Mode 1, and the ignition switch still in the ON (II) position, disconnect the special tool from the multiplex control inspectin connector for about 5 to 10 seconds, then reconnect it. The ignition key light should come on and the beeper should beep for 2 seconds, then blink and beep twice more at 0.2 second intervals. This means the system has gone from Mode 1 to Mode 2. Go to step 15. Mode 2:

IGNITION KEY LIGHT

..

2 sec.

_

0.2 sec.

ON

OFF

-

_

0.2 sec.

NOTE: To cancel Mode 2, disconnect the SCS service connector from the multiplex control inspection connector for 10 seconds or more, or turn the ignition switch OFF.

15. Look in the following tables for the switch most closely related to the problem. Test all the switches in the following order, otherwise the test results maybe inaccurate. While still in Mode 2, operate that switch to test the wire, switch, and its control unit input. If the circuit is OK, the ignition key light should blink once and the beeper should beep once. If the circuit is faulty, there will be no indication.

Multiplex Control Unit, Door: No.9 (7.5A) driver's fuse No. 13 (7.5A) passenger's fuse Communication lines (BRN, PNK) Driver's door lock knob switch (LOCK) Driver's door key cylinder switch (LOCK) Driver's door lock knob switch (UNLOCK) Driver's door key cylinder switch (UNLOCK) Driver's door lock switch (LOCK/UNLOCK)

Does the ignition key light blink and beeper beep? YES- The circuit is OK. Test the other switches. NO-Go to step 16. In each of the following tables, the control unit is followed by list of circuits that it can check in Mode

2. A second key is necessary to test the key cylinder switches. If only one key is available, cut a second key from a non-immobilizer type key blank for the test.

(cont'd)

BACK

22-139

Multiplex Control System Troubleshooting (cont'd) Multiplex Control Unit, Passenger's Test all the switches in the following order, otherwise the test results maybe inaccurate: Front passenger's door lock knob switch (LOCK) Front passenger's key cylinder switch (LOCK) Front passenger's door lock knob switch (UNLOCK)* Front passenger's key cylinder switch (UNLOCK) Front passenger's door lock switch (UNLOCK/LOCK) Right rear door lock knob switch (UNLOCK)* Front passenger's door switch (OPEN) Right rear door switch (OPEN) Keyless transmitter (LOCK) Keyless transmitter (UNLOCK) Keyless transmitter (TRUNK) Security input for the radio. Test by disconnecting and reconnecting the radio connector. *When testing the passenger's door lock knobs, be sure all other passenger lock knobs are in the locked position.

16. Check 2 or 3 more circuits listed for that control unit.

Multiplex Control Unit, Driver's Dash lights brightness controller (ROTATE) Driver's door switch (OPEN) Left rear door switch (OPEN) Left rear door lock knob switch (UNLOCK) Trunk latch switch (OPEN) Trunk key cylinder switch (UNLOCK) Driver's seat belt switch (BUCKLED) Windsheild wiper/washer switch (except MIST switch) Brake pedal position switch (Brake switch) (PRESSED) Parking brake switch (ON) Hood switch (OPEN) Headlight or combination switch (ON) Multiplex Control Unit, Door Test all the switches in the following order, otherwise the test results maybe inaccurate: Driver's door lock knob switch (LOCK) Driver's key cylinder switch (LOCK) Driver's door lock knob switch (UNLOCK) Driver's key cylinder switch (UNLOCK) Driver's door lock switch (LOCK/UNLOCK) Power window master switch (not the passenger's switches) The key cylinder switches should only beep/flash when turned to LOCK or UNLOCK. If they beep/flash when returning to the center position, the switch is defective or misaligned. Adjust or replace the affected key cylinder switch.

22-140

BACK

Does the ignition key light blink and the beeper beep for each additional circuit?

VES- The additional circuits are OK. Repair the short or open in the circuit that failed the test in the proceeding step. Refer to the testIs) for that individual system .• NO-Multiple failed circuits can mean thatthe control unit has failed, but without triggering a DTC. Test a few more circuits. If they also fail, substitute a known-good control unit, then recheck. If the sytem works properly, the original control unit is faulty; replace it. If there is still a malfunction, substitute a known-good control unit for the next most likely faulty control unit, then recheck. If the sytem works properly, that control unit is faulty; replace it.•

~

t.=!..I

Multiplex Control Unit Input Test NOTE: If the multiplex control unit is replaced, never use a multiplex control unit other than the one which is manufactured by the original multiplex control unit maker. Using other multiplex control units, manufactured by a non-original maker could cause a malfunction of communication among the multiplex control unit. Door Unit:

1. Remove the driver's door panel, and disconnect the connectors from the door multiplex control unit. 2. Inspect the connector and socket terminals to be sure they are all making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. • If the terminals look OK, go to step 3. 3. Make the following input tests at connector A. • If a test indicates a problem, find and correct the cause, then recheck the system. • If all the input tests prove OK, go to step 4.


(cont'd)

BACK

22-141

Multiplex Control System Multiplex Control Unit Input Test (cont'd) Cavity A1

Wire WHT/yEl


Test: Desired result Check for voltage to ground: There should be battery voltage.

A2

GRN/WHT



Under all conditions Under all conditions

Check for continuity go ground: There should be continuity. Check for continuity to ground: There should be continuLty~

A12

BlK

A19

BlK

22-142

BACK

Possible cause if result is not obtained • Blown No. 13 (7.5A) fuse in the passenger's under-dash fuse/ relay box • An open in the wire • Blown No. 15 (20A) fuse in the passenger's under-dash fusel relay box • Blown No. 54 (40A) fuse in the underhood fuse/relay box • An oJ:!en in the wire • Poor ground (G401) • An oJ:!en in the wire • Poor ground (G551) • An open in the wire

r:-:'I

~

Passenger's Unit: 4. Remove the passenger's multiplex control unit from the passenger's under-dash fuse/relay box. 5. Inspect the connector and socket terminals to be sure they are a" making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. • If the terminals look OK, go to step 6. 6. Make the following input tests at connector B and the fuse/relay box socket. • If a test indicates a problem, find and correct the cause, then recheck the system. • If a" the input tests prove OK, go to step 7.


PASSENGER'S MULTIPLEX CONTROL UNIT CONNECTOR B

Al

AZ

A3

A4

AS

A6

A7

A8

A9 AID All AIZ

A13 A14 A16 A16 I-- A17 A18 A19 AZO f..- All AZZ AZ3 AZ4

PASSENGER'S UNDER-DASH FUSE/RELAY BOX SOCKET

Cavity A24


A8 A22

B22

BLK

Test condition Under a" conditions


Under a" conditions Ignition switch ON (")

Check for continuity to ground: There should be continuity. Check for voltage to ground: There should be battery voltage.

Under a" conditions


BACK

Possible cause if result is not obtained • Blown No. 13 (7.5A) fuse in the passenger's under-dash fuse/ relay box • Blown No. 54 (40A) fuse in the under-hood fuse/relay box • An open in the wire • Poor ground (G581) • An open in the wire • Blown No.9 (7.5A) fuse in the driver'S under-dash fuse/relay box • Blown No. 42 (50A) fuse in the under-hood fuse/relay box • An open in the wire • Poor ground (G504) • An open in the wire (cont'd)

22-143

Multiplex Control System Multiplex Control Unit Input Test (cont'd) Driver's Unit: 7. Remove the driver's multiplex control unit from the driver's under-dash fuse/relay box. 8. Inspect the connector and socket terminals to be sure they are all making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. • If the terminals look OK, go to step 9. 9. Make the following input tests at connector B and the fuse/relay box socket. • If a test indicates a problem, find and correct the cause, then recheck the system. • If all the inputtests prove OK, troubleshootthe Multiplex Control System (see page 22-137).


Cavity A12

Test condition Wire Fuse/relay Under all box socket conditions

A14 A24

A13

A1

A15

B11

22-144

BLK


Under all conditions Ignition switch ON (II)


Ignition key is inserted into the tgnition switch Under all conditions


Short the multiplex control inspection connector terminals. Under all conditions


Attach to ground: Ignition key light should come on.


BACK

Possible cause if result is not obtained • Blown No. 13 (7.5A) fuse in the passenger's under-dash fuse/relay box • Blown No. 54 (40A) fuse in the under-hood fuse/relay box • An open in the wire • Poor ground (G401) • An open in the wire • Blown No.9 (7.5A) fuse in the driver's under-dash fuse/relay box • Blown No. 42 (50A) fuse in the under-hood fuse/relay box • An open in the wire • Faulty ignition key switch • An open in the wire • Poor ground (G401) • Blown No. 47 (20A) fuse in the under-hood fuse/relay box • Blown LED • An open in the wire • Poor ground (G401) • An open in the wire • Faulty driver's fuse/relay box • Poor ground (G503) • An open in the wire

r--:'I

t.=!..I

Power Mirrors Component Location Index

POWER MIRRORS Function Test. page 22-148 Test. page 22-150 Replacement. page 20-35 Mirror Actuator Replacement. page 22-151

/

POWER MIRROR SWITCH Test. page 22-149

BACK

22-145

Power Mirrors Circuit Diagram - USA without Defogger UNDER-HOOD FUSEIRELAY BOX

<±r +

BATTERY

-&-


IGNITION SWITCH

No.41 (1OGA) No.42 (SOA) BLK -t-o(~7"'\..D---or"\..o--+-WHT

BAT

ND.4(7.5A) YEL

0-...00-1-.....,

IG2

YEUBLK

POWER MIRROR SWITCH

UP RIGHT

LEFT

,,-------------LEFT 4

7

8

RIGHT MIRROR

2

2 LEFT

e

BLUlWHT

2

YELlWHT

LEFT

UP

10

BLK

BLUlGRN

0

RIGHT

9

BLUIWHT

LEFT MIRROR

\

LEFT

RIGHT

0

0

0 0

UP

BLUJORN

G5S1

22-146

BACK

~ ~ Circuit Diagram - Canada with Defogger


&+

BATTERY

-@-


IGNITION SWITCH

No.41 (100A) No.42 (SOA) BlK ---+r--v--C::T"'\J>---C::T"'\J>--1I---WHT

BAT

No.4 (7.SA) YEl -+-~~

I

IG2

. . - - - - YEUBLK

-~P-------

YEUBlK

_____...II

POWER MIRROR SWITCH

3

LEFT

RIGHT

~

~

'V I I

I

il\ lY

DEFOGGER SWITCH

....,..

-Y'

J

'IC)'

I

ORNlWHT

JTRN LEFT MIRROR

7

BLUIWHT

LEFT (

2

~~I~~ UP

RIGHT

DEFOGGER

RIGHT

9

8

YELIWHT

10

2 BLK

ORNlWHT

S

-+-------r---~

4

4

------------------l " RIGHT

LEFT

6

A

OR!HT RIGHT MIRROR

5

2

UP

6

RIGHT

DEFOGGER

6 BLK

.......

.......

......

G551

G581

G551

BACK

22-147

Power Mirrors Function Test Left mirror

1. Remove the driver's door panel (see page 20-8).

6. Connect the No.1 terminal to the No.7 terminal, and the No.4 (or No.9) terminal to body ground with jumper wires. The left mirror should tilt down (or swing left) with the ignition switch ON (II). o

~

~ ~-----

VEl/BlK

(Canada model)

BlU/WHT

o

o


If the mirror does nottilt down (or does not swing left), check for an open in the BLU/WHT (or BLU/ ORN) wire between the left mirror and the 10P connector. If the wire is OK, check the left mirror actuator. If the mirror neither tilts down nor swings left, repair the BLU/GRN wire. If the mirror works properly, check the mirror switch.

Right mirror 7. Connect the No.1 terminal to the No.8 terminal, and the No.4 (or No. 10) terminal to body ground with jumper wires. The right mirror should tilt down (or swing left) with the ignition switch ON (II).

BLU/ORN

2. Disconnect the 1OP connector from the power mirror switch.

o

3. Choose the appropriate test based on the symptom: o o

o o

Both mirrors don't work, go to step 4. Left mirror doesn't work, go to step 6. Right mirror doesn't work, go to step 7. Defogger doesn't work (Canada), go to step 8.

o

o

If the mirror does not tilt down (or does not swing left), check for an open in the BLU/WHT (or LT GRN) wire between the right mirror and the 10P connector. If the wi re is OK, check the right mirror actuator. If the mirror neither tilts down nor swings left, repair the YEL/WHTwire. If the mirror works properly, check the mirror switch.

Both mirrors Defogger (Canada) 4. Check for voltage between the No.1 terminal and body ground with the ignition switch ON (II). There should be battery voltage. o

o

If there is no battery voltage, check for: - blown No.4 (7.5 A) fuse in the driver's underdash fuse/relay box. - an open in the YEL/BLK wire. If there is battery voltage, go to step 5.

8. Connect the No.3 and No.6 terminals with a jumper wire, and check for voltage between the No.3 terminal and body ground. There should be battery voltage and both mirrors should warm up with the ignition switch ON (II). o

5. Check for continuity between the No.2 terminal and body ground. There should be continuity. o o

o

If there is no continuity, check for: - an open in the BLK wire. - poor ground (G551). Ifthere is continuity, check both mirrors individually as described in the next column.

22-148

o

BACK

If there is no voltage or neither warms up, check for: - an open in the YEL/BLK and ORN/WHT wires. - blown No.4 (7.5 A) in the driver's under-dash fuse/relay box. - poor ground (G551, G581). If only one fails to warm up, check its defogger. If both fail to warm up, check the defogger switch.

r--:'I l!!:.I Power Mirror and Mirror Defogger Switch Test 1. Remove the driver's door panel (see page 20-8).

3. Check for continuity between the terminals in each switch position according to the table. Mirror Switch:

1\

Terminal Position

1

\

2

4

7

9

8

10

~

UP DOWN

0-

L LEFT

""

RIGHT

'"'

ro ~

r.

UP DOWN

0- :-0

R

LEFT RIGHT

Defogger Switch (Canada):

1\

Terminal

Position ON

\

3

6

0

D

OFF

4. If the continuity is not as specified, replace the power mirror switch.

BACK

22-149

Power Mirrors Power Mirror Actuator Test 1. Remove the door panel (see page 20-8).

3. Check actuator operation by connecting power and ground according to the table.

2. Disconnect the 3P or 6P connector (A) from the power mirror (B).

1\

USA:

Terminal Position \

141

TILT UP

ffi

TILT DOWN SWING LEFT SWING RIGHT

1

e

2

151

3

161

8 (f) (f)

e

(f)

II: Canada

Defogger Test ICanada) 4. Check for continuity between the No.1 and No.2 terminals of the 6P connector. There should be continuity. 5. If the mirror fails to work properly, replace the mirror actuator.

Canada:

22-150

BACK

r--:'I I.!!!..I Power Mirror Actuator Replacement - Sedan 1. Remove the power mirror from the door (see page 20-35), and disconnect the 6P or 3P connector.

6. Pry off holder (A) from the housing (B). B

/

2. Cut the wire harness (A) with wire cutters.

7. Remove the three screws (A) and the actuator (B) from the housing.

3. Remove the seat base (B).

/E

4. Protect the mirror housing with shop towel (A). 5. Insert the screwdriver (B) along holder ramp (C), and placing flat blade underneath adapter ear (D) at end of ramp. Be careful not to damage the mirror housing.

A

c

o

8. Prying the wire clip (C) with a screwdriver (E). 9. Pull the wire (D) from the housing.

(cont'd)

BACK

22-151

Power Mirrors Power Mirror Actuator Replacement - Sedan (cont'd) Canada: '98-00 models

10. Install in the reverse of removal. Replace the seat base and three screws with new one. 11. Insert the terminals into the connector in the original arrangement as shown below.

Left

BLK/WHT

Right

BLU/RED

BLK/WHT

+

+

+

BETIffi t +

+

VEL/WHT VEL/BLK VEL/RED

BLU/RED

+

~ ~ + t +

VEL/WHT BLU/BLK BLU/GRN

View from wire side

'01-02 models: Left

BLK/WHT

USA: '98-00 models

BLU/RED

BLK/WHT

BLU/RED

+

+

+

+

Right

Left

1f7l 3

1f7l3

1

t

VEL/JHT VtL/BLK VEL/RED

+ VEL/WHT

t

BETIffivt GtN r

BLU

+ BLU/BLK

GtN r

WHT

View from wire side

12. Operate the power mirror to check that the actuator works smoothly.

'01-02 models:

Right

Left

BETIffivt

BLU/GRN

View from wire side

View from wire side

22-152

Right

BACK

r--:'I I.!!!:..I Power Mirror Actuator Replacement - Coupe 1. Remove the power mirror from the door (see page 20-35), and disconnect the connector.

5. Remove the 3 screws (A) and the actuator (8).

2. Cut the wire harness with wire cutters.

A

6. Route the wire harness (A) of the new actuator through the hole in the bracket (8).

3. Record the terminal locations and wire colors. 4. Remove the mirror holder (A) from the mirror housing (8). Gently pull it out by hand.

(cont'd)

BACK

22-153

Power Mirrors Power Mirror Actuator Replacement - Coupe (cont'd) 7. Insert the terminals into the connector in the original arrangement as shown below. USA:

Right

left

I

f

IzI r

GRN

3

\

IzI I f \

I

I

VEL

3

GRN

r

VEL BRN [ORN] '01-02 models

RED [GRV] View from wire side

Canada: left

Right

BlK

BLK

BlK

BlK

\

I

\

I

~ G~

!

RED [BLU]

~El

~ G'N

f V~l

BRN [WHT] '01-02 models

View from wire side

8. Apply tape to seal the intersection of the wire harness. 9. Reassemble in the reverse order of disassembly. Be careful not to break the mirror when reinstalling it to the actuator. 10. Reinstall the mirror assembly to the door. 11. Operate the power mirror to ensure smooth operation.

22-154

BACK

r--:'I

~

Moonroof Component Location Index

MOONROOF SWITCH Removalrrest, page 22-157 KEY -OFF TIMER CIRCUIT [In the multiplex control unit (passenger's)] Input Test, page 22-170 MOONROOF MOTOR Test, page 22-157 Replacement, page 20-65 MOONROOF POSITION SWITCH Adjustment, page 20-70

MOONROOFCLOSERELAY rWire colors: GRN/RED, GRN, LWHT/YEl, BlK, GRN/RED Test, page 22-52 MOONROOF OPEN RELAY rWire colors: GRN/YEl, GRN, LWHT/YEl, BlK, GRY/YEl Test, page 22-52

]

BACK

22-155

Moonroof Circuit Diagram MULTIPLEX CONTROL UNIT (Driver's)

UNDER-HOOD FUSE/RELAY BOX BAlTERY

<±>-

No.41 (10DA)

No.51 (4D_A)

( Ker-olllimer )

•

BlK

cirQlh

WHTlBlU -

~~------------------~

~ NO.7 (20A)

ND.1

~ (3OA)

~

WHTIYEl

GRN

BLK

I

f

GRN

BlK WHTIYEl

POWER WINDOW RELAY

GRN

BLK

BLK

MOONROOF OPEN RELAY

WHTlYEl

MOONROOF CLOSE RELAY MOON ROOF MOTOR

GRNlYEl GRY/YEl

1 ...___ "'1"@.~1,-2___... .;..1

,, , , GRYIYEl

OPEN

CLOSE OPEN

3 GRYIRED

CLOSE

2

YEURED

4

6

CLOSE

• COMBINATION LIGHT SWITCH (DX, LX) , TAllLlGHi RELAY (EX)

Y

REDlBlK

3

LIGHT (D.56Wx2)

I

2

MOONROOF SWITCH

BlK

BlK

1 G501

22-156

MULTIPLEX

CONTROL UNIT (Passenger's)

G501

BACK

1 G581

PASSENGER'S UNDER-DASH FUSElRE:LAY BOX

r--:'I I.!::.J Switch Test

Motor Test

NOTE: The moonroof can still be operated for about 10 minutes after the ignition switch is turned from the "II" to the "I" or "0" positions, as long as neither of the doors have been opened. This provides a convenience to parked occupants while offering a degree of security against unwanted or accidental moonroof operation.

1. Remove the headliner (see page 20-79). 2. Disconnect the 2P connector from the moonroof motor.

1. Remove the driver's dashboard lower cover (see page 20-84). 2. Carefully pry out the switch from the dashboard, and disconnect its connector. Terminal side of male terminal

3. Check the motor by connecting power and ground according to the table.

1\

Terminal

Position


1\ Terminal Position

\

-8-

CLOSE TILT OPEN

3

1

0-

-0

l€)-

2

4

5

0- 4J 0 -0 0

\

1

OPEN

G)

CLOSE

e

2

e G)

4. If the motor does not run, replace it. NOTE: See closing force check (see page 20-71) for motor clutch test.

6

-0

4. If the continuity is not as specified, replace the switch.

BACK

22-157

Rear Window Defogger Component Location Index

REAR WINDOW DEFOGGER SWITCH [ Rear window defogger switch is ] built into heater control panel

REAR WINDOW DEFOGGER Function Test, page 22-160 Defogger Wire Repair, page 22-160

WINDOW ANTENNA COIL Test, page 22-127

22-158

BACK

r--:'I l!!:.I Circuit Diagram IGNITION SWITCH

UNDER-HOOD FUSE I RELAY BOX BATIERY (±)--BLK

No.41 (100A)

No.42 (50A)

l

~3(40A)

WHT----§-AT YEL--_ IG2 .....-I~---.

~

'U

i

No.3 (7.5A)


I

BLKlYEL

BLKlYEL

WHTIGRN


REAR WINDOW DEfOGGER RELAY

~t-----------------18

B~KlYEL

BRNIYEL

BLKlGRN

2

4

HEATER CONTROL PANEL ( Rear window defogger) sw~ch and defogger timer circu~ buitt into neater control panel

~ REAR WINooW DEFOGGER SWITCH INDICATOR (LED)

9 A1

WINDOW ANTENNA COIL

82

B1

BLK

BLKlGRN

BLK

e REAR WINDOW DEFOGGER

G401

BACK

22-159

Rear Window Defogger Function Test

Defogger Wire Repair

NOTE: Be careful not to scratch or damage the defogger wires with the tester probe.

NOTE: To make an effective repair, the broken section must be no longer than one inch.

1. Check for voltage between the positive termi nal (A) and body ground with the ignition switch and defogger switch ON. There should be battery voltage.

1. Lightly rub the area around the broken section (A) with fine steel wool, then clean it with alcohol.

• If there is no voltage, check for: - faulty defogger relay. - faulty window antenna coil - an open in the BLK/GRN wire. • If there is battery voltage, go to step 2.

c 2. Carefully mask above and below the broken portion of the defogger wire (B) with cellophane tape (C). 3. Mix the silver conductive paint thoroughly. Using a small brush, apply a heavy coat of (A) paint extending about 1/8" on both sides ofthe break. Allow 25 minutes to dry. 2. Check for voltage between the positive terminal and the negative terminal (B) and body ground. If there is no voltage, check for an open in the defogger ground wire. 3. Touch the voltmeter positive probe to the halfway point of each defogger wire, and the negative probe to the negative terminal. There should be approximately 6 V with the ignition switch and the defogger switch ON. • If the voltage is as specified, the defogger wire is OK. • If the voltage is not as specified, repair the defogger wire. - If it is more than 6 V, there is a break in the negative half of the wire. - If it is less than 6 V, there is a break in the positive half of the wire.

22-160

4. Check for continuity in the repaired wire. 5. Apply a second coat of paint in the same way. Let it dry 3 hours before removing the tape.

BACK

~

l!!!!.I

Power Windows Component Location Index PASSENGER'S UNDER-DASH FUSE/RELAY BOX

KEY-OFF TIMER CIRCUIT ] [ In the multiplex control unit (passenger's) Input Test, page 22-174

PASSENGER'S WINDOW SWITCH Test, step 6 on page 22-175 Replacement, page 22-179

PASSENGER'S WINDOW MOTOR Test, page 22-180

RIGHT REAR WINDOW MOTOR

RIGHT REAR WINDOW SWITCH

POWER WINDOW MASTER SWITCH Replacement, page 22-179

DRIVER'S WINDOW MOTOR Test, page 22-180 LEFT REAR WINDOW MOTOR

BACK

LEFT REAR WINDOW SWITCH

22-161

Power Windows Circuit Diagram - Sedan '98-99 models PASSENGER'S UNDER-DASH FUSEIRELAY BOX

UNDER-HOOD FUSE/RELAY BOX BATTERY

~

No.41 (I00A)

No.54(40A)

No.13 (7.5A)

&- BLK -+~..J>-..,....or'\" No.42(SOA)

YEL

WHTNEL ° MULTIPLEX

No.51 (4OA)

LC>

WHTIBLU -

5

CONTROLUNIT (Driver's) (To PIlle 22-164) o~ PLEX ROLUNIT (Passanger's) (To page 22-165)

.


~assengar'S) IGNITION SWITCH

Fromr) 2-1 1

*---------i~

POWER WINDOW RELAY GRNlWHT-

No.9 (7.5A)


~

No.7 (20A)

No.8 (20A)

~

No.16 (20A)

BLK


LEFT REAR SWITCH ( To 22-164

(passenger'sl

FRONT PASSENGER'S SWITCH

page} \

(To page 22- 65)

y

( To PIlle)

22-165

G581

22-162

BACK

RIGHT REAR SWITCH

~

No.15 (2OA)

r:-:'I I.=:J

PASSENGER'S SWITCH ( From page ) 22-164,165

r

I

WHTIYEl

WHT/RED POWER WINDOW MASTER SWITCH (In the MULTIPLEX CONTROL UNIT (DOOR))

A1

,,

DRIVER'S SWITCH

,, \~ ON UP'

~, ALITO

-

A2

-GRNlWHT

"

B2

DN:DOWN

H

I ~ L ______ ~

, ON

UP /

lEFT REAR UP /

\DN

RIGHT REAR UP
~

\DN

MAIN SWITCH

L I

CONTROL UNIT

I

~-----.?

...

All

Al0

\-

A4

REDIYEl RED

REDlBlU

2

RIGHT FRONT

A19

BlK

A12

BLK

3

Bl

BlK

A15

BRN

~

MULTIPLEX CONTROL UNIT (DrIve~s)

(1'0 page 22-164) 4

BLK DRIVER'S WINDOW MOTOR

BLK

BlK

1

1

G551

G401

(cont'd)

BACK

22-163

Power Windows Circuit Diagram - Sedan (cont'd) MULTIPLEX CONTROL UNIT (Ooor) ( From 22·163

No.13 (7.5A) PASSENGER'S FUSE (From page 22·162)

page)

T

T

BRN

WHTIYEL

A2

A12

Bl


A16

A19

A7

A14

NO.7 (20A) PASSENGER'S FUSE (From page 22·162) GRNIORN

y

GRN

GRNlBLU

WHT

r

EL

5

DOWN .-

-

I

DRIVER'S DOORsWITCH (Closed: Door open)

~

6

,• ,i-

3

L____ ~

LEFT REAR SWITCH

\UP )

~

~~

r-

~~

~----!) p

I

2

1 1

<4

REDIBLU

I

REDIYEL

' 1

cro--@

I'

LEFT REAR WINDOW MOTOR

I

I

WHTIRED

t

POWER WINDOW MAIN SWITCH (To page 22·163)

BLK

1 G401

22-164

BACK

PNK-

~ ~

No.9 (7.SA) DRIVER'S FUSE (From page 22-162)

No.13 (7.SA) PASSENGER'S FUSE (From page 22-162)

I

I

YEL

WHTIYEL

A22

B9

A24

MULTIPLEX CONTROL UNIT (Passenger's) (Key-oH timer circuH)

A12

A15

GRN

I.8

A7

A8

A19

AS

No.16/20AJ PASSE:NGER'S FUSE (From page 22-162) BLK

I

?

AlB

No.8/2OAJ PASS"ENGER'S FUSE (From page 22-162)

YEUGRN

YEL

WHT

I~LK

5

RIGHT REAR SWITCH

6

I

?

BLUIYEL

BLU

BL~

FRONT

6

5 I

."

POWER WINDOW RELAY ( To page) 22-162

"

)

DOWN(/

, UP

~

~ L~ __ ~

~~

DOWN/

,

~

I ~

~

. ~--:~ />

\UP ~

I

I

~L ___

r

.~

'J

~

FRONT PASSENGER'S DOOR SWITCH

PASSENGER'S SWITCH

~~

,--:~f I

4

(=~n)

REDIBLU

1 REDlYEL

2

4 BLUlWHT

1

2

BLUIYEL

I G581

BACK

22-165

Power Windows Circuit Diagram - Sedan (cont'd) '00-02 models PASSENGER'S UNDER-DASH FUSEIRELAY BOX

UNDER-HOOD FUSE/RELAY BOX BATIERY

No.41 (100A)

&-BLK

No.54 (40A)

No.13 (7_SA)

0--+-- YEL ---------I---
No.42 (5QA) No.51 (40A) r-~r-

WHT

(Passenge~s)

( From page ) 22-166

IGNITION SWITCH

)1 ~---------~~

POWER WINDOW RELAY

~ 9

(. No,7 ~ (20A)

NO.9 (7.5A)

No_8 (20A)

~ No,lS

'i (20A)

LL-_______ GRNIWHT _ __


LEFT REAR SWITCH ( To page) 22-166

YEL

~

FRONT RIGHT PASSENGER'S REAR SWITCH SWITCH ''----Vy--~1

(To page) 22-167

MULTIPLEX CONTROL UNIT (Passenger's) (To page 22-166)

I G581

22-166

No.16 (20A)

BACK

r--:'I

a.=:J

-

WHTlYEl

"'1------------------------

WHTlYEl

-----~G> (~~e~) PASSENGER'S SWITCH ( Frompage ) 22·166,167

'Y

WHTNEl

WHTIRED POWER WINDOW MASTER SWITCH (In lite MULTIPLEX CONTROL UNIT (~OOR))

,

DRIVER'S SWITCH

1: -GRNIWHT

UP'

~"AUTO

U~/

\~

"DN

lEFT REAR U~/

"DN

RIGHT REAR U~/

~MAIN SWITCH

,ON

po---

,

•

.

A2

I I

RIGHT FRONT

-- - ---- -. -- --- 1--- --- -- 1----1--- --- -------

'- ~---

.....-,

Al

B2

DN:DOWN

... ...

POWER WINDOW IMMERSION CIRCUIT

~ I

I

I

I

~ L ______ ~ c

A19

~------~)}

....

-'

-

All

AID

RED/BLU

REDil

2

1

A4

T

A12 BlK

Bl BLK

3

AIS BRN

~

MULTIPLEX CONTROLUNIT (Driver's) (To page 22-1 66)

• ------- - .... 4

PULSER DRIVER'S WINDOW MOTOR

BLK

1 GSSI

BLK

.......

1 GSSI

... ...

...

G401

GSSI

....

(cent'd)

BACK

22-167

Power Windows Circuit Diagram - Sedan (co nt'd) I ): '01-02 models

r:-......

From ) ( ::ous ~-------- WHTIYEL

MULTIPLEX CONTROL UNIT (DOOR) ( From 22-165

NO.9 (7.5) DRIVER'S FUSE ( From page) 22-164

page)

y

r BRN

WHTIYEL

WHTIYEL

A12

A24

A2

A16

A19

A7

B9

NO.7 (20A) PASSENGER'S FUSE (From page 22-164)

GRNIORN

W I

A2

MULTIPLEX CONTROL UNIT (Passenger's) (Key-off timer circuR)


A14

YEL

A8

A15

PNK

I.8

GRNlBLU

GRN

GRN

5(3)

6(1)

LEFT REAR SWITCH POWER WINDOW RELAY

~

DOWN

~

,, L_

n

UP

,00 k),

~

I

----

~ L~ ___ 4~

1

~~

~_~el

10-

~---~

-

FRONT PASSENGER'S DOOR SWITCH ( Closed: Door open

I

r

4(6) RED/BLU

1(2) REDIYEL

2(4)

--"""'I·I~cro.-.@l-+l-l~Il LEFT REAR WINDOW MOTOR

G401

22-168

,, ,t:>

_-1

'I

BLK

f

!!:.

EL WHr 3(5) I

DRIVER'S DOOR SWITCH (Closed: Door open)

A12

POWER WINDOW MAIN SWITCH (To page 22-165)

BLK

1 G581

BACK

~ ~

[ ): '01-02 models

MULTIPLEX CONTROL UNIT (Passenge(s) (Key-off timer circuit)

A7

A19

AS

No.16JZOA~

No.8(20~

PASS NG R'S FUSE (From page 22-164)

y

A18

PASSEN ER'S FUSE (From page 22-164)

VEUGRN

)Y

VEL

WHTIBLK

BLU

BLUJYEL

BLlJIBLK 5 (3)

3[5]

6[1)

4 [6)

RIGHT REAR SWITCH

1[2)

RIGHT REAR WINDOW MOTOR

3 [5]

2[4)


BACK

5[3)

6[1)

FRONT PASSENGER'S SWITCH

1 (2)

4[6)

FRONT PASSENGER'S WINDOW MOTOR

2[4)


22-169

Power Windows Circuit Diagram - Coupe '98-99 models UNDER-HOOO FUSEIRELAY BOX BATTERY ~

&-

No.41 (100A)

BlK

IGNITION SWITCH

~ BAT

No.42 (SOA)

-+-
IGI

~------ BLKlYEl ---P-AS-S-EN-G-E-R'-S- - -

No.54 (40A) PASSENGER'S UNDER·DASH FUSEIRELAY BOX

WHTlBlU

SWITCH

G~.me)

)7

YEl

WHTIRED

No .13 (15A) . WHTIYEl


WHTIYEl POWER WINDOW MASTER SWITCH AI (In the MULTIPLEX CONTROL UNIT (Door))

(Passenger's)

(From page)

\22·171

B2

DN:DOWN DRIVER'S SWITCH

---------1~

POWER WINDOW RELAy

NO.8

(20AJ

I

1

1

I

Upl

, '22 '

,~

C~

, ON

UP /

ON

• p

No.15 (20A)

AUTO

PASSENGER'S SWITCH

H

r

CONTROL UNIT

A2

J GRNIW IHT

11

~

L _______

J

~

_-----J~

\ PASSENGER'S SWITCH (To page 22·167)

MAIN SWITCH

\0-

I

All

Al0

REDIBLU

A4

REDIYEl RED

A19

BlK

. A12

BlK

Bl

BlK

A15

BRN

I 3

4

BlK BLK

1

DRIVER'S WINDOW MOTOR

G581

22-170

BlK

1 G551

BACK

G401

~

l.:!..I DRIVER'S UNDER·DASH FUSEIRELAY BOX -------BL~L----------------~~~o-+_--------------------------~

I

BRN

I

Pf:NIER WINDOW RELAY (To page 22·170)

WHTIYEL

(Fuselrelay box soc:keI)

WHTIYEL

1

VEL

A22

A12

Bl

MULTIPLEX CONTROl UNIT (Driver's)

A14

A16

PNK~

MULTIPLEX CONTROl UNIT (Passenger's) (Kay-olllimer circuit)

A15

A19

AS

A18

No.8 (20A) PASSENGER'S FUSE (From page 22·170)

GRN

GRNIORN

BLK

BLU

Bi~

BLUIYEL

5

•

6

PASSENGER'S WINDOW SWITCH

~.

-

4

DOWN /

, UP ~

~

T

I

DRIVER'S OOORSWITCH (Closed: Door open)

~ L ____

PASSENGER'S DOOR SWITCH (Closed : Door open)

j

~

4~

'I

G401

I

I

1

4

I

~ __!lf 2

BLUIYEL

BLUJWHT

PASSENGER'S WINDOW MOTOR

POWER WINDOW MAlNSWlTCH (To page 22·170)

GSal

BACK

22-171

Power Windows Circuit Diagram - Coupe (cont'd) '00-02 models

@*"----

UNDER-HOOD FUSEIRELAY BOX BATTERY t:i:\....-

IGNITION SWITCH

No.41 (100A)

No.42 (SOl.)

BAT IGI

&- BlK ~-CT"\.J>""----""-cT'-'>-4---WHT--"'" No.54 (401.) PASSENGER'S UNDER-DASH FUSEIRELAY BOX

BlKlYEl - - - - - - - - PASSENGER'S SWITCH

m_ffie)

)1

YEl

WHTIBLU

WHT/RED

r

('01-02 models)

t---

MULTIPLEX CONTROL UNIT Passenger'S) From page ) 2-171

POWER WINDOW MASTER SWITCH (In the MULTIPLEX CONTROL UNIT (Ooor))

a

ON:DOWN

...-

No.8 (201<)

~

~,

I

I~ ~

DRIVER'S SWITCH

I

/, . . .-. \

-,,"

't.

~

I

I

\

-....;-

....-

No.13 (7.51<)

".1J'

:1 up

RED

MAIN SWITCH

ON

---_. - --- --- -

-----

Al

_I-

A2 WHTIYEL

PASSENGER'S SWITCH (To page 22-171)

~

, MULTIPLEX CONTROL UNIT (Driver's) (To page 22,171) • MULTIPLEX CONTROL UNIT (Passenger's) (To page 22-171)

~

... 1

.

*

L _______

~ 'I

~-----~ P ;

j

lr

All

1.10

REDIBLU

1.4

1.19

RED/YEl RED BLK

1.12 Bl

1.15

BlK BLK BRN

I 3

4 BlK

DRIVER'S WINDOW MOTOR

1

BlK

1

GSSI

22-172

--~

I

2

BlK

I

GSSI G401

BACK

A20

I I

lL ~-- J

~

I

.....

~ I

H YEUBLK GRN/WHT WHTIYEl

1-'

UP/~

~, AUTO

--- -- -------~ No.1S (201.)

PASSENGER'S SWITCH I

:~ .?POWER WI NDOW RELAY

-.

B2

~

1..:=..1 DRIVER'S UNDER·DASH FUSEIRELAY BOX

[ J: 'OHl2modelS

Bl~YEl -------------------+-<~~~------------------------------------__. No.13 (7.5A)

PASS~NG~R·S

FUSE ( From gage) 22-17

7

T'

WHTIVEl

WI"IT/YEl

A12

A24 Bl

>--


A16

A2

YEl

B9

IB

A14

I

BRN GRNlORN

MULTIPLEX CONTROL UNIT (Passenger's) (Key-a" limer circu~)

A15

A18

AS

A19

No.8 (20A) PASSENGER'S FUSE (From page 22-170)

GRN

BlK

7

BLUIVEl

BljlK 3[5J

BLU PASSENGER'S WINDOW SWITCH 5[3J

6 [lJ

POWERWINDOW RELAY (To page 22-170)

11r

~6.~~WN

.....- 'r<\j

I

\

\

\ \

'--

----

\

_l ~ I

~

DRIVER'S OOORSWITCH

(g::e:~)

BlK

........

1 G401

PASSENGER'S DOOR SWITCH ( Closed: ) Door open

I G581

BACK

" L_ f

~~

~

1 [2J BLUIVEl

~ j~

~ ___ ~7 4[6J BLUIWHT

2[4J

I~I-I-----II'I l

L.......---I--'

PASSENGER'S WINDOW MOTOR

POWER WINDOW MAIN SWITCH (To page 22,,170)

22-173

Power Windows Control Unit Input Test 1. Before testing the power window control functions, troubleshoot the multiplex control system (see page 22-137).

Driver's Multiplex Control Unit: 2. Remove the driver's multiplex control unit from the driver's under-dash fuse/relay box, and disconnect its connector. 3. Inspect all connector and socket terminals to be sure they are all making good contact. o If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. o If the terminals look OK, go to step 4. DRIVER'S UNDER-DASH FUSE/RELAY BOX SOCKET

DRIVER'S UNDER·DASH FUSE/RELAY BOX CONNECTOR A


4. With the driver's multiplex control unit still disconnected, make these input tests at the driver's under-dash fuse/relay box socket. o If any test indicates a problem, find and correct the cause, then recheck the system. o If all the input tests prove OK, go to step 5.

Cavity A12



A14



Possible cause if result is not obtained Blown No. 13 (7.5A) fuse in the passenger's under-dash fuse/ relay box o An open in the wire o Poor ground (G401) o An open in the wire o

5. Reconnect the driver'S multiplex control unit to the driver's under-dash fuse/relay box, and perform the following input tests at Connector A on the back of the driver'S under-dash fuse/relay box. For driver's under-dash fuse/relay box connector socket location (see page 22-46). o If any test indicates a problem, find and correct the cause then recheck the system. o If all the input tests prove OK, go to step 6.

Cavity A2

A3

A5

A10

22-174

Wire GRN

GRN/ORN

GRN/BLU

GRN/YEL

Test condition Jump A2 to battery voltage

Test: Desired result Check the left rear window motor operation: The window should go down.

Driver's door open Driver's door closed JumpA5to battery voltage

Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more. Check the left rear window motor operation: The window should go up.

Left rear door ORen Left rear door closed

Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more.

BACK

o o o

o o o

o o o

o o o

Possible cause if result is not obtained An open in the wire Faulty window switch Blown No.7 (20A) fuse in the passenger's under-dash fuse/relay box Faulty driver's door switch An open in the wire (no voltage drop) Short to ground (voltage remains less than W) An open in the wire Faulty window switch Blown No.7 (20A) fuse in the passenger's under-dash fuse/relay box Faulty left rear door switch An open in the wire (no voltage drop) Short to ground (voltage remains less than W)

~

I...!!!..I Multiplex Control Unit, Passenger's:

6. Remove the passenger's multiplex control unit from the passenger's under-dash fuse/relay box, and disconnect its connector. 7. Inspect the connector and socket terminals to be sure they are all making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system . • If the terminals look OK, go to step 8. FUSE/RELAY BOX SOCKET

Al

A2

A4

A3

A6

A5

A7

A8

A9

A10

All A12

A13 A14 A15 A16 I-- A17 A18 A19 A20 t - - A21 A22 A23 A24

PASSENGER'S UNDER-DASH FUSE/RELAY BOX CONNECTOR A

... 1

2

3

4

8

9

10 111

12 1 13

...

n

5

6

7

14 1 15

16 1 17

18 1 19

20

--"'l

//

YEL

..

'"

YEL/GRN

GRN


PASSENGER'S UNDER-DASH FUSE/RELAY BOX CONNECTOR F BLU/YEL

I

.... 1

2

3

12

13

14

4151F=11617 15

I I I 16

17

18

~

8

9

10

11

19

20

21

22

/

BLU

Wire side of female terminels

(cont'd)

BACK

22-175

Power Windows Control Unit Input Test (cont'd) 8. With the passenger's multiplex control unit still disconnected, make these input tests at the passenger's underdash fuse/relay box socket . • If any test indicates a problem, find and correct the cause, then recheck the system . • If all the input tests prove OK, go to step 9. Cavity A24




A12



A8



Check for continuity to ground: There should be continuity Check for continuity to ground: There should be continuity.

Possible cause if result is not obtained • Blown No. 13 (7.5A) fuse in the passenger's under-dash fuse/ relay box • Faulty passenger's fuse/relay box • Faulty power window relay Poor ground (G581) • An open in the wire • Poor ground (G581) • Faulty driver's under-dash fuse/ relay box

9. Reconnect the passenger's multiplex control unit to the passenger's under-dash fuse/relay box, and perform the following input tests at the appropriate connectors on the passenger's under-dash fuse/relay box. For passenger's under-dash fuse/relay box connector socket location (see page 22-45) . • If any test indicates a problem, find and correct the cause, then recheck the system . • If all the inputtests prove OK, go to step 10. Cavity A16

Wire GRN

Test condition Front passenger's door open Front passenger's door closed

Test: Desired result Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more.

F18

BLU

Jump F18 to battery voltage

F9

BLU/YEL

Jump F9 to battery voltage

A12

VEL/GRN

JumpA12to battery voltage

A11

VEL

Jump A11 to battery voltage

Check the front passenger's window motor operation: The window should go down. Check the front passenger's window motor operation: The window should go up. Check the right rear window motor operation: The window should go down. Check the right rear window motor operation: The window shouldJJ_o UQ.

22-176

BACK

Possible cause if result is not obtained • Faulty front passenger's door switch • An open in the wire (voltage stays high) • Short to ground (voltage stays low) • Faulty front passenger switch • An open in the wire • Faulty window motor • Faulty front passenger switch • An open in the wire • Faul!y window motor • Faulty right rear switch • An open in the wire • Faulty window motor • Faulty right rear switch • An open in the wire • Faulty window motor

~ ~

Multiplex Control Unit, Door: 10. Remove the door multiplex control unit from the driver's door, and disconnect its connectors. 11. Inspect the connector and socket terminals to be sure they are all making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system . • If the terminals look OK, go to step 12. MULTIPLEX CONTROL UNIT, DOOR CONNECTOR A WHT/VEL

~

RED/VEL

RED

GRN/WHT

tr

A1

A2

A11

A12

+

.s--2

A4

A6

/ / ££

A7

~

, A8

/

A10

A15 A16 A17 A18 A19 f::.2fJ

t

BLK


\

WHT/RED ('01 Coupel

MULTIPLEX CONTROL UNIT, DOOR CONNECTOR B

BLK

~


t

WHT/RED

(cont'd)

BACK

22-177

Power Windows Control Unit Input Test (cont'd) 12. With the door multiplex control unit still disconnected, make these input tests at the connectors . • If any test indicates a problem, find and correct the cause, then recheck the system . • If all the input test prove OK, go to step 13. Cavity A1

Wire WHT/yEl



A2

GRN/WHT



A12 A19 B1 A11 A10

BlK



RED/BlU RED/YEl

A20

WHT/RED

Connect the A10 terminal to the A 12 terminal, and the A11 terminal to the A1 terminal. Operating any passenger's switch with ignition switch ON (II)

Check the driver's window motor operation: The window should go up. NOTE: If the window is up, jump A11 to A12, and A10 to A1; the window should go down. Check for voltage to ground: There should be battery voltage.

Possible cause if result is not obtained • Blown No. 13 (7.5A) fuse in the passenger's under-dash fuse/ relay box • An open in the wire • Blown No. 15 (20A) fuse in the passenger's under-dash fuse/ relay box • An open in the wire • Poor ground (G401,G551) • An open in the wire • Blown No. 13 (7.5A) fuse in the passenger's under-dash fuse/ relay box • Faulty driver's window motor • An open in the wire • Faulty passenger's switch • An open in the wire

13. Reconnect the door multiplex control unit and perform the following input test. • If any test indicates a problem, find and correct the cause, then recheck the system . • If all the input tests prove OK, go to step 14. Cavity A4

Wire RED

B2

WHT/RED

Test condition While operating the driver's window switch with the ignition switch ON (II) Operating any passenger's switch with master main switch OFF, and the ignition switch ON (II)

Test: Desired result Check for the voltage on the A4 and A12 terminals: Approx. 6 V should be indicated as the driver's window motor runs. Check for voltage to ground: There should be battery voltage.

• • • •

Possible cause if result is not obtained Faulty pulser Faulty driver's window motor An open in the wire A short to ground in the wire

• Poor ground (G401, G551) • Faulty passenger's switch • An open in the wire

14. If all the input tests prove OK, one of the control units must be faulty. Substitute a known-good control unit for the one that is most likely at fault, then check the system. If the system works properly, the original control unit is faulty; replace it. If there is still a malfunction, substitute a known-good control unit for the next most likely unit to be at fault, and recheck. If the system works properly, the original unit is faulty; replace it.

22-178

BACK

~ ~ Master Switch Replacement 1. Remove the screw and master switch assembly from the door panel.

2. Remove the four mounting screws, then remove the master switch from the panel.

Passenger's Switch Replacement 1. Remove the screw and passenger's switch assembly from the door panel.

2. Remove the three mounting screws, then remove the passenger's switch from the panel.

BACK

22-179

Power Windows Driver's Window Motor Test

Passenger's Window Motor Test 1. Remove the passenger's door panel (see page 208).

Motor Test: 1. Remove the driver's door panel (see page 20-8).

2. Disconnect the 2P connector from the window motor.

2. Disconnect the 4P connector from the window motor.

Terminal side of male terminals Terminal side of male terminals

3. Test the motor in each direction by connecting battery power and ground according to the table. When the motor stops running, disconnect one lead immediately.

1\

Terminal Direction

UP DOWN

\

1

2

G?>

e

e

3. Check window motor operation by connecting power and ground according to the table. When the motor stops running, disconnect one lead immediately. \

Direction

G?>

UP DOWN

4. If the motor does not run or fails to run smoothly, replace it.

\

1

2

<±>

e

e

<±>

4. If the motor does not run or fails to run smoothly, replace it.

Pulser Test: 5. Connect the test leads of an analog ohmmeter to the No.3 and No.4 terminals. 6. Run the motor by connecting power and ground to the No.1 and No.2 terminals. The ohmmeter needle should move back and forth alternately.

22-180

Terminal

BACK

r:-:'I I.!!!!.I

Wiper/Washer Component Location Index

WINDSHIELD WIPER ARMS and LINKAGE Replacement, page 22-188

WIPER/WASHER SWITCH Test, page 22-187 Replacement, page 22-187

INTERMITTENT WIPER CIRCUIT (In the multiplex control unit (driver's)) Input Test, page 22-184

WINDSHIELD WIPER MOTOR Test, page 22-188 Replacement, page 22-188 WINDSHIELD WASHER TUBE Replacement, page 22-191

WASHER RESERVOIR Replacement, page 22-190

INTERMITTENT WIPER RELAV Test, page 22-52 WASHER MOTOR Test, page 22-189

WASHER LEVEL SWITCH (Canada) Test, page 22-190

BACK

22-181

Wiper/Washer Circuit Diagram UNDER-HOOD FUSE/RELAY BOX

@-

BATTERY

BLK


IGNITION SWITCH

No.41 (I00A) No.42 (50A) ~

.-of---WHT

BAT ~

No.9 (7.5A)

BLKlYEL

IGI

--+-",--",-C-'-'>-+--No.7 (7.5A)

GRNlBLK

::1::-'----"J L-~RN/BLK *2

-----,--__ --.J

*1

I

-----------------------, I

~

A7

~

D

WASHER SWITCH

OFF

YELlGRN ______________ __.J

WINDSHIELD WIPERIWASHER SWITCH

J~---lJ::

~------ T\-----, HI 00 ~9
'y

INT

MIST

MIST

OFFnNT

A2

Al

GRNlBLK

AS

A5

Gr

BLKlYEL

A4

A3

WHT

GRlBLK

WINDSHIELD WIPER MOTOR

1

,

4

-a

HI

-

2 BLU

LO

~-:~I

I

r

~! t)

WINDSHIELD WIPER INTERMITTENT RELAY GRNlRED

'----""'5

BLUlWHT

BLUIYEL

3

BLUlWHT BLKlYEL

BLKlYEL

~_,ru M

WASHER MOTOR

2 BLK

BLK

BLK

BLK

1 L 11 L

G301

0002

0401

*.2:1: '00-02 All '98-99 models, ~2 Sedan Coupe

22-182

BACK

G302

~

I..!::..I

I

YEL

A24

A22 Bl o-________ PNK---------------------------------~B~9~ B14

B16

AS INTERMITTENT -GRN----<"l WIPER CIRCUIT

"':&

:t:1-

• VEHICLE SPEED

\l I

~t~~Kk~WHTIYELBRAKE

•

PEDAL B22

POSITION SWITCH (BRAKE SWITCH)

'n Ihe MULTIPLEX ) ( CONTROL UNIT (Driver's)

-


AS 0----WHTIBLK

A23 BLUIWHT -_-<"l

Bll

Q-~-------BLK--------------------------------~

0-----

BLKlBLU - - - - - - - - - - - - -

B15

-_-0 All

-

GRN/RED

• GAUGE ASSEMBLY • ABS CONTROL UNIT

_

L

BLKlYEL _ _ _ _ _-J

1

\l I

USA : GRN/RED Canada: GRNlWHT

A21

GRN~H~----G~~

GRN/RED

I--F'~~

: 1 I

GRNlREDpARKING

GRNIWHT

1

:

¢) ,

1

PARKING BRAKE

C~~~~ver J: up

L _ ~::J (Canada)

I:

GRNIRED

BRAKE SWITCH

[g~F: t:~: ~~n J:

I'

~

TRANSMISSION RANGE SWITCH ) (AITGEAR POSITION SWITCH (ON : In posillon If))

BRAKE FLUID LEVEL SWITCH

[g~F: ~:: ~~wn J

1

'

i

- - ---(USA)

lBLK

7 G302

BACK

I

I I

G1DI

G503

G504

22-183

Wiper/Washer Control Unit Input Test 1. Before testing the wiper/washer control functions, troubleshoot the multiplex control system (see page 22-137). Multiplex Control Unit, Driver's: 2. Remove the driver's multiplex control unit from the driver's under-dash fuse/relay box, and disconnect its connector. 3. Inspect all connector and socket terminals to be sure they are making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system . • If the terminals look OK, go to step 4.

\

Fuse/relay box socket BLK

GRN/RED (USA) GRN/WHT (Canada) BLU/WHT Wire side of female terminals

4. With the driver's unit still disconnected, make these input tests at the connector and fuse/relay box socket. • If any test indicates a problem, find and correct the cause, then recheck the system . • If all the input tests prove OK, go to step 5. Cavity A9


Test condition Ignition switch ON (II) and wiper switch atlNT

AS

Brake pedal pushed

A11


A21

Ignition switch ON (II) and washer switch ON

A23


A3

Shift lever in [f]

A24


Possible cause if result is not obtained • Blown No.7 (7.5A) [No. 12 (30A)] fuse in the driver's underdash fuse/relay box • Faulty wiper switch • An open in the wire Check for voltage to ground: • Blown No. 47 (20A) fuse in the under-hood fuse/relay box There should be battery voltage. .. • An open in the wire Check for voltage to ground: • Blown No. 12 (30A) fuse in the driver's under-dash fuse/relay box There should be battery voltage. • Faulty intermittent wiper relay • An open in the wire Check for voltage to ground: • Blown No.7 (7.5A) [No. 12 (30A)] fuse in the driver's underThere should be battery voltage. dash fuse/relay box • Faulty washer switch • An open in the wire • Blown No. 12 (30A) fuse in the Check for voltage to ground: driver's under-dash fuse/relay box There should be battery voltage. • An open in the wire • Faulty AfT gear position switch Check for voltage to ground: There should be less than 1 V. • Poor ground (G101) • An open in the wire • Blown No.9 (7.5A) fuse in the Check for voltage to ground: driver's under-dash fuse/relay box There should be battery voltage. • An open in the wire


[] : '00-02 Coupe

22-184

BACK

r:-:'I I.!!:..I Cavity B11

Wire BLK

B15

GRN/RED (USA) GRN/WHT (Canada)

Test condition Under all conditions Parking brake lever up

Test: Desired result Check for continuity to ground: There should be continuity. Check for continuity to ground: There should be continuity.

Possible cause if result is not obtained • Poor ground (G503) • An open in the wire • Faulty parking brake switch • An open in the wire

5. Reconnect the connector to the driver's unit, and make this input test at the connector . • If the test indicates a problem, find and correct the cause, then recheck the system. • If the test proves OK, go to step 6. Cavity B14

Wire BLU/WHT

Test condition Ignition switch ON (II) and rotate one front wheel slowly with other wheel blocked

Test: Desired result Check for voltage to ground: There should be 0 to approx. 5 Vor more.

Possible cause if result is not obtained • Faulty vehicle speed sensor (M{T) or PCM (AfT) • An open in the wire (voltage stays high) • Short to ground (voltage stays low)

(cont'd)

BACK

22-185

Wiper/Washer Control Unit Input Test (cont'd) Multiplex Control Unit, Passenger's: 6. Remove the passenger's under-dash fuse/relay box (see page 22-50). 7. Remove the passenger's multiplex control unit from the passenger's under-dash fuse/relay box, and disconnect its connector. 8. Inspect the connector and socket terminals to be sure they are all making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. • If the terminals look OK, go to step 9.

AI

A2

A3

A4

A5

A6

A7

A8

Al3 Al4 A15 Al6 f-- A17 Al8 Al9 A20

A9

-


AID All Al2

A21 A22 A23 A24

l:ta%RJ~:,liQ GRNffll 1 .1 GRN/VEL Wire side of female terminals

9. With the passenger's unit still disconnected, make these input tests at the connector and fuse/relay box socket. • If a test indicates a problem, find and correct the cause, then recheck the system. • If all the input tests prove OK, the control unit must be faulty; replace it. Cavity B22

Wire BLK

A22


B16 B15

GRN/YEL GRN/WHT

22-186


Test: Desired result Check for continuity to ground: There should be continuity Check for voltage to ground: There should be battery voltage.

Intermittent dwell time control ring turned

Check for resistance between the terminals: It should vary from 0 to 30 kQ as the ring is turned.

BACK

Possible cause if result is not obtained • Poor ground (G504) • An open in the wire • Blown No.9 (7.5A) fuse in the driver's under-dash fuse/relay box • An open in the wire • Faulty intermittent dwell time controller • An open in the wire

r--:'I

~

Wiper /Washer Switch Test/Replacement 1. Remove the dashboard lower cover (see page 20-84) and steering column covers (see page 17-25). 2. Disconnect the connectors (A) from the wiper/washer switch (B). 3. Remove the two screws (e), then pull out the switch (B). 4. Inspect the connector terminals to be sure they are all making good contact.

• If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system . • If the terminals look OK, check for continuity between them in each switch position according to the tables. - If there is no continuity, replace the switch. A

c


8

1\

Terminal

Position

\

A1

OFF

A2

A3

A4

A5

0

()

0 0

()

A7

AS

81

82

INT LO

Mist switch ON Washer switch ON

-0 -0 -0

0 0

HI

0

()

Intermittent dwell time controller turned

"

O~OkQ

BACK

22-187

Wiper/Washer Wiper Motor Replacement

Wiper Motor Test 1. Open the hood, and remove the cap nuts and the wiper arms.

1. Remove the nuts (A) and remove the windshield wiper arms (8).

NOTE: Carefully remove the wiper arms, so that they do not touch the hood. 2. Remove the windshield wiper arms (see page 22188). 3. Disconnect the connector from the wiper motor.

Remove and replace the clips.

2. Remove the hood seal and cowl cover. 3. Remove the bolt (A) and windshield wiper linkage assembly (8).

~:.8 N·m (1.0 kgf·m, 7.2Ibf·ft)

4. Test the motor by connecting battery power and ground according to the table. If the motor does not run or fails to run smoothly, replace it.

1\

_

/B

Terminal

Position

\

1

LOW SPEED HIGH SPEED

e

2

4

e

(B (B

5. Connect an analog voltmeter between the No.5 (+ ) and No.3 (-) terminals, and run the motor at low or high speed. The voltmeter should indicate 0 V and 4 V or less alternately.

D

4. Disconnect the connector (C) from the wiper motor (D).

22-188

C

BACK

~ ~ Washer Motor Test 5. Scribe a line (A) across the link and windshield wiper linkage to show the original adjustment. Separate the windshield wiper linkage (B) from the wiper motor (C).

1. Remove the left inner fender (see page 20-167). 2. Disconnect the connector from the washer motor.

A

18 N·m (1.8 kgf·m, 13lbf·ttl

B

~'"""' __--::~

8N·m (0.8 kgf·m, 6lbf·ttl

3. Test the washer motor by connecting battery power and ground according to the table. If the motor fails to run smoothly, replace it. If the motor runs smoothly, but little or no washer fluid is pumped, check for a disconnected or blocked washer hose, or a clogged pump outlet in the motor.

o o

C

6. Install the motor in the reverse order of removal, and note these items: o o

o o

1\

Grease the moving parts. Before reinstalling the wiper arms, turn the wiper switch ON, then OFF to return the wiper shafts to the park position. If necessary, replace any damaged clips. Check the wiper motor operation.

BACK

Terminal

Battery Connected

\

1

2

(f)

e

22-189

Wiper /Washer Washer Reservoir Replacement

Washer Fluid Level Switch Test (Canada)

1. Pull away the left inner fender (see page 20-167).

1. Remove the left innerfender (see page 20-167).

2. Disconnect the washer tube(s) (A) and washer motor connector (8).

2. Disconnect the switch 2P connector (A).

C 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft)

\---

rTI

.__

I

L=::2

---B

A C 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft)

C 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft)

3. Check for continuity between the terminals in each float (8) position according to the table.

3. Remove the three bolts (C) and washer reservoir (D).

4. Install the reservoir in the reverse order of removal. Check the washer motor operation.

1\

Terminal

Position

\

1

2

0

0

FLOAT UP FLOAT DOWN

22-190

BACK

r--:'I

~

Washer Tube Replacement 1. Remove the left inner fender (see page 20-167). 2. Remove the windshield washer nozzles and clips, then remove the tube.

3. Install in the reverse order of removal. Take care not to pinch the washer tube. Check the windshield washer operation.

BACK

22-191

Power Seat Component Location Index a-way Adjustable: FRONT UP-DOWN MOTOR

SLIDE MOTOR

RECLINE MOTOR

.~~~==..- ADJUSTMENT SWITCH Test/Replacement. page 22-195 REAR UP-DOWN MOTOR

2-way Adjustable:

HEIGHT MOTOR

22-192

BACK

~

L=:I Circuit Diagram - 8-way Adjustable UNDER-HOOD FUSE/RELAY BOX BATIERY

~

No.4l (l00A) No.55 (40A) ~BlK---~--~~----~~~~~-----'

YEUGRN

YEUGRN

No.2 (lOA)

No.4 (lOA)

BlU

RED

B6

UP

BS

BlK

,f DOWN~' A3

REDIYEl

)

A4

RED

FOR- \ ) WARD

Al

A5

BLUIYEl

2

FRONT UP-DOWN MOTOR

POWER SEAT ADJUSTMENT SWITCH

B2

BACK- \ ) WARD

B~U


DOWN~'

UP , )

)

A2

AS

GRN

GRNIYEl

,)

FORWARD

VEL

REAR UP-DOWN MOTOR

,) 53

54

YEUGRN

B1

BlK

2

2

2

SLIDE MOTOR

BACKWARD

RECLINE MOTOR

G551

G551

BACK

22-193

Power Seat Circuit Diagram - 2-way Adjustable UNDER·HOOD FUSE/RELAY BOX BATIERY ~

No.41 (100A) No.55 (40A) ~BLK--~--
YEUGRN

No.2 (20A)


RED

1


~) 4

GRNlYEl

0-

DOWN \

I

2

GRNlRED

5

BlK

3

BlK

BlK

G551

22-194

BACK

r--:'I t=:..I Switch Test - 8-way Adjustable 1. Remove the adjustment switch cover (A) from the driver's seat by removing the three screws (8), and pulling off the adjustment switch knobs (C).

4. Check for continuity between the terminals in each switch position according to the table. Terminal 1\ A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6 Position \ FOR IV h \.J WARD ( \ SLIDE SWITCH BACK \.J If\ \.J In WARD FOR 1(\IV V h RECLINE WARD SWITCH BACK In ~ 1'-' WARD

D

n

FRONT UP UPDOWN SWITCH DOWN REAR UP UPDOWN SWITCH DOWN

E

2. Disconnect the 6P connectors (D) from the adjustment switch (E), then remove the switch from the cover by removing its two mounting screws.

IV ( \

(\

1(\ \.J

h

:'-'

( \ ( \ 1'--'

(\

'-' j::; I'-'

\.J

\.J

Al F=I A2 A3 A41A5 A6

3. Reinstall the adjustment switch knobs.

Bl F=I B2 B3 B41 B5 B6


BACK

22-195

Power Seat Switch Test - 2-way Adjustable 1. Remove the adjustment switch cover (A) from the driver's seat by removing the two screws (B) and the recline knob (e).


D

\

Terminal Position

\

,

2

4

3

~

,...

UP

5

,...

,... ~

~

DOWN

111 12

TIT 41511

B

2. Disconnect the 5P connector (D) from the adjustment switch, then remove the switch from the cover by removing its two mounting screws.

/ 4. If the continuity is not as specified, replace the switch.

22-196

BACK

r--:'I I.!!!:.I Motor Test - 8-way Adjustable 1. Remove the driver's seat (see page 20-98).

3. Test the motor. When the motor stops running, disconnect battery power immediately.

2. Disconnect the 6P connectors from the adjustment switch.

FRONT UP-DOWN MOTOR

Recline motor:

1\

Terminal B3

B4

Forward

(E)

e

Backward

e

(E)

A1

AS

Forward

e

GJ

Backward

GJ

Position Wire side of female terminals

REAR UP-DOWN MOTOR

\

Slide motor:

1\

Terminal

Position SLIDE MOTOR

\

e

Front up-down motor:

RECLINE MOTOR Wire side of female terminals

\

Terminal Position

\

UP

A3

A4

GJ

e

e

DOWN

GJ

Rear up-down motor:

\

Terminal Position UP DOWN

\

A2

A6

GJ

e

e

GJ

4. If the motor does not run or fails to run smoothly, check for an open in the power seat wire harness between the 6P connector and the 2P connectors. If the harness is OK, replace the motor (see page 20122).

BACK

22-197

Power Seat Motor Test - 2-way Adjustable 1. Remove the driver's seat (see page 20-99). 2. Disconnect the 5P connector from the adjustment switch. When the motor stops running, disconnect battery power immediately.


3. Testthe motor:

1\

Terminal

2

4

UP

e

(±)

DOWN

(±)

Position

\

e

4. If the motor does not run or fails to run smoothly, check for an open in the power seat wire harness between the 5P connector and 2P connectors. If the harness is OK, replace the motor (see page 22-115).

22-198

BACK

~

t=:.I

Seat Heaters - Canada Component Location Index

SEAT HEATER RELAY Test, page 22-52

,-

(3) LJ

-------~-~-.

I~

I. .

FRONT PASSENGER'S SEAT CUSHION HEATER Test, page 22-201 FRONT PASSENGER'S SEAT-BACK HEATER Test, page 22-201

'-.-====--

DRIVER'S SEAT-BACK HEATER Test,page 22-201 DRIVER'S SEAT CUSHION HEATER Test, page 22-201

DRIVER'S SEAT HEATER SWITCH TesVReplacement, page 22-201 FRONT PASSENGER'S SEAT HEATER SWITCH TesVReplacement, page 22-201

BACK

22-199

Seat Heaters - Canada Circuit Diagram UNDER·HOOD FUSElRE~AY BOX BATTERY

No.41 (100,1.)

IGNITION SWITCH

~....- - YEl - - - - . . ,

No.42 (SOA)

C±)-BlK

-+-~

WHT

I

No.59 (20,1.) ~

DRIVER'S UNDER·DASH FUSEIRfLAY

BOX

TH : THERMOSTAT [ ON : Below 93°F (34°C) ) OFF: Above 109°F (43°C) BR:BREAKER [ ON : Below 86°F (30°C) ) OFF: Above 122°F (50'C) HI :High lO: low

RED/GRN SEAT HEATER RELAY

• COMBINATION LIGHT SWITCH (DX, LX) • tAilLIGHT RELAY (EX)

WHT/BLK

• COMBINATION LIGHT SWITCH (DX, LX) • TAILLIGHT RELAY (EX)

1

Y

Y

r---- WHT/BlK - - - - - - - - - -..

RED/BLK

WHT/BlK DRIVER'S SEAT HEATER SWITCH

6

/

,

/

HI

LO

FRONT PASSENGER'S SEAT HEATER SWITCH

,

lod

/

HI

REDIBLK

6

,

lO

/

,

/

lod

HI

, HI

LIGHT (O.S6W)

LIGHT (O.56W) INDICATORS (O.56Wx2)

INDICATORS (O.56WlC2)

3 RED

WHT/BlU

7

4

3

BlK

GRNlBlU

8lK

RED

WHT/RED


7

GRN/RED

--::;1 - ,

I IBR I I ITH I

-,

- ,

,

,

, , ,

BACK

CUSHION FRONT PASSENGER'S SEAT HEATER

DRIVER'S SEAT HEATER

,,

----

,, ' - - __ =-.1 ,

1


,,

,,

----

CUSHION

-,

,,

,

22-200

BLKlYEl

BACK

(Wrthoul side airbag)

BlK

BlK

BlK

BLK

1

1

1

1

G551

G501

G581

G202

BACK

r--:'I l!!!!!..I Switch Test

Seat Heater Test


1. Carefully remove the driver's and passenger's seat (see page 20-99).

2. Disconnect the 6P connector (A) from the switch (B), and remove the switch from the console tray.

2. Check for continuity in the driver's seat heater between the No.1 and No.2 terminals, and No.1 and No.3 terminals. There should be continuity.



Terminal Position

ON

HIGH LOW OFF


3. Check for continuity in the passenger's seat heater between the No.3 the No.2 terminals, and No.3 and No.1 terminals. There should be continuity. 4. If the continuity is not as specified, replace the heater.

BACK

22-201

Immobilizer System Component Location Index

c

IMMOBILIZER INDICATOR LIGHT Bulb Location, page 22-59 IMMOBILIZER RECEIVER UNIT Troubleshooting, page 22-206 Replacement, page 22-207

-1-0

~CC3(~~t~_~_!;=_r

/

TRANSPONDER

f""'" 'nto ,h. i9""'0" kovf

IGNITION KEY (Master and valet keys)

22-202

BACK

r--:'I I.!!!:..I Circuit Diagram PASSENGER'S UNDER·DASH FUSEIRELAY BOX

UNDER·HOOD FUSEIRELAY BOX BATIERY ®-BLK

No.41 (100A)
No.S4(40A)

~

-----+-Cr'\...D--t------,

NO.46 (1 SA)

No.1 (ISA) DRIVER'S FUSE

WHTIGRN

No,13 (7.SA)

YEL

No.13 (7.SA) DRIVER'S FUSE

YY

REDlWHT

BLUIORN

'00--+--....'"""+-+-

WHTIBLU

YEUBLK -

IMMOBIUZER INDICATOR LIGHT (1.4W)

....- - YEUBLK

KEY IMMOBILIZER RECEIVER UNIT

~~---------

2

--cUJ

3

PGM·FI MAIN L....ji-----+---.....- J RELAY

BLK

BlKIYEL

GRNNEL

IMOFlR

YEUBLK YEUBLK RED

IGPI

BLU BRN/BlK

IMOCD IMOEN

IMOLMP

ECMOI PCM

P

PNK

LGI

FUEL PUMP (FP)

BLK

Gl01

1

T

GS52

Gl01

BACK

22-203

Immobilizer System System Description The vehicle is equipped with an immobilizer system that will disable the vehicle unless the proper ignition key is used. This system consists of a transponder located in the ignition key, an immobilizer receiver unit, an indicator light, and the ECM/PCM. The vehicle has two kinds of keys . • The black master key for: - ignition switch. - door locks. - trunk lock. - glove box. - trunk handle. - rear seat and pass through . • The gray valet key for: - ignition switch. - door locks. When the key is inserted in the ignition and turned to the (II) position, the immobilizer unit sends power to the transponder in the ignition key. The transponder then sends a coded signal back through the immobilizer unit to the ECM/PCM.

_0\" RECEIVE" UNIT ECM/PCM

IGNITION KEY (Has built-in transponder)

FUEL SUPPLY SYSTEM

\

KEY CYLINDER

• The immobilizer system can store up to six key codes. • If it is necessary to rewrite the ECM/PCM to learn a new key, the dealer needs the customer's vehicle, all its master keys and valet keys, and the Honda PGM Tester equipped with an immobilizer program card. Any key that is not learned during rewriting will no longer start the engine. • If the customer has lost his key, and cannot start the engine, contact Honda Customer Relations.

22-204

BACK

r--:'I l=!..I • If the proper key has been used, the ECM/PCM will energize the fuel supply system. The immobilizer indicator light in the gauge assembly will simultaneously come on for about 2 seconds, then go off, indicating that the immobilizer unit has recognized the code sent by the transponder. • If the wrong key has been used and the code was not received or recognized by the ECM/PCM, the indicator light will come on for about 2 seconds, then it will continue blinking until the ignition switch is turned OFF. • If the ignition switch is turned OFF, the indicator will blink for about 5 seconds to signal that the ECM/PCM has been set correctly, then the indicator will go off. Problems and Replacement Parts:

Part set

Problem

CD Master or valet key has been lost or additional master or valet key is reauired. ® All master and valet keys have been lost. @ Immobilizer receiver unit does not work. G) ECM/PCM does not work. ® Ignition switch does not work.

Blank key Blank key (2), valet key Immobilizer receiver unit ECM/PCM Ignition switch with immobilizer receiver unit Master key

BACK

PGM-Tester required 7 YES

YES NO YES YES

22-205

Immobilizer System Troubleshooting Follow this procedure if the vehicle does not start after rewriting the ECM/PCM with the PGM-Tester.

4. Disconnect the 5P connector (A) from the immobilizer receiver unit (B).

Note these items before troubleshooting: o

o

o

o

Due to the action of the immobilizer system, the engine takes slightly more time to start than engines of vehicle without an immobilizer system. When the system is normal, and the proper key is inserted, the indicator light comes on for 2 seconds, then it will go off. Ifthe indicator starts to blink after 2 seconds, or ifthe engine does not start, repeat the starting procedure. If the engine still does not start troubleshoot the system. If all the transponder and immobilizer unit tests are OK, check the ECM/PCM (see page 11-3). If the ECM/PCM is faulty, substitute a known-good ECM/PCM, and recheck (see page 11-5). 1. Using a scan tool, check for a Diagnostic Trouble Code (DTC) (see page 11-3).


Is DTC P1607 indicated? 5. Check for voltage between the No.1 terminal and body ground.

YES-Replace the ECM/PCM (see page 11-5).• NO-Go to step 2.


2. Turn the ignition switch ON (II) with the proper key.

YES- Go to step 6.

3. Check to see if the immobilizer indicator light comes on.

NO - Check for these problems: o

Does the indicator light blink? o

YES-Go to step 4. o

NO- Check for these problems: o

o

An open in the PNK wire between the gauge assembly and ECM/PCM. A faulty immobilizer indicator light..

A blown fuse No.1 (15A) in the driver's underdash fuse/relay box. A blown No. 46 (15A) fuse in the under-hood fuse/relay box. An open in the YEL/BLK wire between the PGM-FI main relay and the immobilizer receiver unit.•

6. Check for continuity between the No.4 terminal and body ground. Is there continuity? YES-Go to step 7. NO- Repair open in the BLK wire between the immobilizer receiver unit and G101 .•

22-206

BACK

r:-:'I I.!!:..I Immobilizer Receiver Unit Replacement 7. Check for continuity between the No.2 terminal and the ECM/PCM. 1. Remove the driver's dashboard lower cover and steering column covers (see page 17-25).


VES- Go to step 8.

2. Disconnect the 5P and 7P connectors (A) from the immobilizer receiver unit (B).

NO- Repair open in the RED wire between the immobilizer receiver unit and ECM/PCM.

B

8. Check for continuity between the No.3 terminal and ECM/PCM.


VES- Replace the immobilizer receiver unit (see page 22-207) .• NO- Repair open in the BLU wire between the immobilizer receiver unit and ECM/PCM .• A

D

3. Remove the 2 screws (C) and the immobilizer receiver unit from the ignition key cylinder (D). 4. Install in the reverse order of removal. 5. After replacement, check the immobilizer system.

BACK

22-207

Keyless Entry/Security Alarm System Component Location Index

UNLO~ON

~lOCKBUTTON (~\I

------ro/O

~~TRUNKBUTTON

TRANSMITTER Test, page 22-230 Programming, page 22-230

DRIVER'S DOOR LOCK SWITCH Test, page 22-227 IGNITION KEY SWITCH Test, page 22-120

~./

PANIC BUTTON

FRONT PASSENGER'S DOOR KEY CYLINDER SWITCH Test, page 22-227 Replacement, page 20-11 FRONT PASSENGER'S DOOR LOCK ACTUATOR!

KNOB SWITCH Actuator Test, page 22-225 Knob Switch Test, page 22-226 Replacement, page 20-14 FRONT PASSENGER'S DOOR SWITCH RIGHT REAR DOOR LOCK ACTUATOR!

KNOB SWITCH Actuator Test, page 22-225 Knob Switch Test, page 22-226 Replacement, page 20-21 RIGHT REAR DOOR SWITCH

DRIVER'S DOOR KEY CYLINDER SWITCH Test, page 22-227

DRIVER'S DOOR SWITCH TRUNK KEY CYLINDER SWITCH Test, page 22-228

DRIVER'S DOOR LOCK ACTUATOR/

KNOB SWITCH Actuator Test, page 22-225 Knob Switch Test, page 22-226 Replacement, page 20-14

TRUNK LID OPENER MOTOR! LATCH SWITCH Test, page 22-228 LEFT REAR DOOR LOCK ACTUATOR/

KNOB SWITCH Actuator Test, page 22-225 Knob Switch Test, page 22-226 Replacement, page 20-21

22-208

BACK

KEYLESS RECEIVER UNIT (In the multiplex control unit, passenger's) Input Test, step 6 on page 22-220 LEFT REAR DOOR SWITCH

~

I.!!!!!..I


Test, page 22-52 TAILLIGHT RELAY

Test, page 22-52

HEADLIGHT RELAY 1

Test, page 22-52

HEADLIGHT RELAY 2

Test, page 22-52 SECURITY INDICATOR

Test, page 22-229

HEADLIGHT

HOOD SWITCH

Test, page 22-229

LICENSE PLATE LIGHT

TAILLIGHTS

BACK

22-209

Keyless Entry/Security Alarm System Circuit Diagram


<±r+

BATTERY

IGNITION SWITCH

No.41 (100A) BLK -

.....-

No.42 (50A)

BLKlYE L

NO.54 (40A)

t---~~~--~~-~L---i--~----No.l0

~~------

HEADLIGHT RELAY 2

I

NO.9 (7.5A)

I

IGI

: Sedan 110A) 15A) : Coupe HEADLIGHT RELAY 1

I

BAT

....- - - - < 1 ' " U _....--<1'"U_--+--WHT

( To page) 22-213

---@-


I

\

I


I )(

.8 ,.. nI

~

No.45 (20A)

No.43 (20A)

~

!:.

RED/GRN RED/GRN

1

REDtGRN

REDIYEL

~~' ~ Y REDIYEL

BLU/RED B16 TAILLIGHT RELAY

A22

REDIYEL

REDIYEL

LEFT HEADLIGHT (LOW BEAM)

RIGHT HEADLIGHT (LOW BEAM)

BLK

BLK

MULTIPLEX CONTROL UNIT (Passenger's) (To page 22-212)

G201

22-210

~


~D • COMBINATION LIGHT SWITCH • DAYTIME RUNNING LIGHT CONTROL UNIT (Canada)

G301

BACK

A6

RE~

REDIBLK

BLU/RED

A24

AID



DAYTIME RUNNING LIGHTS CONTROL UNIT (Canada)

BLUIWHT

EXTERIOR LIGHTS

REDIBLK

r--:'I I..!=..I

G>

YEL PASSENGER'S UNDER-DASH FUSE/RELAY BOX No.6 (20A)

WHT---B> NO.13 (7.SA)

MULTIPLEX CONTROL UNIT (Passengefs) (To page 22-212, 214)

WHTIYEL~

NO.ll (7.SA) WHTIYEL

WHTIBLU

~

SECURITY INDICATOR (lED)

CEILING LIGHT

(Topa~e ) 22-21

WHTIYEL

REDlBlU

A12

AS

~~

MULTIPLEX

r>~ 7

e

UNIT (Door) (To page 22-214)

BRN

UNIT (Passengefs) (To page 22-212)

PNK

Bl

A2

MULTIPLEX CONTROL UNIT (Driver's) UNLOCK A16

A17

GRNJORN

GRYIYEL

DRIVER'S DOOR SWITCH (Closed: ) Door open

lEFT REAR DOOR SWITCH (Closed' ) Door open (Sedan)

B6

YEl

BlUIWHT

BLK

G201

GRY

IGNITION KEY SWITCH (Closed: ) Kaylnsarted

HOOD SWITCH (Closed: ) Hood open

BLK

G401

Be

B9

A13

BLUIGRN

\ ,0 2 BLK

G551

LEFT REAR DOOR LOCK KNOB SWITCH (Closed: ) Unlocked (Sedan)

GRNlORN

2

2

BLK

BLK

TRUNK LATCH SWITCH 6 (ClOsed: ) UdOpen

Y

Bll

B7

TRUNK KEY CYLINDER SWITCH (Closed: ) Unlocked BlK

BLK

1 G601

G503

(cont'd)

BACK

22-211

Keyless Entry/Security Alarm System Circuit Diagram (cont'd)

No.ll (7.5A) PASSENGER'S FUSE (From page 22-211)

I

WHTIBLU

MUTIPLEX CONTROL UNIT (Drive(s) ( From 22-211

page)

No.13 (7.5A) PASSENGER'S FUSE ( From page) 22-211

NO.6 (20A) PASSENGER'S FUSE (FrOm page) 22-211

No.9 (7.5A) DRIVER'S FUSE (FrOm 22-211

page)

HEADLIGHT RELAY ( From 22-210

page) ,, _-+0' ''0

TTTTT PNK

WHTIYEL

WHT

YEL

BLU/RED

CEILING LIGHT

BLKIWHT

....:

-

A24

B9

A23

A22

A20

A21


A15

A14

GRNIWHT

GRN

821

BlU

B22

BlK

Bl

WHT/RED

4 PASSENGER'S DOORSWlTCH (Closed' ) Oooropen

RIGHT REAR DOOR SWITCH (Closed: ) Oooropen (Sedan)

3

AUDIO UNIT

4

14

BLK

BLK

GSOI

22-212

BACK

TRUNK LID OPENER MOTOR

M

G504

G601

r--:'I

~


No.47 (20A) FUSE

( From page) 22-210

HORN RELAY

WHT/RED

BLUIRED

~ LT GRNlRED RIGHT REAR DOOR LOCK ACTUATOR

BLUIRED

LOW HORN

HORN SWITCH

HIGH HORN

(Sedan)

WHTIRED

LTGRNlBLU

~ LT GRNlRED

(TRANSMITTER) I

Al0

All

LOCK<±)

AS

Bll

I

UNLOCK<±)

LOCK

MULTIPLEX CONTROL UNIT (Passenger's) UNLOCK

UNLOCK

UNLOCK LOCK

A17

A3

KEYLESS RECEIVER UNIT

TRUNK UNLOCK

UNLOCK LOCK

AS

A4

A16

PANIC

A13

AS

DOOR LOCK KONB GRNlBLK KEY

Q

ORN

BLUIORN BLKlBLU

REDIBLU

BLK

BLKIORN

[)::>--~ I

FRONT PASSENGER'S DOOR LOCK KNOB SWITCH

o .......+--' 2

BLK

_____

I I IL

3 __

- .... .2

BLK

3 FRONT PASSENGER'S DOOR KEY CYLINDER SWITCH

, .2

BLK

FRONT PASSENGER'S DOOR LOCK SWITCH

I

0

RIGHT REAR DOOR LOCK KNOB SWITCH (Sedan)

2

BLK

I G581

(cont'd)

BACK

22-213

Keyless Entry/Security Alarm System Circuit Diagram (cont'd) MULTIPLEX CONTROL UNIT (Drivers)

No.13 (7.5A) PASSENGER'S FUSE

( From page)

( FIOm page)

BRN

WHTIYEl

22·211

22·211

r

r

A15

Al

MULTIPLEX CONTROL UNIT (Door)

A17

A7

UNLOCK lOCK

UNLOCK lOCK

A16

AlB

A6

A12

AS

DOOR LOCK KNOB

Q

BlK/RED PNK

3

DRIVER'S

~~

KNOB SWITCH

UNLOCK

lOCK

\~---2

BlK

I

I I

BlU KEY

BlUIWHT

f---cOJ

I I I I I I

----------

1 -~,

3 /

BlKIWHT

1

3

DRIVER'S DOOR KEY CYLINDER SWITCH

2

BlK

I 1 BlK

G40l

22-214

BlK

GRNlRED

BACK

'\

/

DRIVER'S DOOR lOCK SWITCH

2

BLK

I

BlK

I

r--:'I I.!!!!!..I System Description Security Alarm System

Panic Mode

The security alarm system is armed automatically after the doors, hood, and trunk lid are closed and locked. For the system to arm, the ignition switch must be off, the key must be removed, and the security control unit must receive signals that the doors, hood, and trunk lid are closed and locked. The alarm can be disarmed at any time by unlocking either door with the key or the remote transmitter.

The panic mode allows the security system to sound the alarm with the remote transmitter in order to attract attention. When the PANIC button is pressed and held for 2 seconds, the alarm will sound and the exterior lights will flash for about 30 seconds.

When everything is closed and locked, the only control unit inputs that are grounded, and have 0 volts, are the driver's door lock knob switch, and the audio unit. In other words, all of the other switches are open, including the key cylinder switches, and they have about 10 volts. Ten seconds after the doors are locked with the key or the lock knob (with the door open), or immediately after the doors are locked with the LOCK button on the remote transmitter, the security system arms, and the security indicator on the door panel flashes. If the security indicator does not flash, the system is not arming. Check the doors, hood, and trunk to see if they are closed. A beep to confirm the security alarm system is armed will sound if the LOCK button is pressed a second time within 5 seconds.

The panic mode can be canceled at anytime by pressing any button on the remote transmitter or by turning the ignition switch ON (II). The panic mode will not function if the ignition switch is ON (II).

If one of the switches is misadjusted or there is a short in the system, the system will not arm. As long as the control unit continues to receive a ground signal, it senses that the vehicle is not closed and locked, and the system will not arm. Conversely, a switch that is slightly misadjusted can sound an alarm for no apparent reason. In this case, a significant change in outside temperature, the vibration of a passing truck, or someone bumping into the vehicle could cause the alarm to sound. If anything is opened or improperly unlocked after the system is armed, the control unit receives a ground signal from that switch, and the 10 volts reference drops to 0 volts. If the radio is disconnected, the input loses its ground, and the input voltage goes to 10 volts. The system sounds the alarm when any of these things occur: • A door is forced open • A door is unlocked without using the key or the remote transmitter • The hood is opened • The trunk is opened without using the transmitter • The audio unit is disconnected • The panic mode is activated When the system sounds the alarm, the security horn sounds and the exterior lights flash for 2 minutes. The alarm can be stopped at any time by unlocking either door with the key or by pushing any button on the remote transmitter.

BACK

(cont'd)

22-215

Keyless Entry/Security Alarm System System Description (cont'd) Keyless Entry System The security alarm system is integrated with the keyless entry system. The keyless entry system allows you to lock and unlock the vehicle with the remote transmitter. When you push the LOCK button, all doors lock. When you push the UNLOCK button once, only the driver's door unlocks. The remaining doors unlock when you push the button a second time. The ceiling light, if its switch is in the center position, will come on when you press the UNLOCK button. If you do not open a door, the light will go off in about 30 seconds, the doors will automatically relock, and the security system will rearm. If you relock the doors with the remote transmitter within 30 seconds, the light will go off immediately. You cannot lock the doors with the remote transmitter if a door is not fully closed, or if the key is in the ignition switch. If the doors will lock and unlock but the Security System will not arm make sure the trunk and hood are closed. If the doors will unlock, but not lock, the system may think a door is open. Check the door switches, the dome light operation, and the safety indicator. To open the trunk, push the Trunk Release button and hold it for about 2 seconds. The trunk will not open if the key is in the ignition switch. If the doors lock and unlock normally, but the trunk opener is inoperative or erratic, the problem could be a wrong remote or passenger multiplex control unit. 1998-99 remotes and control units are different than 2000-02 control units. Multiplex control units are also different for trim level and body style (coupe and sedan). If a third keyless/security transmitter has been added, the trunk release button must be pushed twice on that transmitter to open the trunk. The system will signal you when the doors lock and unlock by flashing the parking lights, side marker lights, and taillights: once when they lock. and twice when they unlock. Push the LOCK button twice within 5 seconds and the horn will confirm the car is locked with one short beep. If the lights do not flash. make sure the doors the hood and the trunk are closed and locked. Check that the security indicator blinks. If the Security Alarm System does not arm, see multiplex mode and input tests.

22-216

BACK

r--:'I I.:!..I Control Unit Input Test 1. Before testing the keyless entry/security control functions, troubleshoot the multiplex control system with mode 1 and mode 2 tests (see page 22-137). Multiplex Control Unit, Driver's:

2. Remove the driver's multiplex control unit from the driver's under-dash fuse/relay box. 3. Inspect the connector and socket terminals to be sure they are all making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. • If the terminals look OK, go to step 4.

FUSE/RELAY BOX SOCKET

Al

~

1>\1.

A4

A5

A13 A14 Al5 AlB

-----

/lJj

A7

AB

AID All A12

I>S

A17 AlB A19 A20 t-- A21 A22 A23 1>\1.4

MULTIPLEX CONTROL UNIT, DRIVER'S CONNECTOR B GRN/ORN

GRY

Y~ \Bl\,GRN/ Bl

B3

B4

B5

Bll B12 B13 B14 B15

/

t

BlK

RED/GRN

Wire side of female terminals DRIVER'S UNDER-DASH FUSE/RELAY BOX CONNECTOR A

,

GRN/ORN

5

2

3

4

6

9

10


,..

DRIVER'S UNDER-DASH FUSE/RELAY BOX CONNECTOR 0 BlU/WHT

... 1

2

3 10 11 12 .....

4

F=L

5

8

9

18 19

20

6

13 14 1 15 16 17

7

L..


(cont'd)

BACK

22-217

Keyless Entry/Security Alarm System Control Unit Input Test (cont'd) 4. With the driver's multiplex control unit still disconnected, make these input tests at the connector and driver's under-dash fuse/relay box sockets. • If any test indicates a problem, find and correct the cause, then recheck the system . • If all the input tests prove OK go to step S.

Cavity B11

A12

Wire BLK


Fuse/relay Under all box socket conditions

Ignition switch ON

A24

(II)

A10

AS

A22

RED/GRN

The headlights should come on.

Combination light switch ON

Check for continuity to ground: There should be continuity. Check for continuity to ground: There should be no continuity. Check for continuity to ground: There should be no continuity. The taillights should come on.

Combination light switch OFF Combination light switch ON and jump B16to batterv voltaae

22-218


Headlight switch ON (~D) and jump A 10 to battery voltage Under all conditions

Combination light switch OFF B16


Attach to ground: The security indicator should come on.

BACK

Possible cause if result is not obtained • Poor ground (GS03) • An open in the wire • Blown No. 13 (7.SA) fuse in the passenger's under-dash fuse/ relay box • An o~en in the wire • Blown No.9 (7.SA) fuse in the driver's under-dash fuse/relay box • An oQen in the wire • Poor ground (G401) • Faulty headlight relay 1 or 2 • An open in the wire • Faulty combination liaht switch • Blown No. 13 (7.SA) fuse in the passenger's under-dash fuse/ relay box • Faulty security indicator • An o~en in the wire • Poor ground (G401) • Faulty combination light switch • An open in the wire

• Faulty taillight relay • Faulty combination light switch • An open in the wire

~

L.:.I

5. Reconnect the driver's multiplex control unit to the fuse/relay box, and perform the following input tests at the appropriate connectors on the back of the fuse/relay box. o

o

If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, go to step 6. Cavity 09

Wire BLU/WHT

A3

GRN/ORN

B6

VEL

Test condition Ignition key is in the ignition switch Ignition key is out of the ignition switch Driver's door open Driver's door closed Hood open Hood closed

B7

B8

GRN/ORN

BLU/GRN

Trunk key cylinder switch in unlock Trunk key cylinder switch in neutral Trunk lid open Trunk lid closed

B9

GRV

Left rear door lock knob unlocked Left rear door lock knob locked

Test: Desired result Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more.

Possible cause if result is not obtained o Poor ground (G401) o Faulty Ignition key switch o An open in the wire

o o

o o o

o o o

o o o

o

o o

Faulty driver's door switch An open in the wire

Faulty hood switch Poor ground (G201) An open in the wire Faulty trunk key cylinder switch Poor ground (G601) An open in the wire Faulty trunk latch switch Poor ground (G601) An open in the wire Faulty left rear door lock actuator Poor ground (G551) An open in the wire

(cont'd)

BACK

22-219

Keyless Entry/Security Alarm System Control Unit Input Test (cont'd) Multiplex Control Unit, Passenger's:

6. Remove the passenger's mUltiplex control unit from the passenger's under-dash fuse/relay box, and disconnect its connector. 7. Inspect the connector and socket terminals to be sure they are all making good contact. • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system . • If the terminals look OK, go to step 8. FUSE/RELAY BOX SOCKET

AI

~

A2.

M

A5 /lS

p.s AIO All AI2

AB

A7

AI3 AI4 A15 AI6 ~ A17 AlB A19 I® ~ A21 A22 A23 A2.4

MULTIPLEX CONTROL UNIT, PASSENGER'S CONNECTOR B WHT/RED

t

YEl

BLU

BlK


PASSENGER'S UNDER-DASH FUSE/RELAY BOX CONNECTOR A

..

n

.,

4 7 6 1 2 3 5 8 9 101 11 12 113 14 115 161 17 181 19 20

..

,

/

GRN/WHT

RED/BLU

,

..

GRN


PASSENGER'S UNDER-DASH FUSE/RELAY BOX CONNECTOR F BlK/BLU

GRN/BlK

I

\

.... 1

2

3

12

13

14

BlK/ORN

BlU/ORN

I

~/

4lSl1=11617 15

I I J 16

ORN

17

18

9

10

11

19

20

21

22


22-220

BACK

...

8

r--:'I I.!!:..I 8. With the passenger's multiplex control unit still disconnected, make these input tests at the connectors and the passenger's under-dash fuse/relay box sockets . • If any test indicates a problem, find and correct the cause, then recheck the system . • If all the input tests prove OK, go to step 9. Cavity A8

Wire Test condition Fuse/relay Under all box socket conditions

Test: Desired result Check for continuity to ground: There should be continuity. Attach to ground: Horn should sound.

A9


A20 A21

Under all conditions Ceiling light switch in the middle position

Attach to ground: Headlights should come on. Attach to ground: Ceiling light should come on.

A22

Ignition switch ON


(II)

A23



A24




Check for continuity to ground: There should be continuity. Check driver's door lock operation: The door should lock.

B22

A10 B11 A11

B1

BlK

Fuse/relay JumpA10to box socket battery voltage, VEL then jump B11 to body ground. Fuse/relay JumpA10to box socket battery voltage and A 11 to body ground. WHT/RED Connect the B 1 terminal to the A24 terminal momentarily.

All passenger doors should lock.

Check trunk opener operation: Trunk lid should open.

Possible cause if result is not obtained • Poor ground (G581) • An open in the wire • Blown No. 47 (20A) fuse in the under-hood fuse/relay box • Faulty horn relay • Faulty horn • An oQen in the wire • Faulty headlight relay • An o1!en in the wire • Blown No. 11 (7.5A) fuse in the passenger's under-dash fuse/ relay box • Faulty ceiling light • An oQen in the wire • Blown No.9 (7.5A) fuse in the driver's under-dash fuse/relay box • An oJ!en in the wire • Blown No.6 (20A) fuse in the passenger's under-dash fuse/ relay box • An open in the wire • Blown No. 13 (7.5A) fuse in the passenger's under-dash fuse/ relay box • An open in the wire • Poor ground (G504) • An open in the wire • Faulty driver's under-dash fuse/ relay box • An open in the wire • Faulty driver's actuator • Faulty driver's under-dash fuse/ relay box • An open in the wire • Faulty passenger's actuator • Poor ground (G601) • Faulty trunk opener solenoid • An open in the wire

(cont'd)

BACK

22-221

Keyless Entry/Security Alarm System Control Unit Input Test (cont'd) 9. Reconnect the passenger's multiplex control unit to the passenger's under-dash fuse/relay box, and perform the following input tests at the appropriate connectors on the passenger's under-dash fuse/relay box (see connector views page 22-218). For passenger's under-dash fuse/relay box connector socket location (see page 22-46). NOTE: All passenger lock knobs must be in the locked position, then unlocked and locked one at a time, or the test results will not be correct. • If any test indicates a problem, find and correct the cause, then recheck the system . • If all the input tests prove OK, go to step 10. Cavity

Wire

F2

GRN/BLK

F5

F6

F3

F7

A14

Test condition

Front passenger's door lock knob unlocked Front passenger's door lock knob locked BLU/ORN Front passenger's door lock switch in UNLOCK Front passenger's door lock switch in the neutral position BLK/ORN Front passenger's door lock switch in LOCK Front passenger's door lock switch in the neutral position Front passenger's door BLK/BLU lock key cylinder locked Front passenger's door lock key cylinder the neutral position Front passenger's door ORN lock key cylinder unlocked Front passenger's door lock key cylinder the neutral position GRN/WHT Right rear door opened Right rear door closed

A16

GRN

A8

RED/BLU

B21

BLU

22-222

Front passenger's door opened Front passenger's door closed Right rear door lock knob unlocked Right rear door lock knob locked Under all conditions

Test: Desired result Check for voltage to ground: There shoudl be 1 V or less. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be less than 1 V. Check for voltage to ground: There should be 5 V or more.

• • • • • •

Possible cause if result is not obtained Poor ground (G581) Faulty front passenger's door lock actuator An open in the wire Poor ground (G581) Faulty front passenger's door lock switch An open in the wire

Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more.

• Poor ground (G581) • Faulty front passenger's door lock key cylinder switch • An open in the wire

Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be 1 V or less. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There shoudl be 1 V or less. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There shoudl be 1 V or less.

BACK

• Faulty right rear door switch • An open in the wire

• Faulty front passenger's door switch • An open in the wire • Poor ground (G581) • Faulty right rear door lock switch • An open in the wire • An open in the wire • Poor ground (G501) • Faulty connections at the audio unit • Faulty audio unit

~ ~

Multiplex Control Unit, Door: 10. Remove the driver's multiplex control door unit, and disconnect its connector. 11. Inspect all the connector and socket terminals to be sure they are making good contact . • If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system . • If the terminals look OK, go to step 12. BLU/WHT WHT/YEL

~

C,

r

Al

A2

A11

A12

1/ 1/ 1/ / A4

A15

BLK

I

BRN

BLK/WHT

!

i

~~NK

A6

A7

A8

A16

A17

A18

Btu

I

n

1/ 1/ Al0

A19


GRN/RED

BLK/RED

12. With the door unit still disconnected, make these input tests at the connector. • If any test indicates a problem, find and correct the cause, then recheck the system . • If all the input tests prove OK, go to step 13. Cavity A12

Wire BlK

A1

WHT/YEl


Test: Desired result Check for continuity to ground: There should be continuity. Check for voltage to ground: There shoudl be battery volltage.

Possible cause if result is not obtained • Poor ground (G401) • An open in the wire • Blown No. 13 (7.5A) fuse in the passenger's under-dash fuse/ relay box • An ooen in the wire

(cont'd)

BACK

22-223

Keyless Entry/Security Alarm System Control Unit Input Test (cont'd) 13. Reconnect the connectors to the door multiplex control unit, make these input tests at the connector. • If any test indicates a problem, find and correct the cause, then recheck the system . • If all the input tests prove OK, go to step 14. Cavity A6

A16

Wire BLU/WHT

BLU

A7

PNK

A17

BLK/RED

A8

BLK/WHT

A18

GRN/RED

Test condition Driver's door key cylinder switch in LOCK Driver's door key cylinder switch in neutral Driver's door key cylinder switch in UNLOCK Driver's door key cylinder switch in neutral Driver's door lock knob locked Driver's door lock knob unlocked Driver'S door lock knob unlocked Driver's door lock knob locked Driver's door lock switch in LOCK Driver's door lock switch in neutral Driver's door lock switch in LOCK Driver'S door lock switch in neutral

Test: Desired result Check for voltage to ground: There should be less than 1 V. Check for voltage to ground: There should be 5 V or more.

Possible cause if result is not obtained • Faulty driver's door key cylinder switch • Poor ground (G401) • An open in the wire

Check for voltage to ground: There should be less than 1 V. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be less than 1 V. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be less than 1 V. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be less than 1 V. Check for voltage to ground: There should be 5 V or more. Check for voltage to ground: There should be less than 1 V. Check fQr voltage to ground: There should be 5 V or more.

• Faulty driver'S door lock actuator • Poor ground (G401) • An open in the wire

• Faulty driver's door lock switch • Poor ground (G401) • An open in the wire

14. If all the input tests prove OK, one of the control units must be faulty. Substitute a known-good control unit for the one that is most likely at fault, then recheck the system. If the system works properly, the original control unit is faulty; replace it. If there is still a malfunction, substitute a known-good control unit for the next most likely unit to be at fault, and recheck. If the system works properly, the original unit is faulty; replace it.

22-224

BACK

~

t..=..I Rear Door Lock Actuator Test

Front Door Lock Actuator Test 1. Remove the front door panel (see page 20-8).

1. Remove the rear door panel (see page 20-8).

2. Disconnect the 2P connector from the actuator.

2. Disconnect the 2P connector from the actuator.

3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily.

3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily.

1\

!\

Terminal

1

2

LOCK

CB

8

UNLOCK

8

CB

Position

\

4. If the actuator does not operate as specified, replace it.

Terminal 1

2

LOCK

CB

8

UNLOCK

8

CB

Position

\

4. If the actuator does not operate as specified, replace it.

BACK

22-225

Keyless Entry/Security Alarm System Driver's Door Lock Knob Switch Test

Passenger's Door Lock Knob Switch Test


1. Remove the passenger's door panel (see page 208).

2. Disconnect the 3P connector from the actuator. 2. Disconnect the 3P connector from the actuator. • FRONT PASSENGER'S: • RIGHT REAR:

LEFT REAR:

3. Check for continuity between the terminals in each knob switch position according to the table.

\

3. Check for continuity between the terminals in each knob switch position according to the table.

Terminal Position LOCK UNLOCK

\

1

2

0

0 0

3 • FRONT PASSENGER'S: • RIGHT REAR:

\

0

Terminal

Position

4. Ifthe continuity is not as specified, replace the lock knob switch.

\

1

2

0

-0

2

3

0

-0

LOCK UNLOCK

LEFT REAR:

\

Terminal

Position

\

LOCK UNLOCK

4. If the continuity is not as specified, replace the lock knob switch.

22-226

BACK

~ ~ Door Key Cylinder Switch Test

Door Lock Switch Test

1. Remove the front door panel (see page 20-8).

1. Remove the front door inner handle (see page 20-8).

2. Disconnect the 3P connector from the key cylinder switch.

2. Remove the two screws, then remove the door lock switch.


1\

3. Check for continuity between the terminal in each switch position according to the table. \

Position LOCK

Terminal Position LOCK

\

1

2

3

0

0

0

)

\

1

2

C"

0

3

OFF UNLOCK

OFF UNLOCK

Terminal

0

0



BACK

22-227

Keyless Entry/Security Alarm System Trunk Lid Opener Motor/Latch Switch Test

Trunk Key Cylinder Switch Test 1. Open the trunk lid.


2. Disconnect the 2P connector from the trunk key cylinder switch.

2. Disconnect the 6P connector from the trunk latch.

---

/

Terminal side of male terminals Terminal side of male terminals

3. Check for continuity between the terminals in each switch position according to the table. 3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily.

\

Terminal Position

\

1

2

0

-0

LOCK

1\

Terminal

Position

\

UNLOCK

3

4

8)

8

UNLOCK

4. If the continuity is not as specified, replace the trunk key cylinder switch.

4. Check for continuity between the terminals in each trunk lid position according to the table.

1\

Terminal

Position Open

\

2

6

0

-0

Closed

5. If the motor does not operate as specified or the continuity is not as specified, replace the opener motor/latch switch.

22-228

BACK

r--:'I

~

Security Indicator Test

Hood Switch Test


1. Open the hood.

2. Disconnect the 2P connector from the security indicator.

2. Disconnect the 2P connector from the hood switch.



3. Check for continuity between the terminals in each switch position according to the table. 3. The LED should come on when power is connected the No.2 terminal and ground is connected to the No.1 terminal.

f\

Terminal

Position \ Hood open (Lever released) Hood closed (Lever pushed down)

4. If the LED does not come on, replace it.

1

2

0

4. If the continuity is not as specified, replace the hood switch.

BACK

22-229

Keyless Entry/Security Alarm System Transmitter Test

Transmitter Programming

NOTE: • If the doors unlock or lock with the transmitter, but the LED on the transmitter does not come on, the LED is faulty; replace the transmitter. • If any door is open, you cannot lock or unlock the door with the transmitter. • If you unlocked the doors with the transmitter, but do not open any of the doors within 30 seconds, the doors relock automatically. • The doors do not lock or unlock with the transmitter if the ignition key is inserted in the ignition switch.

Storing transmitter codes: The codes of up to three transmitters can be read into the keyless receiver unit memory. (If a fourth code is stored, the code which was input first will be erased.)

1. Press the lock or unlock button 5 or 6 times to reset

NOTE: It is important to maintain the time limits between the steps. 1. Turn the ignition switch ON (II).

2. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the keyless receiver unit behind the glove box.

the transmitter.

3. Within 1 to 4 sec., turn the ignition switch OFF. • If the locks work, the transmitter is OK .• • If the locks don't work, go to step 2.

4. Within 1 to 4 sec., turn the ignition switch ON (II).

2. Open the transmitter and check for water damage. • If you find any water damage, replace the transmitter. • • If there is no water damage, go to step 3.


6. Within 1 to 4 sec., turn the ignition switch OFF.

3. Replace the transmitter battery (A) with a new one,

and try to lock and unlock the doors with the transmitter by pressing the lock or unlock button 5 or 6times. • If the doors lock and unlock, the transmitter is OK.• • If the doors don't lock and unlock, go to step 4.

7. Within 4 sec., turn the ignition switch ON (II). 8. Within 1 to 4 sec., push the transmitter lock or unlock button with the transmitter aimed at the keyless receiver unit behind the glove box.

9. Within 1 to 4 sec., turn the ignition switch OFF. 10. Within 4 sec., turn the ignition switch ON (II).

,r-)


12. Confirm you can hear the sound ofthe door lock actuators. Within 1 to 4 sec., push the transmitter lock or unlock button again. 13. Within 15 sec., aim the remaining transmitters at the keyless receiver unit (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock buttons. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored.

4. Reprogram the transmitter, then try to lock and unlock the doors (see page 22-227). • If the doors lock and unlock, the transmitter is OK.• • Ifthe doors don't lock and unlock, replace the tra nsmitter..

14. Turn the ignition switch OFF, and pull out the key. 15. Confirm proper operation ofthe transmitters.

NOTE: The transmitters for LX models and EX models are different and are not interchangeable.

22-230

BACK

~ ~

Power Door Locks Component Location Index DRIVER'S DOOR LOCK SWITCH Test, page 22-227 FRONT PASSENGER'S DOOR KEY CYLINDER SWITCH Test, page 22-227 Replacement, page 20-14

FRONT PASSENGER'S DOOR SWITCH RIGHT REAR DOOR LOCK ACTUATOR Test,page 22-225 Replacement, page 20-21 RIGHT REAR DOOR SWITCH

DRIVER'S DOOR KEY CYLINDER SWITCH Test, page 22-227

DRIVER'S DOOR LOCK ACTUATORI KNOB SWITCH Test, page 22-225 Replacement, page 20-14

FRONT PASSENGER'S DOOR LOCK ACTUATOR Test, page 22-225 Replacement, page 20-14

LEFT REAR DOOR LOCK ACTUATOR Test, page 22-225 Replacement, page 20-21 LEFT REAR DOOR SWITCH

BACK

22-231

Power Door Locks Circuit Diagram IGNITION SWITCH

UNDER·HOOD FUSE/RELAY BOX BATTERY

No.41 (l00A)

No.42 (50A) WHT

(±)--BLK

-@-

ATNo.9(7.SA) BLKlYEL IGl

-+-c:rVJ-+-- YEL - - - - -

No.12 (20A)

No.54 (40A) ~


YEL

-+-....-a--.....o--t----------WHT----No.13 (7.SA)


~--~---------WHTNEL-----

MULTIPLEX CONTROL UNIT (Door) (To page 22·234)

I

PNK

WHTIYEL

Bl

A12


A13

Bl1

BLUfWHT

A2

BRN

LEX ~ MULTIP f~ROLUNIT 2

~

22-232

BlK

BLK

G503

G401

BACK

IGNITION KEY SWITCH Inserted ) OFF: Removed

(ON :

(To page 22·234)

r:-:'I I..!=:.J

DRIVER'S DOOR LOCK ACTUATOR

r-- WHTIRED

11'0M 12

LTGRNlRED-

FRONT PASSENGER'S DOOR LOCK ACTUATOR

~ WHTIRED ~ LTGRN/REDLEFT REAR DOOR LOCK ACTUATOR (Sedan)

~ WHTIRED ~ LTGRNlREDRIGHT REAR DOOR LOCK ACTUATOR (Sedan) WHTNEL

PNK

WHT

A24

B9

YEL

A23

A22

~ WHTIRED ~ LTGRN/REDAl0

All

LOCK(±)

UNLOCK(±)

MULTIPLEX CONTROL UNIT (Passenger's) UNLOCK LOCK A17

UNLOCK LOCK A4

AS

A16

AS

B22

DOOR LOCK KONB

KEY

Q

ORN

BLU/ORN BLKiBLU

[p--~

3

I

~-----'-- / L.....---II--.I 2

BLK

BLK

BLKJORN

3 FRONT PASSENGER'S DOOR KEY CYLINDER SWITCH

,

/

FRONT PASSENGfiR'S DOOR LOCK SWITCH

2 BLK

BLK

I G581

(cont'd)

BACK

22-233

Power Door Locks Circuit Diagram (cont'd) MULTIPLEX CONTROL UNIT (Driver's)

No.13 (7.5A) PASSENGER'S FUSE

page)

page)

( From 22·232

( From 22·232

r

r

BRN

WHTIYEL

A15

Al

MULTIPLEX CONTROl UNIT (Door)

A17

A7

UNLOCK LOCK

UNLOCK LOCK

A16

AlB

A6

A12

A8

DOOR LOCK KNOB

Q

BLKlRED

I

PNK

3 DRIVER'S

l'88:

KNOB

UNLOCK

LOCK

,~~ ---

I

BLU

GRNlRED

KEY

I I I I I I

3

-~:

/

SWITCH

2

BLK

I

3 DRIVER'S DOOR KEY CYLINDER SWITCH

2

BLK

I

BLK

1 -.

G40l

22-234

BLKIWHT

BLUIWHT

:---c:[]

BLK

BACK

,

/

DRIVER'S DOOR LOCK SWITCH

2

BLK

I

BLK

I

Restraints Restraints Special Tools ................................................................. 23-2

Seat Belts Component location Index -Coupe ....................................................................... -Sedan ........................................................................ Front Seat Belt Replacement -Coupe ....................................................................... -Sedan ........................................................................ Rear Seat Belt Replacement -Coupe ....................................................................... -Sedan ........................................................................ Inspection ...................................................................... Child Seat Tether Anchor Installation -'98-99 models ........................................................... Child Seat Anchor Plate Removal/Installation -'00 model Coupe ...................................................... -'01-02 models Coupe ............................................... -'00-02 models Sedan ...............................................

23-3 23-4 23-5 23-7 23-12 23-15 23-17 23-19 23-20 23-21 23-22

SRS (Supplemental Restraint System) Component location Index ......................................... Precautions and Procedures ....................................... General Troubleshooting Information ....................... SRS Unit Identification ................................................. DTC Troubleshooting Index ........................................ Symptom Troubleshooting Index ............................... System Description ...................................................... Circuit Diagram ............................................................. DTC Troubleshooting ................................................... SRS Indicator light Circuit Troubleshooting ............. Component Replacement! Inspection After Deployment ................................... Driver's Airbag Replacement ...................................... Front Passenger's Airbag Replacement ..................... Side Airbag Replacement ............................................ Airbag Disposal ............................................................ Cable Reel Replacement .............................................. SRS Unit Replacement ................................................. Side Impact Sensor Replacement ............................... OPDS Unit Replacement ..............................................

23-23 23-28 23-41 23-47 23-48 23-61 23-62 23-67 23-74 23-242 23-277 23-278 23-280 23-282 23-283 23-289 23-295 23-297 23-300

Restraints Special Tools Tool Number Descril!tion 07HAZ-SG00500 Deployment Tool 07PAZ-0010100 SCS Service Connector SRS Inflator Simulator 07SAZ-TB4011A ® 07TAZ-SZ5011A SRS Simulator Lead C CD @*2 Backprobe Adapter, 17 mm 07TAZ-001020A 07XAZ-S1A0100 SRS Test Box 4P ® (J) SRS Simulator Lead E 07XAZ-S1A0200 07 XAZ -SZ30 100 SRS Simulator Lead F ® SRS Simulator Lead H 07YAZ-S3AA 100 ® * 1: Included In SRS Tool Set 07MAZ-SM5000B *2: Use with the stacking patch cords from TIN 07SAZ-001000A, Backprobe Set. Ref.No. CD*' @

Qt}'

1 1 1 1 2 1 1 1 1

®

@

CD

@

.g}"

"~,.~

~ CD

23-2

@

®

®

®

BACK

_0'

'9' lQI

Seat Belts Component Location Index - Coupe

REAR SEAT BELT Replacement, page 23-12 Inspection, page 23-17 CHILD SEAT

TETHER ANCHOR Installation-'98-99 models, page 23-19 Removal/Installation -'00 model, page 23-20 -'01-02 models, page 23-21

,/ /

/

----------------.~'.

REAR CENTER BELT and REAR SEAT BELT BUCKLES page 23-13

FRONT SEAT BELT Replacement, page 23-5 Inspection, page 23-17 FRONT SEAT

BELT BUCKLES page 23-9

BACK

23-3

Seat Belts Component Location Index - Sedan

SHOULDER ANCHOR ADJUSTER step 10 on page 23-8 REAR SEAT BELT Replacement, page 23-15 Inspection, page 23-17

CHILD SEAT ANCHOR PLATE Installation-'98-99 models, page 23-19 Removal/lnstallation-'OO-02 models, page 23-22

REAR CENTER BELT and REAR SEAT BELT BUCKLES page 23-16

FRONT SEAT BELT Replacement, page 23-7 Inspection, page 23-17

FRONT SEAT BELT BUCKLES page 23-9

23-4

BACK

Front Seat Belt Replacement - Coupe '01-02 models: SRS components are located in this area. Review the SRS component locations (see page 23-23), and precations and procedures (see page 23-28) in the SRS section before preforming repairs or service.

7. Remove the middle cross-member gusset (A):

NOTE: Check the front seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and installation.

-1 Detach the clips, and pull back the carpet (B).

-2 Remove the bolts (C, D) and nut, then remove the gusset. Fastener Locations

c ~: Bolt,4 Front Seat Belt

10X1.2smm 38N·m (3.9 kgf·m, 2.8Ibf·ft)

•

1. '01-02 models: Make sure you have the anti-theft code for the radio, then write down the frequencies for the preset buttons.

D ~:Bolt,2 •

8X1.2smm 22N·m (2.2 kgf.m, 16Ibf·ft)

. : Nut, 1

~ 22N·m (2.2kgf·m,

8x1.2Smm

2. Slide the front seat forward fully. 3. '01-02 models: Disconnect the negative battery cable, and wait at least 3 minutes before beginning work.

16Ibf·ft)

4. Remove these items (see page 20-128): • Rear seat-backs • Rear seat cushion 5. Remove these items (see page 20-76): • Rear bulkhead cover • Rear side trim panel 6. Remove the side trim (see page 20-74). B

(cont'd)

BACK

23-5

Seat Belts Front Seat Belt Replacement - Coupe (cont'd) 8. Remove the upper anchor cap (A) and lower anchor cap (8).

A

\

10. Disconnect the seat belt tensioner connector (A) ('01-02 models). Remove the upper anchor bolt (8) and lower anchor bolt (e), the retractor mounting bolt (D), and the retractor bolt (E). Remove the front seat belt (F) and retractor (G). '98-00 models (without tensioner): B

CE>

7/16-20 UNF 32N·m (3.3 kgf·m, 24 Ibf·ftl

F

D 6x 1.0mm 9.8N·m (1.0 kgf·m, 7.2Ibf·ftl

E

7/16-20 UNF 32N·m (3.3 kgf·m, 24 Ibf·ftl

G C 7/16-20 UNF 32N·m (3.3 kgf·m, 24 Ibf·ftl

'01-02 models (with tensioner):

II ~ \\

7/16-20 UNF B 32 N·m (3.3 kgf·m,

9. Remove the bolts, then remove the seat belt guide (A).

241.'·ftl

\

/

"'~ F

Fastener Locations ~: Bolt, 2

@mm ) I

6X1.0mm 9.8 N·m (1.0 kgf·m, 7.2Ibf·ftl

D 6x 1.0 mm 9.8N·m (1.0kgf·m, 7.2Ibf·ftl

A

E 7/16-20 UNF

G

23-6

BACK

Front Seat Belt Replacement Sedan 11. Install the seat belt and retractor in the reverse order of removal, and note these items: • Check that the retractor locking mechanism functions (see page 23-17). • Assemble the washers, collar and bushing on the upper and lower anchor bolts as shown. • Before installing the anchor bolts, make sure there are no twists or kinks in the front seat belt. '01-02 models: • Make sure the seat belt tensioner connector is plugged in properly. • Reconnect the negative cable to the battery. • Enter the anti-theft code for the radio, then enter the customer's radio station presets. Upper anchor bolt construction: UPPER

'01-02 models: SRS components are located in this area. Review the SRS component locations (see page 23-23), and precations and procedures (see page 23-28) in the SRS section before preforming repairs or service. NOTE: Check the front seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and installation.

Front Seat Belt 1. '01-02 models: Make sure you have the anti-theft code for the radio, then write down the frequencies for the preset buttons. 2. Slide the front seat forward fully.

TOOTHED

3. '01-02 models: Disconnect the negative battery cable, and wait at least 3 minutes before beginning work. 4. Remove the rear seat cushion (see page 20-129). 5. Remove these items (see page 20-75): • Front side trim • Rear side trim • Center pillar lower trim panel

BUSHING

Lower anchor bolt construction: LOWER ANCHOR

WAVE WASHER

BUSHING

6. Remove the upper anchor cover (A), and pull the lower anchor cover (B) back.

I

LOWER ANCHOR

Retractor bolt construction:

\

RElRACTOR

(cont'd)

BACK

23-7

Seat Belts Front Seat Belt Replacement - Sedan (cont'd) 7. Disconnect the seat belt tensioner connector (A), ('01-02 models). Remove the upper anchor bolt (B) and lower anchor bolt (C), the retractor mounting ET screw (D), the retractor bolt (E), and remove the front seat belt (F) and retractor (G). '98-00 models (without tensioner):

8. Remove the front and rear door trim as necessary (see page 20-75). 9. Remove the center pillar upper trim (see page 2075). 10. Remove the shoulder anchor adjuster (A).

B 7/16-20UNF 32N·m 13.3 kgf·m, 24 Ibf·ft)

8x 1.2Smm 22 N·m (2.2 kgf·m, 16Ibf·ft) D 6x1.0mm 4N·m 10.4 kgf.m, 3 Ibf·ft)

G

11. Install the seat belt and retractor in the reverse order of removal, and note these items:

c-

7/16-20 UNF 32 N·m (3.3 kgf·m, 24Ibf·ft)

7/16-20UNF 32N·m (3.3 kgf·m, 24 Ibf·ft)

'01·02 models (with tensioner): B 7/16-20UNF 32N·m 13.3 kgf·m, 24 Ibf·ft)

'01·02 models: • Make sure the seat belt tensioner connector is plugged in properly. • Reconnect the negative cable to the battery. • Enter the anti-theft code for the radio, then enter the customer's radio station presets.

F

~X1.0~ 4N·m

A

10.4kgf.m, 3Ibf·ft)

G

c-

7/16-20UNF 32 N·m (3.3 kgf·m, 24 Ibf·ft)

23-8

• Apply liquid thread lock to the upper anchor bolt before reinstallation. • If the threads on the retractor mounting ET screw are worn out, use an oversized ET screw (PIN 90133-SZ4-0030)made specifically for this application. • Check that the retractor locking mechanism functions as described (see page 23-17). • Assemble the washers, collar and bushing on the upper and lower anchor bolts as shown. • Before installing the anchor bolts, make sure there are no twists or kinks in the front seat belt.

E 7/16-20UNF 32N·m (3.3 kgf·m, 24 Ibf·ftl

BACK

Seat Belt Buckle

Upper anchor bolt construction:

1. Remove the front seat (see page 20-99). UPPER ANCHOR COLLAR

"1

2. Remove the following parts from the front seat:

~))))I)I))-c-c-

• Manual seat: center cover (see page 20-104) • Manual height adjustable seat: center cover (see page 20-108) • 8-way power seat: center cover (see page 20-114) • 2-way power height adjustable seat: Bracket cover (see page 20-110)

/

TOOTHED LOCK WASHER

BUSHING

3. On a driver's seat and '00-02 models passenger's seat with side airbag, disconnect and/or detach the seat belt switch connector and clip (A) and harness clips (B).

Lower anchor bolt construction: Manual seat: SPRING WASHER

Retractor bolt construction: Manual height adjustable seat:

TOOTHED

RETRACTOR BOLT

l~wr~

\

A B

~lll)lll))

@ \

r-.. .---.

RETRACTOR

- - 1


(cont'd)

BACK

23-9

Seat Belts Front Seat Belt Replacement - Sedan (cont'd) 2-way power seat ('98-99 models);

8-way power seat;

A

B

To seat belt buckle. To seat belt buckle.

A

2-way power seat ('00 model);

2-way power seat ('01-02 models);

B


23-10

BACK

4. Remove the center anchor bolt (A), and remove the seat belt buckle (B).

6. Install the seat belt buckle in the reverse order of removal. Assemble the washers on the center anchor bolt as shown.

NOTE: The 2-way power seat is shown, the manual seat, and the manual height adjustable seat are similar. .I

Center anchor bolt installation: CENTER ANCHOR BOLT

COLLAR \

TOOTHED

I,1\ ))@-B ((III ) ~~ ~ ®Jy~ \

\\

LOCKW......

.

/

A

7/16-20UNF 32 N·m (3.3 kgf·m, 24 Ibf·ftl

WAVE WASHER

!

'

CENTER ANCHOR

\

SPRING WASHER

5. On a driver's seat and '00-02 models passenger's seat with side airbag, remove the seat belt switch harness (A): • Without manual seat and without 2-way power seat ('00-02 models): Adjust the seat cushion to its maximum height, and remove the harness . • With manual seat: Remove the seat cushion mounting bolts (B) from the inner seat track (e), then pull the inner seat track down away from the seat cushion, and remove the harness. Take care not to damage the hinge bracket (D).

B

10x1.25mm 47 N·m (4.8 kgf.m, 35lbf·ftl

BACK

23-11

Seat Belts Rear Seat Belt Replacement - Coupe Check the rear seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and installation.

6. Remove the upper anchor bolt (A) and lower anchor bolt (B), and the retractor bolt (C). Remove the rear seat belt (D) and retractor (E).

Rear Seat Belt

A 7/16-20 UNF 32 N·m 13.3 kgf·m, 24 Ibf·ftl

1. Slide the front seat forward fully.

E

2. Remove these items (see page 20-128): • Rear seat-backs • Rear seat cushion 3. Remove these items (see page 20-76): • Rear bulkhead cover • Rear side trim panel 4. Remove the side trim (see page 20-74). 5. Remove the upper anchor cap (A).

D

A

C 7/16-20 UNF 32 N·m (3.3 kgf·m, 24lbf·ftl

B 7/16-20 UNF 32 N·m (3.3 kgf·m, 24lbf·ftl

23-12

BACK

Center Belt and Seat Belt Buckles

7. Install the seat belt and retractor in the reverse order of removal, and note these items:

1. Slide the front seat forward fully. • Check that the retractor locking mechanism functions (see page 23-17). • Assemble the washers, collar and bushing on the upper anchor bolt as shown. • Before installing the anchor bolts, make sure there are no twists or kinks in the rear seat belt.

2. Remove these items (see page 20-128): • Rear seat-backs • Rear seat cushion 3. Remove these items (see page 20-76):

Upper anchor bolt installation:

Tl UPPER ANCHOR

UPPER

CHOR

@mmn-

• • • • • •

TOOTHED

LOCKW\HER

~;7S))~~~ @

v:LR

I, BUSHING

WASHERS

Rear bulkhead cover Rear side trim panel High mount brake light Lock cylinder trim Center belt cover Rear shelf

4. Remove the side trim, both sides as necessary (see page 20-74). 5. Remove the center anchor bolts (A), and remove the seat belt buckles (B).

COLLAR

A 7/16-20 UNF 32 N·m (3.3 kgf·m, 24Ibf·ft)

Lower anchor bolt installation:

_ _ LOWER ANCHOR

~I~~TOOTHED ~

LOCK WASHER

Retractor bolt installation:

~\~ -~ \OJII~)~\r:;:=\C=~ @ \ \~ / ! RETRACTOR BOLT

RETRACTOR

B

TOOTHED LOCK WASHER

(cont'd)

BACK

23-13

Seat Belts Rear Seat Belt Replacement - Coupe (cont'd) 6. Remove the retractor mounting ET screw (A) and the retractor bolt (B). Remove the center belt (C) and retractor (0).

8. Install the seat belt and retractor in the reverse order of removal. and note these items: • Check that the retractor. locking mechanism functions (see page 23-17). • Assemble the washers on the center anchor bolt as shown. • Before installing the center anchor bolt. make sure there are no twists or kinks in the center belt.

B 7/16-20UNF 32 N·m 13.3 kgf·m.

Center anchor bolt installation:

-WASHER

____ CENTER ANCHOR

__---TOOTHED lOCK WASHER

Retractor bolt installation:

7. Remove the protector (A).

t::::I----- RETRACTOR BOLT

~ ~.....

23-14

BACK

TOOTHED lOCK WASHER

Rear Seat Belt Replacement - Sedan Lower anchor bolt construction:

NOTE: Check the rear seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and installation.

Rear Seat Belt 1. Remove these items (see page 20-129): • Rear seat cushion • Rear seat side bolster, both sides _ _ LOWER ANCHOR

2. Remove these items (see page 20-77): • • • • • • •

Rear door trim Rear pillar trim, both sides Rear bulkhead cover Center belt cover High mount brake light Lock cylinder trim Rear shelf

~I~~TOOTHED ~

LOCK WASHER


3. Remove the center anchor bolt of the center belt. 4. Remove the lower anchor bolt (A), the retractor mounting ET screw (B), the retractor bolt (C), and remove the rear seat belt (0) and retractor (E). ~~____ --RETRACTOR

~:X1.0mm

4 N·m 10.4 kgf·m, 3Ibf·ft)

6

1<:'\

--TOOTHED

~----- LOCK WASHER

5. Install the seat belt and retractor in the reverse order of removal, and note these items: • If the threads on the retractor mounting ET screw are worn out, use an oversized ET screw (PIN 90133-SZ4-0030) made specifically for this application. • Check that the retractor locking mechanism functions as described (see page 23-17) . • Before installing the anchor bolt, make sure there are no twists or kinks in the rear seat belt.

D

o

A 7/16-20 UNF 32 N·m 13.3 kgf·m, 24Ibf·ft)

/

(cont'd)

BACK

23-15

Seat Belts Rear Seat Belt Replacement - Sedan (cont'd) Center Belt and Seat Belt Buckles

4. Remove the retractor mounting ET screw (A), and the retractor bolt (B), then remove the center belt (C) and retractor (0).

1. Remove the rear seat cushion and rear seat side bolster, both sides (see page 20-129).

A 6x 1.0mm 4 N·m (0.4 kgf.m, 3 Ibf·ft) _____________

2. Remove the center anchor bolts (A), and remove the seat belt buckles (B). A 7/16-20 UNF 32 N·m (3.3 kgf·m, 24 Ibf·ft)

"-- '-L

/~Jf=- ~~~ _~-C:

)l

-=:::-;

~ ~-_ Vi ~

3. Remove these items (see page 20-77): Rear door trim, both sides as necessary Rear pillar trim, both sides Rear bulkhead cover High mount brake light Lock cylinder trim Center belt cover Rear shelf

....... '-'

/'

<~

""r-

~

B

• • • • • • •

B 7/16-20 UNF 32 N·m (3.3 kgf·m, 24Ibf·ft)

C

5. Remove the protector (A).

----A

23-16

BACK

Inspection Retractor

6. Install the seat belt and retractor in the reverse order of removal, and note these items: • If the threads on the retractor mounting ET screw are worn out, use an oversized ET screw (PIN 90133-SZ4-0030) made specifically for this application. • Check that the retractor locking mechanism functions properly (see step 1 on page 23-17). • Assemble the washers on the center anchor bolt as shown. • Before installing the center anchor bolt, make sure there are no twists or kinks in the center belt.

Center anchor bolt construction:

'01-02 models: SRS components are located in this area. Review the SRS component locations (see page 23-23), and precations and procedures (see page 23-28) in the SRS section before preforming repairs or service. 1. Before installing the retractor, check that the seat belt can be pulled outfreely. 2. Make sure the seat belt does not lock when the retractor (A) is leaned slowly up to 15° from the mounted position. The seat belt should lock when the retractor is leaned over 40°. Do not attempt to disassemble the retractor.

Coupe: Front:

*: Mounted Position

*

*I

I

40"

_____-.-____ ,40"

~"-A

_ _ _ CENTER ANCHOR

Forward Rear:

I_---TOOTHED LOCK WASHER

Inside

b

*

*

40:-"...----..,-..____ 40" 15 15"

1


\17,/ ~l'

~"- A I

Forward

b

40"

40"

15; 15"

~ ..

Inside

Rear center:

*

~I~

TOOTHED

~"""J-----LOCK WASHER

Inside

b

.. Forward

(cont'd)

BACK

23-17

Seat Belts Inspection (co nt'd) In-vehicle

Sedan:

1. Check that the seat belt is not twisted or caught on anything.

Front:

2. After installing the anchors, check for free movement on the anchor bolts. If necessary, remove the anchor bolts and check that the washers and other parts are not damaged or improperly installed.

Forward

3. Check the seat belts for damage or discoloration. Clean with a shop towel if necessary. Use only soap and water to clean.

Inside

Rear:

~

NOTE: Dirt build-up in the metal loops ofthe upper anchors can cause the seat belts to retract slowly. Wipe the inside of the loops with a clean cloth dampened in isopropyl alcohol.

A

~ 15~4'~@~~rh ~ :u:.•

o

,

4. Check that the seat belt does not lock when pulled out slowly. The seat belt is designed to lock only during a sudden stop or impact.

40. 1 5 ; J o / ,,/.

/'

Inside

Forward

5. Make sure that the seat belt will retract automatically when released.

Rear Center:

Inside

6. For each passenger's seat belt, check the seat belt retractor locking mechanism ALR (automatic locking retractor). This function is for securing child seats. - 1 Pull the seat belt all the way out to engage the ALR. The seat belt should retract with a ratcheting sound, but not extend. This is normal. - 2 To disengage the ALR, release the seat belt and allow it to fully retract, then pull the seat belt out part-way. The seat belt should retract and extend normally.

Forward

3. Replace the seat belt with a new one if there is any abnormality.

23-18

7. Replace the seat belt with a new one if there is any abnormality.

BACK

Child Seat Tether Anchor Installation - '98-99 Models Coupe:

Sedan:

Attachment points are provided for a rear seat mounted child restraint system which uses a top tether. The attachment points are located on the rear shelf, just behind the rear seat-back.

Attachment points are provilled for a rear seat mounted child restraint system which uses a top tether. The attachment points are located on the rear shelf, just behind the rear seat-back. When using a child seat with a top tether, install the child seat anchor plates securely.

NOTE: • Do not remove the toothed washer (E) from the child seat anchor plate. Use the child seat anchor plate with the toothed washer attached to it. • When installing a child seat on the rear seat, follow the instructions of the manufacturer of the child seat. • Additional anchor plates are available. • Make sure the rear seat-backs are locked firmly when installing a child seat. The rear shelf (A) is perforated at each attachment point (8). Use a razor blade or sharp knife to carefully cut a 1 inch diameter circle at the attachment point, then cut the rear shelf along the perforations to make a hole. When using a child seat with a top tether, install the child seat anchor plates (C) securely.

NOTE: • Do not remove the toothed washer from the child seat anchor plate. Use the child seat anchor plate with the toothed washer attached to it. • When installing a child seat on the rear seat, follow the instructions of the manufacturer of the child seat. • Additional anchor plates are available. • Make sure the rear seat-backs is locked firmly when installing a child seat. 1. On a Canada model, remove the plug (A) from the attachment point (8) on the rear shelf then go to step 4. On a U.S. mode/, go to step 2.

~92 mm (11.5 in.)

A

- , 141 mm (5.6 in.)

'_~\~~~~¥;A .

B

'.

i -.--.-.- ,

. ,~. . ::0(

- --- __

B

/._<::/ 355 mm (14 in.)


'"

298 mm (11.7 in.)

8x 1.25 mm 22 N·m (2.2 kgf·m, 16Ibf·ft)

~.-

E

2. From inside the trunk, select one of the three attachment points (weldnuts) and poke an awl through it to make a marker hole in the rear shelf fabric. 3. From inside the vehicle, use a sharp knife to cut a 22 mm (7/8 in.) diamater hole in the rear shelf fabric and pad at the marker hole. 4. Install the child seat anchor plate (C). Torque the bolt to 22 N·m (2.2 kgf·m, 16Ibf·ft).

BACK

23-19

Seat Belts Child Seat Tether Anchor Removal/Installation - '00 model Coupe 1. Remove the middle child seat tether anchor cover (A) and both side child seat tether anchor covers (8) from the attachment points (e) on the rear shelf (D).

c

8x 1.25 mm 22 N·m (2.2 kgf.m, 16Ibf·ft)

2. Remove the child seat tether anchors (E). Do not remove the toothed washer (F) from the tether anchor. 3. Install the child seat tether anchors in the reverse order of removal. When installing the middle and both side covers on each child seat tether anchor, the one with a slot (G) goes in the middle.

23-20

BACK

Child Seat Tether Anchor Removal/Installation '01-02 models Coupe 1. Remove the rear shelf (see page 20-76). 2. Remove the middle child seat tether anchor (A) and both side child seat tether anchors (8). Do not remove the toothed washer (e) from the tether anchor. Unit: mm (in.)

ax 1.2Smm 22 N·m (2.2 kgf·m, 16Ibf·ft)

A

" >---=====~~--'.

/

B

,--~

3. Install the child seat tether anchors in the reverse order of removal. When installing the middle and both side tether anchors on the body, the one with a shorter spacer goes in the middle.

BACK

23-21

Seat Belts Child Seat Tether Anchor Removal/Installation - '00-02 models Sedan 1. '00 model: Remove the child seat tether anchor covers (A) from the attachment points (8) on the rear shelf (C). B

Unit: mm (in.)

'01-02 models: '00 model:

G

o

8x 1.25mm 22 N·m (2.2 kgf·m, 16Ibf·ft)

8(0.3)

Forwar

Y

8x1.25mm 22N·m (2.2 kgf·m, 16Ibf·ft)

~ ____~''A Forward

::' .. F

17 (0.67)

I~~ ~yo'-J-./

8x 1.25mm 22N·m (2.2kgf·m, 16Ibf.ft)

~

13 (0.51)

Forwa~

Y

I

8 x 1.25 mm 22N·m (2.2 kgf·m. 16Ibf·ft)

I

2. '01-02 models: Release the hooks (D), and remove the middle child seat tether anchor upper cover (E) and both side child seat tether anchor upper covers (F) from the attachment points (8) on the rear shelf (C). 3. Remove the middle child seat tether anchor (G) and both side child seat tether anchors (H). Do not remove the toothed washer (I) from the tether anchor. 4. Install the child seat tether anchors in the reverse order of removal. When installing the middle and both side tether anchors on the rear shelf, the one with a shorter spacer goes in the middle.

23-22

BACK

SRS Component location Index '98-00 Models (without side airbags) SRS INDICATOR LIGHT Troubleshooting, page 23-242

MEMORY ERASE SIGNAL (MES) CONNECTOR (2P) [GRN, GRN] or [BLK, LTGRN/BLK]

FRONT PASSENGER'S AIRBAG Replacement, page 23-280 Disposal, page 23-283

SRS UNIT GROUND SRS UNIT Replacement, page 23-295

DATA LINK CONNECTOR (DLC) (16P)

DRIVER'S AIRBAG Replacement, page 23-278 Disposal, page 23-283

BACK

23-23

SRS Component Location Index (cont'd) '00 Model-Sedan (with side airbags) SRS INDICATOR LIGHT Troubleshooting, page 23-252

SIDE AIRBAG INDICATOR LIGHT


FRONT PASSENGER'S AIRBAG Replacement, page 23-280 Disposal, page 23-284 MEMORY ERASE SIGNAL (MES) CONNECTOR (2P) [GRN, GRN] or

lLT GRNIBLK.

BLKl~/~/_,\:;;,;;;;~/-;.;::~===~ SRS UNIT GROUND ~~--OPDSSENSOR

FRONT PASSENGER'S SIDEAIRBAG Replacement, page 23-282 Disposal, page 23-284

FRONT PASSENGER'S SIDE IMPACT SENSOR Replacement, page 23-297

DATA LINK CONNECTOR (DLC) 16P DRIVER'S SIDE AIRBAG Replacement, page 23-282 Disposal, page 23-284 DRIVER'S SIDE IMPACT SENSOR Replacement, page 23-297

23-24

BACK

'00 Model-Coupe (with side airbags) SRS INDICATOR LIGHT Troubleshooting, page 23-260

SIDE AIRBAG INDICATOR LIGHT


MEMORY ERASE SIGNAL (MES) CONNECTOR (2P) [GRN, GRN] or [LT GRN/BLK, BLK]

FRONT PASSENGER'S AIRBAG Replacement, page 23-280 Disposal, page 23-284

OPDSSENSOR

-FRONT PASSENGER'S SIDEAIRBAG Replacement, page 23-282 Disposal, page 23-284 OPDSUNIT

FRONT PASSENGER'S SIDE IMPACT SENSOR Replacement, page 23-298

DATA LINK CONNECTOR (DLC)16P DRIVER'S SIDE AIRBAG Replacement, page 23-282 Disposal, page 23-284 DRIVER'S SIDE IMPACT SENSOR Replacement, page 23-298

BACK

23-25

SRS Component Location Index (co nt'd) '01-02 Models (with side airbag) SRS INDICATOR LIGHT

Troubleshooting, page 23-265 SIDE AIRBAG INDICATOR LIGHT

DRIVER'S AIRBAG

Replacement, page 23-278 Disposal, page 23-286

FRONT PASSENGER'S AIRBAG

Replacement, page 23-280 Disposal, page 23-286 MEMORY ERASE SIGNAL (MES) CONNECTOR (2P)

SRSUNIT

Replacement, page 23-296 OPDSSENSOR

FRONT PASSENGER'S SIDEAIRBAG

Replacement, page 23-282 Disposal, page 23-286 RIGHT SIDE SEAT . / BELT TENSIONER

,.

DATA LINK CONNECTOR (DLC) 16P

Replacement (Sedan), page 23-12 Replacement (Coupe), page 23-15 Disposal, page 23-286

FRONT PASSENGER'S SIDE IMPACT SENSOR

Replacement, page 23-299 SRS UNIT GROUND

LEFT SIDE SEAT BELT TENSIONER DRIVER'S SIDE IMPACT SENSOR


Replacement (Sedan). page 23-12 Replacement (Coupe), page 23-15 Disposal, page 23-286

DRIVER'S SIDE AIRBAG

Replacement, page 23-282 Disposal, page 23-286

23-26

BACK

'01-02 Models

(WI-thout

- bag) side air SRS INDICAT~R Lpl~~; 23-265 Troubleshooting,

DRIVER'S AIRB!Ge 23-278 Replacement, P2:r-286 Disposal, page

SESIGNAL MEMOCROY J~:CTOR (2P) (MES)

BAG

ENGER'S AIR FRONT PAS~ page 23-280 Replacemen, 23-286 Disposal, page

SRS UNIT t , page 23-296 Replacemen

RIGHT SIDE SEAT /

TeE~~~?~~~an), 2

BEL Rep TIac

pagl~;;~ent (Coupe), Rep 2315 p.age I- page 23-286 Dlsposa,

SRS UNIT GROUND

BELT TENSIONER LEFT SIDE SEAT dan) page 23-12 Replacement l~~upe): page 23-15 Replacement e 23-286 Disposal, pag

BACK

23-27

SRS Precautions and Procedures General Precautions Please read the following precautions carefully before performing airbag system service. Observe the instructions described in this manual, or the airbags could accidentally deploy and cause damage or injuries. • Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. • Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs.

• Use only a digital multi meter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. • Do not put objects on the front passenger's airbag. • The original radio has a coded theft protection circuit. Be sure to get the customer's radio code and write down the frequencies for the radio's preset stations before disconnecting the battery cable. • Before returning the vehicle to the customer, enter the radio code, then enter the customer's radio station presets, and set the clock.

• Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks, or deformation .

• Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector.

23-28

BACK

Airbag Handling and Storage

• Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 0 F/

Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused.

93 0 C).

For temporary storage of the airbag during service, please observe the following precautions . • Store the removed airbag with the pad surface up. Never put anything on the removed airbag.

• Never perform electrical inspections to the airbags, such as measuring resistance. • Do not position yourself in front ofthe airbag assembly during removal, inspection, or replacement .

• Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly.

• Refer to the scrapping procedures for disposal of the damaged airbag.

(cont'd)

BACK

23-29

SRS Precautions and Procedures (cont'd) SRS Unit-'98-01 models and Side Impact Sensors-'OO-02 models with Side Airbags

• Do not disassemble the SRS unit or the side impact sensors .

• Be careful not to bump or impact the SRS unit or the side impact sensors whenever the ignition switch is ON (II), or at least for three minutes after the ignition switch is turned OFF.

• Turn the ignition switch OFF, disconnect the battery negative cable, and wait at least 3 minutes before beginning installation or replacement ofthe SRS unit, or disconnecting the connectors from the SRS unit.

• During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the SRS unit and the side impact sensor. The airbags could accidentally deploy and cause damage or injury.

• Be sure the SRS unit and side impact sensors are installed securely, with the mounting bolts torqued to 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft) • Do not spill water or oil on the SRS unit or the side impact sensors, and keep them away from dust. • Store the SRS unit and the side impact sensors in a cool (less than 104°F/40°C) and dry (less than 80% relative humidity, no moisture) area .

• After a collision in which any airbags or seat belt tensioners ('01-02 models) were deployed, replace the SRS unit and other related components. After a collision in which the side airbag was deployed, replace the side impact sensor on the deployed side and the SRS unit. After a collision in which the airbags or the side airbags did not deploy, inspect for any damage or any deformation on the SRS unit and the side impact sensors. If there is any damage, replace the SRS unit and/or the side impact sensors.

23-30

BACK

Steering-related Precautions Cable Reel Alignment

• Misalignment of the cable reel could cause an open in the wiring, making the SRS system and the horns inoperative. Center the cable reel whenever the following is performed (see step 6 on page 23-291). -

Installation ofthe steering wheel Installation of the cable reel Installation of the steering column Other steering-related adjustment or installation

• Do not disassemble the cable reel. • Do not apply grease to the cable reel. • If the cable reel shows any signs of damage, replace it with a new one. For example, it does not rotate smoothly.

(cont'd)

BACK

23-31

SRS Precautions and Procedures (cont'd) Wiring Precautions

Precautions for Electrical Inspections

SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Observe the instructions described in this section.

• When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector.

• Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness.

• Use a U-shaped probe. Do not insert the probe forcibly. • Be sure to install the harness wires so they do not get pinched or interfere with other parts.

-mD~)

C...L-.--l

• Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. • Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-tometal contact. Poor grounding can cause intermittent problems that are difficult to diagnose.

23-32

BACK

Spring-loaded Lock Connector

Side Airbag Connector:

Some SRS system connectors have a spring-loaded lock.

Disconnecting To release the lock, pull the spring-loaded sleeve (A) and the slider (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half.

Front Airbag Connectors: Disconnecting To release the lock, pull the spring-loaded sleeve (A) toward the stop (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half.

B

Connecting 1. To reconnect, hold the pawl-side connector half, and press on the back of the sleeve-side connector half in the direction shown. As the two connector halves are pressed together, the sleeve (A) is pushed back by the pawl (C). Do not touch the sleeve.

Connecting Hold both connector halves, and press them firmly together until the projection (C) of the sleeve-side connector clicks.

2. When the connector halves are completely connected, the pawl is released, and the springloaded sleeve locks the connector.

(cont'd)

BACK

23-33

SRS Precautions and Procedures (cont'd) Backprobing Spring-loaded Lock Connectors

Seats with Side Airbags

When checking voltage or resistance on this type of connector the first time, you must remove the retainer to insert the tester probe from the wire side.

Seats with side airbags have a "SIDE AIR BAG" label on the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts.

NOTE: It is not necessary to reinstall the removed retainer; the terminals will stay locked in the connector housing.

Label SlDEAlRBAG

A

To remove the retainer (A), insert a flat-tip screwdriver (B) between the connector body and the retainer, then carefully pry out the retainer. Take care not to break the connector.

Because the seats are made by more than one manufacturer, make sure you replace any seat components (seat-back cover, frame, etc.) with the correct parts. The name of the seat manufacturer is indicated on the seat-back.

Label Manufacturer TSJ __ TS-Japan TSU - - TS-USA SETEX-- SETEX

The manufacturer name is also on the seat-back frame and the seat-back pad. Confirm the name when you exchange these parts. o

A o

o

o

23-34

When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. Do not repair torn or frayed seat-back covers. Replace the seat-back cover. After a collision in which the side airbag was deployed, replace the seat-back cover and the side airbag with new parts. Ifthe seat-back cushion is split, it must be replaced. If the seat-back frame is deformed, it must be replaced. Never put after market accessories on the seat (covers, pads, seat heaters, etc.).

BACK

Disconnecting the Airbag Connectors

Disconnect the negative battery cable, and wait at least 3 minutes.

'98-99 Models Driver's Airbag: Before removing the airbag or SRS related devices (the SRS unit and the cable reel), disconnecting connectors from SRS related devices, or removing the dashboard or the steering column, disconnect the airbag connectors from the airbags to prevent accidental deployment. Turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures .

Remove the access panel from the steering wheel, then disconnect the driver's airbag 2P connector (A) and cable reel 2P connector (B).

• Before disconnecting the SRS main harness (A) from the SRS unit, disconnect both airbags (C, D) . • Before disconnecting the cable reel 2P connector (B), disconnect the driver's airbag 2P connector (C).

I

I

SRS UNIT

I

I

i

lA

L

r'l

IB

SRSMAIN HARNESS

Front Passenger's Airbag: Remove the glove box, then disconnect the front passenger's airbag 2P connector (A) and SRS main harness 2P connector (B).

CABLE REEL

I

r-,

I

D


I

r'l

B

I

C

DRIVER'S AIRBAG

A

(cont'd)

BACK

23-35

SRS Precautions and Procedures (cont'd) Disconnecting the Airbag Connectors and Side Airbag Connectors '00 Model-Sedan Before removing a front airbag, side airbag or other SRS related devices (the SRS unit, the cable reel and the side impact sensors), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. • Before disconnecting SRS unit connector A (18P) (A) from the SRS unit, disconnect the driver's airbag 2P connector (e) and front passenger's airbag 4P connentor (D). • Before disconnecting SRS unit connector B (14P) (E) from the SRS unit, disconnect both side airbag 2P connectors (F, G). • Before disconnecting the cable reel 2P connector (B), disconnect the driver's airbag 2P connector (e).

--

r L

r C

B

A

CABLE REEL

-

L

,...D

.

SRS MAIN HARNESS

I--

""-

.-

-.

!-E

I

SRSFLOOR HARNESS

.

-.

--

,...F h

n

~

-.~ I I

DRIVER'S SIDE IMPACT SENSOR

-h


U

DRIVER'S SIDEAlRBAG

I I

I I

G

I I

.

I

FRONT PASSENGER'S SlDEAlRBAG

~

I I

fRONT PASSENGER'S SIDE IMPACT SENSOR

I-

,

23-36

-

""-

--

--

DRIVER'S AIRBAG

--

--

I I

I I

_J

(WIth side alrbag)

BACK

Disconnecting the Airbag Connectors and Side Airbag Connectors '00 Model-Coupe

Before removing a front airbag, side airbag or other SRS related devices (the SRS unit, the cable reel and the side impact sensors), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. • Before disconnecting SRS unit connector A (18P) (A) from the SRS unit, disconnect the driver's airbag 2P connector (e) and the front passenger's airbag 4P connector (D). • Before disconnecting SRS unit connector B (14P) (E) from the SRS unit. disconnect both side airbag 2P connectors (G,I). • Before disconnecting the cable reel 2P connector (B), disconnect the driver's airbag 2P connector (e). • Before disconnecting the left side wire harness 4P connector e556 (F), disconnect the driver's side airbag 2P connector (G). • Before disconnecting the right side wire harness 4P connector e584 (H), disconnect the front passenger's side airbag 2P connector (I).

C

B

A

r--

r

I-

r

CABLE REEL

L

I""

DRIVER'S AlRBAG

~

I..

DI..

,...

FRONT PASSENGER'S AlRBAG

h SRS MAIN HARNESS

I-l..-

!

E

--

--

..-

roo

I""

l-

,

~

-- G

--

--

F

I..

iSRSMAIN HARNESS


,,

"-

--

n

~

I

n

to-

I


... I-J

I

i-

--

--

FRONT PASSENGER'S SIDEAIRBAG


,

I l - L-L __

DRIVER'S SIDfAiRBAG


H I"" ,

--

--

--

--

--

-- ::.J

(With side airbag)

(cont'd)

BACK

23-37

SRS Precautions and Procedures (cont'd) Disconnecting the Airbag Connectors and Side Airbag Connectors

Side Airbag 4. Disconnect the side airbag 2P connector (A) from the SRS floor harness 2P connectors (8) or both side wire harness 2P connectors (8).

'00 Model 1. Disconnect the negative battery cable, and wait at least 3 minutes. Driver's Airbag 2. Remove the access panel from the steering wheel, then disconnect the driver's airbag 2P connector (A) and cable reel 2P connector (8).

B

A A

Front Passenger's Airbag 3. Remove the glove box, then disconnect the front passenger's airbag 4P connector (A) and SRS main harness 4P connector (8).

B

23-38

BACK

Disconnecting the Airbag Connectors, Side Airbag Connectors, and Seat Belt Tensioner Connectors '01-02 Models

Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, the side impact sensor and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. • Before disconnecting SRS unit connector A (18P) (A) from the SRS unit, disconnect the driver's airbag 4P connector (C), front passenger's airbag 4P connector (0), and both seat belt tensioner 2P connectors (F, H). • Before disconnecting SRS unit connector B (14P) (I) from the SRS unit, disconnect both side airbag 2P connectors (K, M). • Before disconnecting the cable reel 4P connector (B), disconnect the driver's airbag 4P connector (C). • Before disconnecting the driver's side wire harness 4P connector C557 (E), disconnect the left side seat belt tensioner 2P connector (F). • Before disconnecting the passenger's side wire harness 4P connector C583 (Coupe) or C584 (Sedan) (G), disconnect the right side seat belt tensioner 2P connector (H). • Before disconnecting the driver's side wire harness 4P connector (J), disconnect the driver's side airbag 2P connector (K). • Before disconnecting the passenger's side wire harness 4P connector (L), disconnect the front passenger's side airbag 2P connector (M). A

8

SRS MAIN HARNESS E

LEFT SlOE WIRE HARNESS

G


SRSMAIN HARNESS


RIGHT SIDE WIRE HARNESS G

(cont'd)

BACK

23-39

SRS Precautions and Procedures (cont'd) Disconnecting the Airbag Connectors and Side Airbag Connectors

Side Airbag 4. Disconnect the side airbag 2P connector (A) from the SRS floor harness 2P connector (B) or both side wire harness 2P connectors (B).

'01-02 Models 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag 2. Remove the access panel from the steering wheel, then disconnect the driver'S airbag 4P connector (A) and cable reel 4P connector (B).

B

A

Seat Belt Tensioner

A

5. Disconnect both seat belt tensioner 2P connectors (A) from the side wire harness 2P connectors (B).

Front Passenger's Airbag 3. Remove the glove box, then disconnect the front passenger's airbag 4P connector (A) and SRS main harness 4P connector (B).

A

B

B

23-40

BACK

General Troubleshooting Information DTC (Diagnostic Trouble Codes) The self-diagnostic function of the SRS system allows it to locate the causes of system problems and then store this information in memory. For easier troubleshooting, this data can be retrieved via a data link circuit. • When you turn the ignition switch ON (11), the SRS indicator will come on. If it goes off after 6 seconds, the system is normal. • If there is an abnormality, the system locates and defines the problem, stores this information in memory, and turns the SRS indicator light on. The data will remain in the memory even when the ignition switch is turned off or if the battery is disconnected. • When you connect the Honda PGM Tester to the 16P Data Link Connector (DLC) to short the SCS terminal, and turn the ignition switch ON (II), the SRS indicator light will indicate the diagnostic trouble code (DTC) by the number of blinks. • After reading and recording the DTC, proceed with the troubleshooting procedure for the code indicated. Precautions • Use only a digital multimeter to check the system. If it's not a Honda multimeter, make sure it's output is 10 mA (0.01 A) or less when switched to the smallest value in the ohmmeter range. A tester with a higher output could damage the airbag circuit or cause accidental airbag deployment and possible injury. • Whenever the ignition switch is ON (11), or has been turned OFF for less than 3 minutes, be careful not to bump the SRS unit; the airbags could accidentally deploy and cause damage or injuries. • Before you remove the SRS main harness, disconnect the driver's airbag connector and the front passenger's airbag connector. • Before you remove the SRS main harness or SRS floor harness, disconnect the driver's side airbag connector and the front passenger's side airbag connector (on model with side airbags). • Make sure the battery is sufficiently charged. If the battery is dead or low, the measured values won't be correct. • Do not touch a tester probe to the terminals in the SRS unit or harness connectors, and do not connect the terminals with a jumper wire. Use only the backprobe set to backprobe spring-loaded lock type connectors (see step 1 on page 23-33).

Reading the DTC When the SRS indicator light is on, read the DTC using either ofthe following methods: Honda PGM Tester "SRS" Menu Method Connect the Honda PGM Tester (A) to the 16P DLC (B), and follow the Tester's prompts in the "SRS" menu. If the Tester indicates no DTC, DTC 9-1, or DTC 9-2, double-check by selecting "SCS" on the display, and watching the SRS indicator light.

(cont'd)

BACK

23-41

SRS General Troubleshooting Information (cont'd) Honda PGM Tester "ses" Menu Method (retrieving the flash codes) -'98-99 Models The SRS indicator light (A) indicates the OTC by the number of blinks when the Honda PGM Tester (C) is connected to the OLC (B). 1. Make sure the ignition switch is OFF. 2. Connect the Honda PGM Tester (C) to the OLC (16P)(B), and follow the Tester's prompts in the"SCS"menu (see the Honda PGM Tester Operator's Manual). A

3. Turn the ignition switch ON (II). The SRS indicator light (A) comes on for about 6 seconds, and then goes off. Then it will blink to indicate the OTCs (see the table below). • • • •

The OTC consists of a main code and a sub-code. Including the most recent problem, up to 3 different malfunctions can be indicated. In case of a continuous failure, the OTC will be indicated repeatedly (see example 1 below). In case of an intermittent failure, the SRS indicator light will indicate the OTC one time, then it will stay on (see example 2 below). • If a continuous and an intermittent failure occur at the same time, both OTCs will be indicated as continuous failures. • When the system is normal (no OTCs), the SRS indicator light will stay on (see example 3). 1. Continuous failure, SRS Indicator Light blinks like this:

::

J, 2S

~

'~2S 1f2S h US 'H].O.3S I... ~._. t ~ ~ ~ I I U I

nt-----i~

S:Second

[.,-., Sub-code (11 Main code 111 Sub-code (21 Main code (11 Sub-code (1) are repeated , '------v-----' '-------y-' in case of DTC 2-1 DTC 1-2 DTC 1-1 continuous Most recent problem Second-most recent Third-most recent failure. problem problem 2. Intermittent failure, SRS Indicator Light blinks like this:

Bul~ check: period

Main code (21

'----~

~

ON OFF I--_~_-===--_==_-=~=-_==-_===-_~_----' Bulb check--: y period DTC 5-1 3. Normal (no failurel, SRS Indicator Light blinks like this:

:: J Bulb check period

I~NODTC._;'OO~".the light stays on.

4. Read the OTC (proceed with the troubleshooting procedure for this OTC). 5. Turn the ignition switch OFF, and wait for 10 seconds. 6. Oisconnectthe Honda PGM Testerfrom the OLC (16P).

23-42

BACK

Light stays on in case of intermittent failure.

Honda PGM Tester "SCS" Menu Method (retrieving the flash codes) -'00-02 Models

Patterns of DTC Indications: The DTC consists of a main code and sub-code.

The SRS indicator light (A) indicates the DTC by the number of blinks when the Honda PGM Tester (C) is connected to the DLC (16P) (B).

5: Second 65

1. Make sure the ignition switch is OFF.

A

25

35

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

ON

2. Connect the Honda PGM Tester (C) to the DLC (16P) (B), and follow the Tester's prompts in the "SCS" menu (see the Honda PGM Tester Operator's Manual).

35

OFF

I - I I-I I-I First emitting Main code

5ub-code

Reading the main code: Incaseof1-10 Count the number of the blinks. Example: 1.251.251.251.251.25

1--1--1--1--1---1

ON OFF

+

Maincode=

3. Turn the ignition switch ON (II). The SRS indicator light (A) comes on for about 6 seconds, and then goes off. Then it will blink to indicate the DTCs (see the table below).

=3

Example: 0.15

~

4. Read the DTC (proceed with the troubleshooting procedure for this DTC).

ON 5. Turn the ignition switch OFF, and wait for 10 seconds. 6. Disconnect the Honda PGM Tester (C) from the DLC (16P) (B).

+

In case of 11 - 15 Four continuous blinks count as ten. Add any further blink together as shown.

1.25 1.25 1.25 1.25

--I I I I I I I I-I-~-+--I

OFF Main code=

10

+

+

= 12

Reading the sub code: Count the number of the blinks. Example: 0.3 5 0.3 5 0.3 5 0.3 5 0.3 5 0.3 5 0.3 5

ON

1-1-1-1-1-1-1-1

OFF 5ubcode=

+

+

+

=4

In case of main code is '3', sub code is '4', record a DTC 3-4.

(cont'd)

BACK

23-43

SRS General Troubleshooting Information (cont'd) • Including the most recent problem, up to three different malfunctions can be indicated (see example 1 below). • In case of a continuous failure, the DTC will be indicated repeatedly (see example 1 below). • In case of an intermittent failure, the SRS indicator light will indicate the DTC one time, then it will stay on (see example 2 below). • If both a continuous and an intermittent failure occur, both DTCs will be indicated as continuous failures. • When the system is normal (no DTCs), the SRS indicator light will stay on (see example 3). • If the SRS indicator light comes on continuously without a DTC, there may be a problem with the system. • If the SRS indicator light does not come on, always check for an open or a short to ground in the SCS circuit before troubleshooting the system.

Example of the DTC Indications: 1. Continuous failure, SRS Indicetor Light blinks like this:

ON

Bul~

OFF

S:Second

lSfR-t2Sft2S:h"~S:M~·3S .n. XL [dkafl••.

check: penod

I

~ub-code

Main code 11) Sub-code 12) Main code 11) Sub-code 11) are repeated ''-------y--' in case of DTC 2-1 DTC 1-2 DTC 1-1 continuous Most recent problem Second-most recent Third-most recent failure. problem problem 2. Intermittent failure, SRS Indicator Light blinks like this:

ON

Main:: 12)

' y

(1)

"

~

_

'-__. . .

OFF ~_ _...J'---_-==~~==- _=:::==___==--_==::::~ Bulb check ~ DTC 5.1 period 3. Normallno failure). SRS Indicator Light blinks like this:

::

Bulb check period

23-44

JI-__..JI~ N. DTC. _em;' ......t ,h, light stays on.

BACK

Indicator stays on intermittent in case oflight failure.

Erasing the DTC Memory

Troubleshooting Intermittent Failures

Special Tools Required SCS Service Connector 07PAZ-0010100

If there was a malfunction, but it doesn't recur, it will be stored in the memory as an intermittent failure, and the SRS indicator light will come on.

To erase the DTC(s) from the SRS unit, use a Honda PGM Tester (see the Honda PGM Tester SRS Vehicle System Supplement) or the following procedure.

After checking the DTC, troubleshoot as follows: 1. Read the DTC (see "Reading the DTC").

1. Make sure the ignition switch is OFF. 2. Connect the SCS service connector (A) to the MES connector (2P)(B). Do not use a jumper wire.

2. Erase the DTC memory (see "Erasing the DTC Memory").

3. With the shift lever in Park or neutral, start the engine, and let the engine idle. 4. The SRS indicator light will come on for about 6 seconds and then go off.

5. Shake the wire harness and the connectors, take a

B

test drive (quick acceleration, quick braking, cornering), turn the steering wheel fully left and right, and hold it there for 5 to 10 seconds. If the problem recurs, the SRS indicator light will come on. 6. If you can't duplicate the intermittent failure, the system is OK at this time.

07PAZ-0010100

3. Turn the ignition switch ON (II). 4. The SRS indicator light will come on for about 6 seconds, and then go off. Remove the SCS service connector from the MES connector (2P) within 4 seconds after the light goes off. 5. The SRS indicator light will come on again. Reconnect the SCS service connector to the MES connector (2P) within 4 seconds after the light comes on. 6. When the SRS indicator light goes off, remove the SCS service connector from the MES connector (2 P) within 4 seconds. 7. The SRS indicator light will blink two times indicating that the memory has been erased. 8. Turn the ignition switch OFF, and wait for 10 seconds. 9. Turn the ignition switch ON (II) again. The SRS is OK if the SRS indicator light comes on for 6 seconds, and then goes off. (cont'd)

BACK

23-45

SRS General Troubleshooting Information (cont'd) Initializing the OPDS (Occupant Position Detection System) Unit-'OO-02 Models with side airbags When a seat-back cover. seat-back cushion. and/or OPDS unit is replaced with a new one. initialize the OPDS by following the procedure below. 1. Set the seat-back in the normal position. and make sure there is nothing on the front passenger's seat. 2. Make sure the front passenger's seat is dry. If it is not dry, start the engine, and turn on the air conditioning system for 30 minutes to dry any moisture from it. 3. Turn the ignition switch OFF. 4. Connect the Honda PGM Tester (A) to the DLC (16P) (B), and follow the Tester's prompts in the "SCS" menu (see the Honda PGM Tester Operator's Manual). 5. Connect the SCS service connector (C) to the MES connector (2P) (D). Do not use a jumper wire.

D

A

6. Turn the ignition switch ON (II). 7. The SRS indicator light comes on for about 6 seconds and goes off. Remove the SCS service connector from the MES connector within 4 seconds after the SRS indicator light went off. 8. The SRS indicator light comes on again. Reconnect the SCS service connector to the MES connector within 4 seconds after the SRS indicator light comes on. 9. The SRS indicator light goes off. Remove the SCS service connector from the MES connector within 4 seconds. 10. Watch the SRS indicator light. • If the indicator light blinks two times and then stays on, the OPDS is initialized, but the DTCs need to be erased. Go to step 11, then erase the DTCs. • If the indicator light blinks two times and then goes off, the OPDS unit is initialized. Go to step 11. • If the indicator light stays on without first blinking, the OPDS is not initialized. Read the DTC, and go to the appropriate page in the DTC Troubleshooting Index. 11. Turn the ignition switch off, and disconnect the PGM Tester.

Blinking SRS indicator light

~ ON

OFF

MES connector terminals

CONNECTED - - - i - - i

DISCONNECTED

23-46

BACK

SRS Unit Identification '98-02 Models The troubleshooting procedures are different for each type of SRS unit. Identify the SRS unit in the vehicle using the chart below, then follow the proper flow chart in the following pages. The identification mark is at the end of the model number on the SRS unit.

MAKER

IDENTIFICATION MARK

NEe

M1

'98-02 Models

KEIHIN

M2

'99 Model

SIEMENS

M3

'98-02 Models

BACK

NOTE

23-47

SRS DTC Troubleshooting Index '98-99 Models NEC (M1) SRS unit

DTC 1-1 1-2 1-3 1-4

1-5 2-1 2-2 2-3 2-4 2-5 5-1 5-4 6-1 6-2 6-3 6-4 7-1 7-2 7-3 8-1 8-2 8-6 9-1

9-2

10-1

23-48

Detection Item Open in driver's airbag inflator Increased resistance in driver's airbag inflator Short to another wire or decreased resistance in driver's airbag inflator Short to power in driver's airbag inflator Short to ground in driver's airbC!g inflator Open in front passenger's airbag inflator Increased resistance in front l!assenger's airbag inflator Short to another wire or decreased resistance in front passenger's airbaj} inflator Short to power in front passenger's airbag inflator Short to ground in front passenger's airbag inflator Internal failure of SRS unit NOTE: Before troubleshooting DTCs 5-1 through 8-2, check battery/system voltage. If voltage is low, repair the charging system before troubleshooting the DTCs.

Internal failure of SRS unit or two failures at a time Internal failure of the SRS unit. If intermittent, it could mean internal failure of the unit or a faulty indicator light circuit. Refer to Troubleshooting Intermittent Failures (see page 23-45). Internal failure of the SRS unit. If intermittent, it could mean internal failure of the power supply (VB line). Refer to Troubleshooting Intermittent Failures (see page 23-45). SRS airbag deployed (SRS unit must be replaced)

BACK

Notes (see page 23-74) (see page 23-74) (see page 23-76)

(see (see (see (see (see

page 23-78) page 23-80) page 23-82) page 23-82) page 23-83)

(see page 23-85) (seepage 23-86) (see page 23-106)

(see page 23-89) (see page 23-106)

(see page 23-88)

'99 Model KEIHIN (M2) SRS unit Dle 1-1 1-2 1-3 1-4 1-5 2-1 2-2 2-3 2-4 2-5 5-1 5-2 5-3 5-4 6-1 6-2 6-3 6-4 7-1 7-2 7-3 8-1 8-2 8-5 8-6 9-1

9-2

10-1

Detection Item Open in driver's airbag inflator Increased resistance in driver's airbag inflator Short to another wire or decreased resistance in driver's airbag inflator Short topower in driver's airbag inflator Short to ground in driver's airbag inflator Open in front passenger's airbag inflator Increased resistance in front passenger's airbag inflator Short to another wire or decreased resistance in front passenger's airbag inflator Short to power in front passenger's airbajJ inflator Short to ground in front passenger's airbag inflator Internal failure of SRS unit NOTE: Before troubleshooting DTCs 5-1 through 8-6, check battery/system voltage. If voltage is low, repair the charging system before troubleshooting the DTCs.

Notes (seeJJage 23-74) (see page 23-74) (see page 23-76)

Internal failure of the SRS unit. If intermittent, it could mean internal failure of the unit or a faulty indicator light circuit. Refer to Troubleshooting Intermittent Failures (see p~ge 23-45). Internal failure of the SRS unit. If intermittent, it could mean internal failure of the power supply (VB line). Refer to Troubleshooting Intermittent Failures (see page 23-45). SRS airbag deployed (SRS unit must be replaced)

(see page 23-106)


page 23-78) page 23-80) page 23-82) page 23-82) page 23-83)

(see p~e 23-85) (see page 23-86) (see page 23-106)

(see page 23-88)

(cont'd)

BACK

23-49

SRS DTC Troubleshooting Index (cont'd) '98-99 Models SIEMENS (M3) SRS unit DTC 1-1 1-3 1-4 1-5 2-1 2-3 2-4 2-5 5-1 5-4 6-3 6-4 7-1 7-2 7-3 8-1 8-2 8-6 9-1

9-2

10-1

23-50

Detection Item Open or increased resistance in driver's airbag inflator Short to another wire or decreased resistance in driver's airbag inflator Short to power in driver's airbag inflator Short tog round in driver's airbag inflator Open or increased resistance in front passenger's airba~ inflator Short to another wire or decreased resistance in front passenger's airbag inflator Short to power in front passenger's airbag inflator Short to ground in front passenger's airbag inflator Internal failure of SRS unit NOTE: Before troubleshooting DTCs 5-1 through 8-6, check battery/system voltage. If voltage is low, repair the charging system before troubleshooting the DTCs.

Internal failure of the SRS unit. If intermittent, it could mean internal failure of the unit or a faulty indicator light circuit. Refer to Troubleshooting Intermittent Failures (see page 23-45). Internal failure of the SRS unit. If intermittent, it could mean internal failure of the power supply (VB line). Refer to Troubleshooting Intermittent Failures (see page 23-45). SRS airbag deployed (SRS unit must be replaced)

BACK

Notes (see page 23-74) (see page 23-76)

(see ~age 23-78) (see page 23-80) (see page 23-82) (see page 23-83) (see page 23-85) (see page 23-86) (see page 23-106)

(see page 23-106)

(see page 23-88)

'00 Model-Sedan-without side airbags NEC (M1) SRS unit DTC 1-1 1-2 1-3 1-4 1-5 2-1 2-2 2-3 2-4 2-5 5-1 5-2 5-4 5-5 5-8 6-1 6-2 6-3 6-4 7-1 7-2 7-3 8-1 8-2 8-5 8-6 9-1

9-2

9-3 9-4 10-1

Detection Item Open in driver's airbaq inflator Increased resistance in driver's airbag inflator Short to another wire or decreased resistance in driver's airbaq inflator Short to power in driver's airbag inflator Short to ground in driver's airbag inflator Open in front passenger's airbag inflator Increased resistance in front passenger's airbag inflator Short to another wire or decreased resistance in front passenger's airbag inflator Short to power in front passenger's airbag inflator Short to !:Hound in front passenger's airbag inflator Internal failure of SRS unit NOTE: Before troubleshooting DTCs 5-1 through 8-6, check battery/system voltage. If voltage is low, repair the charging system before troubleshooting the DTCs.

Notes (see paqe 23-92) (see page 23-92) (see page 23-94)

Internal failure of the SRS unit. If intermittent, it could mean internal failure of the unit or a faulty indicator light circuit. Refer to Troubleshooting Intermittent Failures (see page 23-45). Internal failure of the SRS unit. If intermittent, it could mean internal failure of the power supply (VB line). Refer to Troubleshooting Intermittent Failures (see page 23-45). Faulty driver'S seat belt buckle switch Faulty front passenqer's seat belt buckle switch Airbags deployed (SRS unit must be replaced)

(see page 23-106)

(see~age 23-96) (see page 23-98) (see~age 23-100) (see page 23-100) (see page 23-101) (see page 23-103) (see page 23-104) (see page 23-106)

(see ~age 23-204) (see page 23-208) (see ~al!e 23-106)

(cont'd)

BACK

23-51

SRS DTC Troubleshooting Index (cont'd) '00 Model-Sedan-with side airbags SIEMENS (M3) SRS unit DTC 1-1 1-3 1-4 1-5 2-1 2-3 2-4 2-5 5-1 5-2 5-4 5-8 6-3 6-4 6-7 6-8 7-1 7-2 7-3 8-1 8-2 8-3 8-4 8-5 8-6 8-7 8-8 9-1

9-2

9-3 9-4

23-52

Detection Item Open or increased resistance in driver's airbag inflator Short to another wire or decreased resistance in driver's airbaa inflator Short to power in driver's airbag inflator Short to around in driver's airbag inflator Open or increased resistance in front passenger's airbag inflator Short to another wire or decreased resistance in front passenger's airbag inflator Short to power in front passenger's airbag inflator Short to ground in front passenger's airbag inflator Internal failure of SRS unit NOTE: Before troubleshooting DTCs 5-1 through 8-8, check battery/system voltage. If voltage is low, repair the charging system before troubleshooting the DTCs.

Internal failure of the SRS unit. If intermittent, it could mean internal failure ofthe unit or a faulty indicator light circuit. Refer to Troubleshooting Intermittent Failures (see page 23-45). Internal failure of the SRS unit. If intermittent, it could mean internal failure of the power supply (VB line). Refer to Troubleshooting Intermittent Failures (see page 23-45). Faulty driver's seat belt buckle switch Faultv front passenger's seat belt buckle switch

BACK


(see page 23-96) (seepa~e 23-98) (see page 23-100) (see page 23-101) (see page 23-103) (see page 23-104) (see page 23-106)

(see page 23-106)

(see~age 23-204) (see page 23-208)

SIEMENS (M3) SRS unit DTC 10-1 10-2 10-3 10-4 10-5 10-6 10-7 11-1 11-3 11-4 11-5 12-1 12-3 12-4 12-5 13-1 13-2 13-3 13-4 14-1 14-2 14-3 14-4 15-1 15-2 15-3

Detection Item Airbags deployed Driver's side airbag deployed Airbags and driver's side airbag deI!loyed Front passenger's side airbag deployed Airbags and front passenger's side airbag deployed Driver's and front passenger's side airbag deployed Airbags and driver's and front passenger's side airbags deployed Open or increased resistance in driver's side airbag inflator Short to another wire or decreased resistance in driver's side airbag inflator Short to power in driver's side airbag inflator Short to ground in driver's side airbag inflator Open or increased resistance in front passenger's side airbag inflator Short to another wire or decreased resistance in front passenger's side airbag inflator Short to power in front passenger's side airbag inflator Short to ground in front passenger's side airbag inflator Internal failure of the driver's side impact sensor

Notes (see page 23-106)

No signal from the driver's side impact sensor Faulty power supply to the driver's side imI!act sensor Internal failure of the front passenger's side impact sensor No signal from the front passenger's side impact sensor Faulty power supply to the front passenger's side impact sensor Faulty_OPDS unit or OPDS system not initialized Faulty side airbag indicator light circuit Faulty OPDS sensor

(see page 23-120) (see pajle 23-122) (see page 23-107)

BACK

(see page 23-108) (see page 23-109) (see page 23-111) (see page 23-112) (see page 23-114) (see page 23-115) (see page 23-117) (see page 23-118) (see page 23-107)

(see page 23-124) (see page 23-126) (see page 23-128) (see page 23-133) (see page 23-138)

23-53

SRS DTC Troubleshooting Index (cont'd) '00 Model-Coupe-without side airbags NEC (M1) SRS unit DTC 1-1 1-2 1-3 1-4 1-5 2-1 2-2 2-3 2-4 2-5 5-1 5-2 5-4 5-5 5-8 6-1 6-2 6-3 6-4 7-1 7-2 7-3 8-1 8-2 8-5 8-6 9-1

9-2

9-3 9-4 10-1

23-54

Detection Item Open in driver's airbag inflator Increased resistance in driver's airbaginflator Short to another wire or decreased resistance in driver's airbaJJ inflator Short to power in driver's airbag inflator Short to ground in driver's airbl!Rinflator Open in front passenger's airbag inflator Increased resistance in front passenoer's airbaginflator Short to another wire or decreased resistance in front passenger's airbag inflator Short to power in front passenger's airbag inflator Short to ground in front passenger's airbag inflator Internal failure of SRS unit NOTE: Before troubleshooting OTCs 5-1 through 8-6, check battery/system voltage. If voltage is low, repair the charging system before troubleshooting the OTCs.

Notes (see paoe 23-92) (see page 23-92) (see page 23-94)

Internal failure of the SRS unit. If intermittent, it could mean internal failure of the unit or a faulty indicator light circuit. Refer to Troubleshooting Intermittent Failures (see page 23-45). Internal failure of the SRS unit. If intermittent, it could mean internal failure of the power supply (VB line). Refer to Troubleshooting Intermittent Failures (see page 23-45). Faultv driver's seat belt buckle switch Faulty front passenger's seat belt buckle switch Airbags deploved (SRS unit must be replaced)

(see page 23-106)

BACK

(see paoe 23-96) (see page 23-98) (see page 23-100) (see page 23-100) (see page 23-101) (see page 23-103) (see page 23-104) (see page 23-106)


'00 Model-Coupe-with side airbags SIEMENS (M3) SRS unit DTC 1-1 1-3 1-4 1-5 2-1 2-3 2-4 2-5 5-1 5-2 5-4 5-8 6-3 6-4 6-7 6-8 7-1 7-2 7-3 8-1 8-2 8-3 8-4 8-5 8-6 8-7 8-8 9-1

9-2

9-3 9-4

Detection Item Open or increased resistance in driver's airbag inflator Short to another wire or decreased resistance in driver's airbag inflator Short to power in driver's airbag inflator Short to ground in driver's airbag inflator Open or increased resistance in front passenger's airbag inflator Short to another wire or decreased resistance in front passenger's airbag inflator Short to power in front passe~er's airbag inflator Short to ground in front passenger's airbag inflator Internal failure of SRS unit NOTE: Before troubleshooting DTCs 5-1 through 8-8, check battery/system voltage. If voltage is low, repair the charging system before troubleshooting the DTCs.


Internal failure of the SRS unit. If intermittent, it could mean internal failure of the unit or a faulty indicator light circuit. Refer to Troubleshooting Intermittent Failures (see page 23-45). Internal failure of the SRS unit. If intermittent, it could mean internal failure of the power supply (VB line). Refer to Troubleshooting Intermittent Failures (see page 23-45). Faul!v driver'S seat belt buckle switch Faulty front passenger's seat belt buckle switch

(see page 23-106)

(see page 23-96) (see page 23-98) (see page 23-100) (see page 23-101 ) (see PClge 23-103) (see page 23-104) (see page 23-106)

(see page 23-204) (see page 23-208)

(cont'd)

BACK

23-55

SRS DTC Troubleshooting Index (cont'd) SIEMENS (M3) SRS unit DTC 10-1 10-2 10-3 10-4 10-5 10-6 10-7 11-1 11-3 11-4 11-5 12-1 12-3 12-4 12-5 13-1 13-2 13-3 13-4 14-1 14-2 14-3 14-4 15-1 15-2 15-3

23-56

Detection Item Airbags deployed Driver's side airbag deployed Airbags and driver's side airbag deployed Front passenger's side airbag deployed Airbags and front passenger's side airbag deployed Driver's and front Qassenger's side airbag deployed Airbags and driver's and front passenger's side airbags deployed Open or increased resistance in driver's side airbag inflator Short to another wire or decreased resistance in driver's side airbag inflator Short to power in driver's side airbag inflator Short to ground in driver's side airbag inflator Open or increased resistance in front passenger's side airbag inflator Short to another wire or decreased resistance in front passenger's side airbag inflator Short to power in front passenger's side airbag inflator Short to ground in front passenger's side airbag inflator Internal failure of the driver's side impact sensor

No signal from the driver's side impact sensor Faulty power supply to the driver's side impact sensor Internal failure of the front passenger's side impact sensor No signal from the front passenger's side impact sensor Faulty power supply to the front passenger's side impact sensor Faulty OPDS unit or OPDS system not initialized Faultyside airbag indicator light circuit Faulty OPDS sensor

BACK


(see page 23-139) (see page 23-141) (see page 23-143) (see page 23-145) (see page 23-147) (see page 23-149) (see page 23-151) (see page 23-153) (see page 23-107) (see page 23-155) (see page 23-157) (see page 23-107) (see page 23-159) (see page 23-161 ) (see page 23-163) (see page 23-168) (see page 23-173)

'01-02 Models-Sedan-without side airbags NEC (M1) SRS unit Detection Item DTC Open in driver's airbag inflator 1-1 Increased resistance in driver's airb~inflator 1-2 Short to another wire or decresed resistance in driver's airbag 1-3 inflator Short to power in driver's airbag inflator 1-4 Short to ground in driver's airbag inflator 1-5 Open in front passenger's airbag inflator 2-1 2-2 Increased resistance in front passenger's airbag inflator 2-3 Short to another wire or decreased resistance in front passenger's airbag inflator 2-4 Short to power in front passenger's airbag inflator 2-5 Short to ground in front passenger's airbag inflator 3-1 Open in left side seat belt tensioner 3-2 Increased resistance in left side seat belt tensioner 3-3 Short to another wire or decreased resistance in left side seat belt tensioner 3-4 Short to power in left side seat belt tensioner 3-5 Short to ground in left side seat belt tensioner 4-1 Open in right side seat belt tensioner 4-2 Increased resistance in right side seat belt tensioner 4-3 Short to another wire or decreased resistance in left side seat belt tensioner 4-4 Short to power in left side seat belt tensioner 4-5 Short to ground in right side seat belt tensioner 5-1 Internal failure of SRS unit 5-2 NOTE: Before troubleshooting DTCs 5-1 through 8-6, check battery/ 5-3 system voltage. If voltage is low, repair the charging system before 5-4 troublshooting the DTCs. 5-5 6-1 6-2 6-3 6-4 7-1 7-2 7-3 8-1 8-2 8-3 8-4 8-5 8-6 9-1 Internal failure of the SRS unit. If intermittent, it could mean internal failure of the unit or a faulty indicator light circuit. Refer to Troubleshooting Intermittent Failures (see page 23-451. 9-2 Internal failure of the SRS unit. If intermittent, it could mean internal failure of the power supply (VB line). Refer to troubleshooting Intermittent Failures (see page 23-45). 9-3 Faultv driver's seat belt buckle switch 9-4 Faulty front passenger's seat belt buckle switch 10-1 Seat belt tensioners (and airbag (s) ) deployed

Notes 23-174) (see page 23-174) (see page 23-176) (see~aJle

(seej>aJle 23-178) (see page 23-180) (see~age 23-182) (see page 23-182) (see page 23-183) (see_~aJle 23-185) (see page 23-186) (see~aJle 23-188) (see page 23-188) (see page 23-190)

(see page 23-192) (seej)~e 23-194) (see page 23-196) (see~~e 23-196) (see page 23-197) (see page 23-199) (seej)~e 23-200) (see page 23-202)

(see page 23-202)

(see page 23-204) (see page 23-208) (see page 23-202) (cont'd)

BACK

23-57

SRS DTC Troubleshooting Index (cont'd) '01-02 Models SIEMENS (M3) SRS unit

DTC 1-1 1-3 1-4 1-5 2-1 2-3 2-4 2-5 3-1 3-3 3-4 3-5 4-1 4-3 4-4 4-5 5-1 5-2 5-4 5-8 6-3 6-4 6-7 6-8 7-1 7-2 7-3 8-1 8-2 8-3 8-4 8-5 8-6 8-7 8-8

23-58

Detection Item Open or increased resistance in driver's airbag inflator Short to another wire or decreased resistance in driver's airbag inflator Short to power in driver's airbag inflator Short to around in driver's airbag inflator Open or increased resistance in front passenger's airbag inflator Short to another wire or decreased resistance in front passenger's airbag inflator Short to power in front passenger's airbag inflator Short to ground in front passenger's airbC!Q inflator Open or increased resistance in left side seat belt tensioner Short to another wire or decreased resistance in left side seat belt tensioner Short to power in left side seat belt tensioner Short to ground in left side seat belt tensioner Open or increased resistance in right side seat belt tensioner Short to another wire or decreased resistance in left side seat belt tensioner Short to power in left side seat belt tensioner Short to ground in left side seat belt tensioner Internal failure of SRS unit NOTE: Before trobleshooting DTCs 5-1 through 8-8, check battery/ system voltage. If voltage is low, repair the charging system before troubleshooting the DTCs.

BACK

Notes (seeJ!age 23-174) (see page 23-176)

(see_page 23-178) (see page 23-180) (see page 23-182) (see page 23-183) (see page 23-185) (see page 23-186) (see page 23-188) (see page 23-190) (see page 23-192) (see~C!ge 23-194) (see page 23-196) (see page 23-197) (seeJ!age 23-199) (see page 23-200) (see page 23-202)

DTC 9-1

9-2

9-3 9-4 10-1 10-2 10-3 10-4 10-5 10-6 10-7 11-' 11-3 11-4 11-5 12-1 12-3 12-4 12-5 13-1 13-2 13-3 13-4 14-1 14-2 14-3 14-4 15-1 15-2 15-3

Detection Item Internal failure of the SRS unit. If intermittent, it could mean internal failure of the unit or a faulty indicator light circuit. Refer to Troubleshooting Intermittent Failures (see paQe 23-45). Internal failure of the SRS unit. If intermittent, it could mean internal failure of the power supply (VB line).Refer to Troubleshooting Intermittent Failures (see page 23-45). Faulty driver's seat belt buckle switch Faulty front passenger's seat belt buckle switch Seat belt tensioners (and airbaQ(s)) deployed Driver'S side airbag deployed Seat belttensioners (and airbag(s)) and driver's side airbag deployed Front passenQer's side airbag deployed Seat belt tensioners (and airbag(s)) and front passenger's side airbag deployed Driver'S and front passenger's side airbags deployed Seat belttensioners (and airbag(s)) and driver's and front passenger's side airbags deployed Open or increased resistance in driver's side airbag inflator Short to another wire or decreased resistance in driver's side airbag inflator Short to power in driver'S side airbaQ inflator Short to ground in driver's side airbag inflator Open or increased resistance in front passenger's side airbag inflator Short to another wire or decreased resistance in front passenger's side airbag inflator Short to power in front passenger's side airbag inflator Short to ground in front passenger's side airbag inflator Faulty driver's side impact sensor


No signal from the driver's side impact sensor Faulty power supply to the driver's side impact sensor Faulty front passenger's side impact sensor

(see pa~e 23-226) (see page 23-227) (see page 23-203)

No signal from the front passenger's side impact sensor Faulty power supply to the front passenQer's side impact sensor Faulty_OPDS unit or OPDS system not initialized Faulty side airbag indicator light circuit Faulty OPDS sensor

(see page 23-229) (see page 23-230) (see page 23-232) (see page 23-236) (see page 23-241 )

BACK


(see page 23-211) (see page 23-212) (see page 23-214) (see page 23-216) (see page 23-218) (see page 23-220) (see page 23-222) (see page 23-224) (see page 23-203)

23-59

SRS Symptom Troubleshooting Index '98-99 Models Symptom SRS indicator light doesn't come on The SRS indicator light stays on when in "SCS" menu method

The SRS indicator light comes on for the bulb check, goes off, then comes back on after self-diagnosis, but no OTCs are stored (NEC SRS unit only)

'00 Model-Sedan Symptom SRS indicator light doesn't come on The SRS indicator light stays on when in "SCS" menu method


Diagnostic procedure SRS Indicator Light Troubleshooting (see page 23-242) SRS Indicator Light Troubleshooting (see step 1 on page 23-244)

Also check for

Inability to retrieve OTCs with the PGM Tester. Retrieve the flash codes with the SCS mode (see page 23-42).

SRS Indicator Light Troubleshooting (see step 1 on page 23-248)


Also check for


SRS Indicator Light Troubleshooting (see page 23-257)

00 M odeIeoupe Symptom SRS indicator light doesn't come on The SRS indicator light stays on when in "SCS" menu method


23-60



BACK

Also check for


'01-02 Models Symptom SRS indicator light doesn't come on The SRS indicator light stays on when in "SCS" menu method

The SRS indicator light comes on for the bulb check, goes off, then comes back on after self-diagnosis, but no OTCs are stored (NEC SRS unit only).


Also check for



'00-02 Models Symptom Side airbag indicator light stays on after bulb check

Diagnostic procedure • Make sure nothing is on the front passenger's seat • Make sure the front passenger's seat isn't wet. If the seat is wet, start the engine, and turn on the air conditioning system for 30 minutes to dry any moisture from the seat. • If the side airbag indicator light stays on after the ignition switch is turned ON (11), initialize the OPOS unit (see page 23-46). - Ifthe side airbag indicator light operates normally, the system is OK. - If the side airbag indicator light stays on, replace the OPOS sensor (see section 20). The sensor is part of the seatback pad.

BACK

Also check for

23-61

SRS System Description '98-99 Models SRS Components The SRS is a safety device which, when used in conjunction with the seat belt, is designed to help protect the driver and front passenger in a frontal impact exceeding a certain set limit. The system consists ofthe SRS unit, including safing sensor and impact sensor (A), the cable reel (B), the driver'S airbag (C) and the front passenger's airbag (D). B

C

SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit respectively will keep voltage at a constant level. For the SRS to operate: (1) The impact sensor must activate, and send electric signals to the microprocessor. (2) The microprocessor must compute the signals, and must send signals to the airbag inflators. (3) The inflators must ignite and deploy the airbags.

DRIVER'S UNDER-DASH FUSEIRElAY

BOX

I

SRSUNIT

CABLE REEL

DRIVER·S AIRBAG INFlATOR

FRONT PASSENGER'S AlRBAG INFLATOR

OLe

MES SCS

Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator light comes on and goes off after about 6 seconds ifthe system is operating normally. If the light does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the memory will store the cause ofthe malfunction, and the data link circuit passes on the information from the memory to the Data Link Connector (DLC). This information can be read with the Honda PGM Tester connected to the DLC (16P).

23-62

BACK

'00 Model SRS Components Airbags

The SRS is a safety device which, when used with the seat belt, is designed to help protect the driver and front passenger in a frontal impact exceeding a certain set limit. The system consists ofthe SRS unit, including safing sensor and impact sensor (A), the cable reel (B), the driver's airbag (e) and the front passenger's airbag (D). Side Airbags

Some models are equipped with side airbags (E) which located in each front seat-back. They help protect the upper torso of the driver or front seat passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. OPOS

The side airbag system includes an Occupant Position Detection System (OPDS). This system consists of sensors (G) and an OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the SRS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, it will automatically disable the airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the Side Airbag indicator light on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag indicator light will go off, alerting the driver that the side airbag will deploy in a side impact.

o

A

c

G

(cont'd)

BACK

23-63

SRS System Description (cont'd) SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit, respectively, will keep voltage at a constant level. For the SRS to operate: Driver's and Front Passenger's Airbag(sl

(1) The frontal impact sensor must activate, and send electric signals to the microprocessor. (2) The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). (3) The inflators that received signals must ignite and deploy the airbags. Side Airbag(sl

(1) The side impact sensors must activate, and send electric signals to the microprocessor. (2) The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag ifthe SRS unit determines that the front passenger's head is in the deployment path ofthe side airbag. (3) The inflator that received the signal must ignite and deploy the side airbag.

SRSUNIT

DRIVER'S UNDER·DASH FUSEIRELAY

1

DRIVER'S AlRBAG INFLATOR

BOX

FRONT

PASSENGER'S AIRBAG SECOND INFLATOR

I ,

DRIVER'S SIDE AIABAG INfLATOR

FRONT

'

,

J

PASSENGER'S ' SIDE AIRBAG INFLATOR

~----------o_--~--~--~>-----~~--DlC

MES

SCS

---------(~ae~l

IDC

Self-diagnosis System

A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator light comes on and goes off after about 6 seconds ifthe system is operating normally. If the light does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the Data Link Connector (DLC). This information can be read with the Honda PGM Tester when it is connected to the DLC (16P).

23-64

BACK

'01-02 Models SRS Components Airbags

The SRS is a safety device which, when used with the seat belt, is designed to help protect the driver and front passenger in a frontal impact exceeding a certain set limit. The system consists of the SRS unit, including safing sensor and impact sensor (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), side airbags (E), and seat belt tensioners (I). Side Airbags

The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seat passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. Seat Belt Tensioner

The seat belt tensioner (I) is linked with the SRS airbags to further increase the effectiveness of the seat belt. In a frontend collision, the tensioner instantly retracts the belt firmly to secure the occupants in their seats. OPOS The side airbag system includes an Occupant Position Detection System (OPDS). This system consists of sensors (G) and an OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the SRS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, it will automatically disable the airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the Side Airbag indicator light on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag indicator light will go off, alerting the driver that the side airbag will deploy in a side impact.

c

B

D

G

(cont'd)

BACK

23-65

SRS System Description (cont'd) SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit, respectively, will keep voltage at a constant level. For the SRS to operate: Driver's and Front Passenger's Airbag(s) (1) The frontal impact sensor must activate, and send electric signals to the microprocessor. (2) The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflators. (3) The inflators that received signals must ignite and deploy the airbag(s). Side Airbag(s) (1) The side impact sensors must activate, and send electric signals to the microprocessor. (2) The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the SRS unit determines that the front passenger's head is in the deployment path of the side airbag. (3) The inflator that received the signal must ignite and deploy the side airbag(s).

--

(WIIhside airbag) _ _ __

,-----

FRONT

--:-1

PASSENGER'S DRIVER'S

~~rG ~~8rG:

FRONT PASSENGER'S AlReAG SECOND INFlATOR

DRIVER'S AlR8AG

~mTOR

TRIGGER CIRCUIT

7

scs

IDC

Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator light comes on and goes off after about 6 seconds if the system is operating normally. If the light does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the Data Link Connector (DLC). This information can be read with the Honda PGM Tester when it is connected to the DLC (16P).

23-66

BACK

Circuit Diagram '98-99 Models UNDER·HooD FUSE/RELAY BOX BATTERY

No.41 (100Al

-@IGNITION SWITCH

No.42 (SOA)

+ 1--+-oC""'\...C>----+-WHT

BAT IGI

+-____---,

BLKlYEL - - -...-_ --_ __ _.

IGI HOT in ON (II) and START (III)

No.2 (lOA)

TERMINAL NUMBER

YEL SRS INDICATOR CIRCUIT (In .he gauge assembly)

FEMALE \ iliTERMINAL CONNECTOR NUMBER ~ '\.. C3 2

I

C4


SRS INDICATOR LIGHT (1.4W)

T\

MALE TERMINAL

SRSMAIN HARNESS

FRONT PASSENGER'S AIRBAG INFLATOR BLU

DASHBOARD WIRE HARNESS

BLK

CABLE REEL

I

GRN (YEL)

I

GRN (BLUIYEL)

GRN (BRN)

I

GRN (GRN)

GRN (BLU)

GRN GRN (REDIBLU) (BLKlWHT)

SRS UNIT 18

GRN (BLK I)

GRN (BLK2)

GRN (LT GRN/RED)

GRN (RED)

31

21

I

I

•

LTBLU

I

BRN

9 9 G501

GOOl

GRN (BLK3) I

21

GRN SRSMAIN (L T GRNlBLK) HARNESS

"

I

MEMORY ERASE SIGNALelMES) CONNE TOR


BACK

23-67

SRS Circuit Diagram (cont'd) '00 Model-Sedan BATTERY DRIVER'S AIRBAG INFLATOR

~

UNDER·HOOD FUSEIRELAY

BOX

RED

1 I

I

RED

1

21

, ,

I

~~~~ ~

FRONT PASSENGER'S AIRBAG SECOND INFLATOR

No.2 (lOA)

BlK

BLK

/, , GRN

YElJGRN

21

RED

RED

RED

GRN (BLK)

RED

~I'==:::::::1:===:='==:!:J'

I

, GRN (GRNlBLK)

4'

1, GRN (BLUlYEL)

I

Gaol

GRN (REDlYEL)

SRS MAIN HARNESS

SRSUNIT

11


Bn

GRN--~-------------'

G501

BLU

I I I

GRN YElJGRN BLK

I I

YELIBLU

BLU

BLU 41 OPDS I UNIT HARNESS 7

31

11

21

31

I

21


16

GAUGE ASSEMBlY FRONT PASSENGER'S SEAT BELT BUCKLE SWITCH

I G501

23-68

BACK

G501

5

6

I

BLK SRSFLOOR HARNESS 11

ITl : WIth heated seal II] : WlthouI haatad sail

,--(Wnh side airbag)

----------------------

FRONT PASSENGER'S SIDE AIRBAG INFLATOR

DRIVER'S SIDE AIRBAG INFLATOR

: r@l r@l II I I I 211 21' RED

'I

SRS FLOOR HARNESS

REO

1

REO

'I

GRN (GRNlYEL)

GRN



RED

1

GRN (REDIYEL)

GRN (REO)

4 SRSUNIT 4

6 BRN

DASHBOARD WIRE HARNESS A -

REDIBLU

1

LTGRNlBLK

--+----+---------....

2 9

14

12

DRIVER'S UNDER-OASH FUSEIRELAY BOX

~~J


SRSMAIN HARNESS

W J I

I

BLK

REDIBLUBLUIRED

GS51

1


2

3

<'U GRN

DRIVER'S SEAT BELT BUCKLE SWITCH

DATA"LlNK CONNECTOR (OLC) (t6P)

BACK

GRN

MEMORY ERASE SIGNAL (MES) CONNECTOR (2P)

23-69

SRS Circuit Diagram (cont'd) '00 Model-Coupe BATTERY DRIVER'S AIRBAG INFLATOR

rSl

UNDER·HooD FUSEIRELAY BOX

RED

1 I

IGl HOT in ON (II) and START (III) DRIVER'S UNDER·DASH FUSE/RELAY BOX

FRONT PASSENGER'S AIRBAG FIRST INFLATOR

1 i

1 1

GRN

BLK

21 I 1

GRN (BRN)

FRONT PASSENGER'S AIRBAG SECOND INFLATOR

BlK

rE1rE1

REEL

BLK

YEIJGRN

RED

21 I 1

H~~E Lf---f-J

No.2 (lOA)

YEL

1 1

RED

RED

RED

1

1

I

I

1

RED

I

G801

,

41

1 GRN (BLUlYEl)

GRN (WHT)

SRS MAIN HARNESS

SRSUNIT

5 11

SRS


MAIN

HARNESS

----+-------+--....----+--+--- REDIBLU GRN


BLU

--+---il------.. 1

10 11 BLUIWHT

31 16

GAUGE

,.t:=========::L,

ASSEMBLY

OPDS UNIT HARNESS

1

10d

BL2jRN

*===::===

~I

G501

FRONT PASSENGER'S BUCKLED SEAT BELT BUCKLE SWITCH

23-70


G561

BACK

I

..---1--1---.

' - - - - t - -........

I

BLK

G581

i--

(WHh side airbag) FRONT PASSENGER'S SIDEAIRBAG INFLATOR

DRIVER'S SIDEAIRBAG INFLATOR

re,

I

I

'1

I

21 SRS MAIN • HARNESS

I , 21 I

LEFT SIDE REDIVEL WIRE HARNESS I

re,


RED

RED

GRN (REDIVEL)

I

GRNIWHT GRNiORN

RED

I

I

'1

31

GRN (RED)

1 41

RED

RED

I

I

1

21

RIGHT SIDE ' WIRE BLUIVEL HARNESS

1 I 21

I

GRN GRN (GRNIWHT) (GRNlORN)

GRN (BLU/YEL)



I

YEL

REDIWHT

RED/BLU

BLU

I ~

I

1 'GRN 1

I

31

GRN GRN (REDIWHT) (REDIBLU)

(YEL)

7f

T

41

GRN (BLU)

BLU

4

SRS UNIT

21

6 BRN

LTGRN

41

8

51

I

RE.a"

BRN

LT GRNIBLK

,1

81

I

I

LTGRN

SRS MAIN HARNESS

BLU/RED

WIRE HARNESS A DASHBOARD

BLK

d

MEMORY ERASE SIGNAL (MES) CONNECTOR (2P)

BLU/RED

1.. 9

14

12

DRIVER'S UNDER,DASH FUSEIRELAY BOX

8

MULTIPLEX CONTROL UNIT LEFT SIDE WIRE HARNESS 9BRN

LTGRN

~,~ ~

-------..---.-

nBLK

G~1

2

~

DATA LINK CONNECTOR (DLC) (16P)



BACK

23-71

SRS Circuit Diagram (cont'd) '01-02 Models

BATTERY

DRIVER'S AIRBAG FIRST INFLATOR

DRIVER'S AIRBAG SECOND INFLATOR

LEFT SIDE SEAT BELT TENSIONER

FRONT

FRONT

AlRBAG

AIRBAG SECOND INFLATOR

RIGHT SIDE SEAT BELT TENSIONER

PASSENGER~ PASSENGER~

FIRST INFLATOR

YEL

YEl/GRN

VA


VB SRSUNIT

5 11

3


BLU

YEUBLU

~N--~-----------, 5 SRS INDICATOR CIRCUIT

BLU

GRN YEUGRN BLK

SAS INDICATOR LIGHT

16

GAUGE ASSEMBLY

31 OPDS UNIT HARNESS

d d

I I I GRN WHT/RED BLK

I

I

FRONT ON:UN· BUCKLED

G501

23-72

4

6

BACK

ON: BUCKLED

PASSENGER~

SEAT BELT BUCKLE SWITCH

III : Sedan

m:Coupe

(W~h

*1 :5edan *2 : Coupe

-------------

side airbag)

FRONT PASSENGER'S SIDE AIRBAG INFLATOR

DRIVER'S SIDE AIRBAG INFLATOR

...c:;:;:;.., I \.;,J 1

~


nEL --T .:r 'r-JT l n RED

I

RED

I

2

*~RNIY! 1_'21 -,-,,

i

13

1

I

L

L

_2-,

31 __

SRS •I MAIN HARNESS 4

1

-

"21 __ II'

-------

' lTIJ

,,

----------

41

81

21

&1

1

1 lTGRNlBLK

R_E....

12

DRIVER'S UNDER-DASH

,

_TI

SRS UNIT

~~tn 1-(WI_,tho_ut_he_at_:_d-sea::t): : _-_-__ ~._I_.1 ~ ~ ! I 1: ¢:) , ~ :~ ,~rJJ' . (WIth heated

I

~

11 i-----7 -

-&-1

13

--

9

Rr __

-"41

DASHBOARD WIRE HARNESS

20

I

2

R,GHT SIDE WIRE HARNESS

',EDrl

~[ ,

1,3 :

12

LEFT SIDE W,RE HARNESS

I \.;,JREDI RED

......-----q=1~-,-9'--1--.

*1

G801

,


------,

~~EJRELAY

UNIT

I!I ,2

BLK

i

REDIBLU

L,1-,

~

1

REDlBlU

ON: UN-

BUCKlED~

I~

(Wrth power seat)

1 - DRIVER'S

BLUIRED

21 I ~

2

ERASE SIGNAL IMES) CONNECTOR (2P)

BlUIRED

1 -- d 1 --

BLK

MEMORY

, WIRE DATAUNK HARNESS CONNECTOR (DLC)(16P)

~~6[X

1

POWER SEAT WIRE

HA_R~E~~

BlK

_3_"'I_ _

I

L------i ~

I

ON:

I~BUCKLED

I


I

G551

I

BACK

G501

23-73

SRS DTC Troubleshooting - '98-99 Models DTC 1-1: Open in driver's airbag inflator

6. Reconnect the battery negative cable.

DTC 1-2: Increased resistance in driver's airbag inflator

7. Erase the DTC memory. 8. Read the DTC.

1. Erase the DTC memory (see page 23-45).

Is DTC 1-1 or DTC 1-2 indicated? 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

YES-Go to step 9. NO-Open or increased resistance in the driver's airbag inflator; replace the driver's airbag (see page

Does the SRS indicator light stay on?

23·278).• YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).

9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the cable reel 2P connector from the SRS main harness 2P connector (A).

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the driver's airbag 2P connector from the cable reel 2P connector (A).

A

07TAZ·SZ5011A

C?: /~SA2-~IA --:::::===7~07TAZ.SZ5011A

,-0

5. Connect the special tool (2 Q connector) to the cable reel connector.

11. Connect the special tool (2 Q connector) to the SRS main harness 2P connector. 12. Reconnect the battery negative cable. 13. Erase the DTC memory.

23-74

BACK

14. Read the DTC.

18. Check resistance between the No.1 terminal and the No. 13 terminal of the SRS main harness 18P connector. There should be 2.0 - 3.0 Q.

Is DTC 1-1 or DTC 1-2 indicated? YES-Go to step 15.

SRS MAIN HARNESS 18P CONNECTOR

NO-Open or increased resistance in the cable reel; replace the cable reel (see page 23-289) .• r---1

15. Disconnect the battery negative cable, and wait for 3 minutes. 16. Disconnect the front passenger's airbag 2P connector (A).

1 1/ 3 10

VV Q

~ :/

6 7 8 9 13 14 15 16 17 18

I

Wire side of femal e terminals.

Is the resistance as specified?

YES - Faulty SRS unit or poor contact at the SRS main harness 18P connector and the SRS unit. Check the connection between the SRS main harness 18P connector and the SRS unit. If the connection is OK, replace the SRS unit (see page 23-295) .• NO-Open or increased resistance in the SRS main harness; replace the SRS main harness .• A

17. Disconnect the SRS main harness 18P connector (A) from the SRS unit.

A

BACK

23-75

SRS DTC Troubleshooting - '98-99 Models (cont'd) DTC 1-3: Short to another wire or decreased resistance in driver's airbag inflator.

8. Read the DTC.

Is DTC 1-3 indicated? 1. Erase the DTC memory (see page 23-45). YES-Go to step 9. 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.


NO- Short in the driver's airbag; replace the driver's airbag (see page 23-278) .• 9. Disconnect the battery negative cable, and wait for 3 minutes.

YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).

10. Disconnect the cable reel 2P connector from the SRS main harness 2P connector (A).


A

07TAZ-SZ5011A

-::::::==-::7~07TAZ-SZ5011A

~

/07SAZ-.-llA

,-0 5. Connect the special tool (2 Q connector) to the cable reel 2P connector.

11. Connect the special tool (2 Q connector) to the SRS main harness 2P connector. 12. Reconnect the battery negative cable. 13. Erase the DTC memory. 14. Read the DTC.


Is DTC 1-3 indicated? 7. Erase the DTC memory. YES-Go to step 15. NO- Short in the cable reel; replace the cable reel (see page 23-289) .•

23-76

BACK

15. Disconnect the battery negative cable, and wait for 3 minutes.

19. Check resistance between the No.1 terminal and the No. 13 terminal of the SRS main harness 18P connector. There should be 1 M Q or more.

16. Disconnect the front passenger's airbag 2P connector (A) from the SRS main harness 2P connector (B).


B

10

6

7

8 9

15

16 17 18

Wire side of female terminals.

Is the resistance as specified? YES - Faulty SRS unit; replace the SRS unit (see

page 23-295) .•

A

17. Disconnect the special tool from the SRS main harness 2P connector.

NO- Short in the SRS main harness; replace the SRS main harness.•

18. Disconnectthe SRS main harness 18P connector (A) from the SRS unit.

A

BACK

23-77

SRS DTC Troubleshooting - '98-99 Models (cont'd) DTC 1-4: Short to power in driver's airbag inflator

8. Read the DTC.

Is DTC 1-4 indicated? 1. Erase the DTC memory (see page 23-45). YES- Go to step 9. 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.


NO- Short to power in the driver's airbag; replace the driver's airbag (see page 23-278) .• 9. Disconnect the battery negative cable, and wait for 3 minutes.


10. Disconnect the cable reel2P connector from the SRS main harness 2P connector (A).

3. Turn the ignition switch OFF. Disconnectthe battery negative cable, and wait for 3 minutes. 4. Disconnect the driver's airbag 2P connector from the cable reel 2P connector (A).

A

q: f

.~07TAZ-SZ5011A

/~SAZ-~11A

,-0

5. Connect the special tool (2 Q connector) to the cable reel 2P connector.


6. Reconnect the battery negative cable. 7. Erase the DTC memory.

23-78

BACK

14. Read the DTC.

20. Check for voltage between the No.1 terminal of the SRS main harness 18P connector and body ground, and between the No. 13 terminal and body ground. There should be 0.5 V or less.

Is DTC 1-4 indicated? YES - Go to step 15.


NO - Short to power in the cable reel; replace the cable reel (see page 23-289) .• 15. Disconnect the battery negative cable, and wait for 3 minutes.

10

16. Disconnect the front passenger's airbag 2P connector (A) from the SRS main harness 2P connector (8).

6

7

8

9

15

16 17 18


B

=

=

Is the voltage as specified? YES - Faulty SRS unit; replace the SRS unit (see page 23-295) .•

NO - Short to power in the SRS main harness; replace the SRS main harness.•

A


A

18. Reconnect the battery negative cable. 19. Turn the ignition switch ON (II).

BACK

23-79

SRS DTC Troubleshooting - '98-99 Models (cont'd) DTC 1-5: Short to ground in driver's airbag inflator

8. Read the DTC. Is DTC 1-5 indicated?

1. Erase the DTC memory (see page 23-45). YES- Go to step 9. 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off. Does the SRS indicator light stay on?

NO-Short to ground in the driver's airbag inflator; replace the driver's airbag (see page 23-278) .• 9. Disconnect the battery negative cable, and wait for 3 minutes.

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).

10. Disconnect the SRS main harness 2P connector from the cable reel 2P connector (A).


A

07TAZ-SZ5011A

~01TAZ-SZ5011A

~

/075AZ-1840".

,0 5. Connect the special tool (2 Q connector) to the cable reel 2P connector.



23-80

BACK

14. Read the DTC.

18. Check resistance between the No.1 terminal of the SRS main harness 18P connector and body ground, and between the No. 13 terminal and body ground. There should be 1 M Q or more.

Is DTC 1-5 indicated? YES- Go to step 15. NO- Short to ground in the cable reel; replace the cable reel (see page 23-289) .• 15. Disconnect the battery negative cable, and wait for 3 minutes.


10


6

7

8

9

15

16 17 18


B

= Is the resistance as specified? YES- Faulty SRS unit; replace the SRS unit (see page 23-295) .• NO-Short to ground in the SRS main harness; replace the SRS main harness.•

A


A

BACK

23-81

SRS DTC Troubleshooting - '98-99 Models (cont'd) DTC 2-1: Open in passenger's airbag inflator DTC 2-2: Increased resistance in passenger's airbag inflator

5. Connect the special telol (2 Q connector) to the SRS main harness 2P conrlector. 6. Reconnect the batter" negative cable.


7. Erase the DTC memory.

2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

8. Read the DTC. Is ore 2-1 or 2-2 indicated?


YES-Go to step 9.

YES - Go to step 3.

NO - Open or increased resistance in the front

NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.

passenger's airbag inflator; replace the front passenger's airbag (see page 23-280) .• 9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the driver's airbag 2P connector (A) from the cable reel 2P connector (8).

4. Disconnect the front passenger's airbag 2P connector from the SRS main harness 2P connector (A).

A

23-82

BACK

DTC 2-3: Short to another wire or decreased resistance in passenger's airbag inflator.


1. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

Does the SRS indicator light stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).

A

12. Check resistance between the No. 10 and No. 14 terminals ofthe SRS main harness 18P connector. There should be 2.0-3.0 Q.

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the front passenger's airbag 2P connector from the SRS main harness 2P connector (A).


6

7

8

9

15

16 17 18

A


Is the resistance as specified? 07SAZ-TB4011A

~

YES- Faulty SRS unit or poor contact at the SRS unit connector; check the connection between the SRS main harness 18P connector and the SRS unit. If the connector is OK, replace the SRS unit (see page 23-295) .• NO-Open or increased resistance in the SRS main harness; replace the SRS main harness.•

O~

5. Connect the special tool (2 Q connector) to the SRS main harness 2P connector.

(cont'd)

BACK

23-83

SRS DTC Troubleshooting - '98-99 Models (cont'd) 6. Reconnect the battery negative cable.


7. Erase the DTC memory. 12. Disconnect the SRS main harness 18P connector (A) from the SRS unit.

8. Read the DTC.

Is DTC 2-3 indicated? YES-Go to step 9. NO- Short in the front passenger's airbag inflator; replace the front passenger's airbag (see page 23280) .• 9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the driver's airbag 2P connector (A) from the cable reel 2P connector (8).

A

13. Check resistance between the No. 10 and No. 14 terminals ofthe SRS main harness 18P connector. There should be 1 M Q or more.


6

7

8

9

15

16 17 18

Wire side of female terminals. A

Is the resistance as specified? YES- Faulty SRS unit; replace the SRS unit (see page 23-295) .• NO- Short in the SRS main harness; replace the SRS main harness.•

23-84

BACK

DTC 2-4: Short to power in passenger's airbag inflator







Is DTC 2-4 indicated?

YES - Go to step 3.

YES-Go to step 9.

NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).

NO-Short to power in the front passenger's airbag inflator; replace the front passenger's airbag (see page 23-280) .•


9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the driver's airbag 2P connector (A) from the cable reel 2P connector (8), and disconnect the special tool from the SRS main harness 2P connector.

A

(cont'd)

BACK

23-85

SRS DTC Troubleshooting - '98-99 Models (cont'd) DTC 2-5: Short to ground in passenger's airbag inflator



Does the SRS indicator light stay on? YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).

A

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.

12. Reconnect the battery negative cable. 13. Turn the ignition switch ON (II). 14. Check for voltage between the No.1 0 terminal of the SRS main harness 18P connector and body ground, and between the No. 14 terminal and body ground. There should be 0.5 V or less.



6

7

8

9

15 16 17 18 Wire side of female terminals.

=

=

Is the voltage as specified? YES- Faulty SRS unit; replace the SRS unit (see page 23-295) .• NO- Short to power in the SRS main harness; replace the SRS main harness.•

23-86


BACK




Is DTC 2-5 indicated? YES-Go to step 9. NO- Short to ground in the passenger's airbag inflator; replace the passenger's airbag (see page 23-280) .• 9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the driver's airbag 2P connector (A) from the cable reel 2P connector (B), and disconnect the special tool from the SRS main harness 2P connector.

A

12. Check resistance between the No. 10 terminal of the SRS main harness 18P connector and body ground,and between the No. 14 terminal and body ground.There should be 1 M Q or more.


6

7

8

9

15

16 17 18

Wire side offemale terminals.

Is the resistance as specified? A

YES- Faulty SRS unit; replace the SRS unit (see page 23-295) .• NO- Short to ground in the SRS main harness; replace the SRS main harness .•

BACK

23-87

SRS OTe Troubleshooting - '98-99 Models (cont'd) DTC 5-1, 5-2, 5-3, 5-4, 5-8, 6-1, 6-2, 6-3, 6-4, 6-7,6-8, 7-1, 7-2, 7-3, 8-1, 8-2, 8-5, 8-6, 9-1, 9-2: Internal Failure of the SRS unit

DTC 10-1: Airbags deployed The SRS unit must be replaced after any airbags have deployed (see page 23-295).

Note: Before Troubleshooting any of these DTCs, check batterysystem voltage. If the voltage is low, repair the charging system before troubleshooting the SRS.lf the battery/system voltage is now OK, ask the customer if the battery ever went dead. 1. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

Does the SRS indicator light stay on? YES - Replace the SRS unit (see page 23-295) .• NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).

23-88

BACK

DTC 8-6: Internal Failure of SRS unit, or two Failures at a time

4. Disconnect the driver's airbag and front passenger's airbag connectors (A).

Besides indicating an abnormality in the SRS unit, DTe 8-6 may also indicate that two problems equivalent to DTe 1-1 and 2-4,1-4 and 2-1, or 1-4 and 2-4 occurred at the same time. Proceed in the order shown below.

1. Erase the DTe memory (see page 23-45). 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.


A


A

(cont'd)

BACK

23-89

SRS DTC Troubleshooting - '98-99 Models (cont'd) 5. Disconnect the SRS main harness 18P connector (A) from the SRS unit (B).

9. Check for voltage between the No.1 terminal ofthe SRS main harness 1ap connector and body ground, and between the No. 13 terminal and body ground. There should be 0.5 V or less. SRS MAIN HARNESS 18P CONNECTOR

6

7

8

9

16 17 18

10


A

=


Is the voltage as specified?

8. Check for voltage between the No.1 0 terminal of the SRS main harness 18P connector and body ground, and between the No. 14 terminal and body ground. There should be 0.5 V or less.

YES- Faulty SRS unit; replace the SRS unit (see page 23-295) .•


6

7

8

15

16 17 18

NO-Goto step 10. 10. Turn the ignition switch OFF.

9


Is the voltage as specified? YES-Go to step 9. NO- Short to power in the SRS main harness; replace the SRS main harness.•

23-90

BACK

11. Disconnect the cable reel 2P connector (A) from the SRS main harness 2P connector (8).

B

12. Turn the ignition switch ON (II). 13. Check for voltage between the No.1 terminal of the SRS main harness 18P connector and body gro.!.Jnd, and between No. 13 terminal and body ground. There should be 0.5 V or less. SRS MAIN HARNESS 18P CONNECTOR

10

6

7

8

9

15

16 17 18


=

=

Is the voltage as specified? YES-Short to power in the cable reel; replace the cable reel (see page 23-289) .• NO-Shortto power in the SRS main harness; replace the SRS main harness .•

BACK

23-91

SRS DTC Troubleshooting - '00 Model DTC 1-1: Open in driver's airbag inflator


DTC 1-2: Increased resistance in driver's airbag inflator




YES-Go to step 9. NO-Open or increased resistance in the driver's airbag inflator; replace the driver's airbag assembly (see page 23-278) .•

Does the SRS indicator light stay on? YES-Goto step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).

9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the cable reel 2P connector from the SRS main harness 2P connector (A).


A

07TAZ·SZ5011A

07SAZ·TB4011A

~

0.-

11. Connect the special tool (2 Q connector) to the SRS main harness 2P connector. 5. Connect the special tool (2 Q connector) to the cable reel connector.


23-92

BACK

14. Read the DTC.

18. Check resistance between the No.7 terminal and the No. 16 terminal of SRS unit connector A (18P). There should be 2.0-3.0 Q.

Is DTC 1-1 or DTC 1-2 indicated?


SRS UNIT CONNECTOR A (18P)

NO-Open or increased resistance in the cable reel; replace the cable reel (see page 23-289) .• 15. Disconnect the battery negative cable, and wait for 3 minutes. 16. Disconnect the front passenger's airbag 4P connector (A).

3

4

5

6

12 13 14 15



YES- Faulty SRS unit or poor contact at SRS unit connector A (18P) and the SRS unit. Check the connection between the connector and the SRS unit. If the connection is OK, replace the SRS unit (see page 23-296) .• NO-Open or increased resistance in the SRS main harness; replace the SRS main harness.•

A

17. Disconnect SRS unit connector A (18P) from the SRS unit. A

BACK

23-93

SRS DTC Troubleshooting - '00 Model (cont'd) OTe 1-3: Short to another wire or decreased resistance in driver's airbag inflator

8. Read the DTC.

Is OTe 1-3 indicated? 1. Erase the DTC memory (see page 23-45). YES-Go to step 9. 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

NO-Short in the driver's airbag; replace the driver's airbag (see page 23-278) .• 9. Disconnect the battery negative cable, and wait for 3 minutes.




A

A

07TAZ-SZ5011A

07SAZ·TB4011A

q::

-::::::===~:.-------07TAZ-SZ5011A

/~SAZ-~l1A

-.0

5. Connect the special tool (2 Q connector) to the cable reel 2P connector.

11. Connect the special tool (2 Q connector) to the SRS main harness 2P connector. 12. Reconnectthe battery negative cable. 13. Erase the DTC memory. 14. Read the DTC.


Is OTe 1·3 indicated? 7. Erase the DTC memory. YES - Go to step 15. NO - Short in the cable reel; replace the cable reel (see page 23-289) .•

23-94

BACK


19. Check resistance between the No.7 terminal and the No. 16 terminal of SRS unit connector A (18P). There should be 1 M Q or more.


SRS UNIT CONNECTOR A (18PI

3

4

5

6

12 13 14 15


Is the resistance as specified? YES - Faulty SRS unit; replace the SRS unit (see page 23-296) .•

NO- Short in the SRS main harness; replace the SRS main harness .•

A

17. Disconnect the special tool from the SRS main harness 2P connector. 18. Disconnect SRS unit connector A (18P) from the SRS unit. A

BACK

23-95

SRS DTC Troubleshooting - '00 Model (cont'd) DTC 1-4: Short to power in driver's airbag inflator

8. Read the DTC.






A

07TAZ-SZ5011A

07SAZ-TB4011A

~ O~ 11. Connect the special tool (2 Q connector) to the SRS main harness 2P connector. 12. Reconnect the battery negative cable. 5. Connect the special tool (2 Q connector) to the cable reel 2P connector.



23-96

BACK


14. Read the DTC. Is DTC 1-4 indicated?

20. Check for voltage between the No.7 terminal of SRS unit connector A (18P) and body ground, and between the No. 16 terminal and body ground. There should be 0.5 V or less.

YES - Go to step 15. NO-Short to power in the cable reel; replace the cable reel (see page 23-289) .•


15. Disconnect the battery negative cable, and wait for 3 minutes. 345 16. Disconnect the front passenger's airbag 4P connector (A) from the SRS main harness 4P connector (B), and disconnect the special tool from the SRS main harness 2P connector.

6

12 13 14 15

-= -= Wire side of female terminals

Is the voltage as specified? YES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO-Short to power in the SRS main harness; replace the SRS main harness.•

A



BACK

23-97

SRS DTC Troubleshooting - '00 Model (cont'd) DTC 1-5: Short to ground in driver's airbag inflator

8. Read the DTC.


NO- Short to ground in the driver's airbag inflator; replace the driver's airbag (see page 23-278) .• 9. Disconnect the battery negative cable, and wait for 3 minutes.


10. Disconnect the SRS main harness 2P connector from the cable reel 2P connector (A).


A

07TAZ-SZ50 11 A

--:::::===~:..------07TAZ-SZ5011A

~

/07SAZ-T84011A

~U 5. Connect the special tool (2 Q connector) to the cable reel 2P connector.



23-98

BACK

18. Check resistance between the No.7 terminal of SRS unit connector A (18P) and body ground, and between the No. 16 terminal and body ground. There should be 1 M Q or more.

14. Read the DTC.

Is DTC 1-5 indicated? VES- Go to step 15.

SRS UNIT CONNECTOR A (1ap)

NO - Short to ground in the cable reel; replace the cable reel (see page 23-289) .• 15. Disconnect the battery negative cable, and wait for 3 minutes.

345

6

12 13 14 15

16. Disconnect the front passenger's airbag 4P connector (A) from the SRS main harness 4P connector (8), and disconnect the special tool from the SRS main harness 2P connector.


=

=

Is the resistance as specified? VES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO-Short to ground in the SRS main harness; replace the SRS main harness .•

A


BACK

23-99

SRS DTC Troubleshooting - '00 Model (cont'd) DTC2-1: Open in passenger's airbag inflator DTC 2-2: Increased resistance in passenger's airbag inflator

5. Connect the special tool (2 Q connector) to the SRS main harness 2P connector. 6. Reconnect the battery negative cable.




8. Read the DTC.

Is DTC 2-1 or 2-2 indicated?


YES - Go to step 9.

YES-Go to step 3.

NO-Open or increased resistance in the front passenger's airbag inflator; replace the front passenger's airbag (see page 23-280) .•

NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.

9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the driver'S airbag 2P connector (A) from the cable reel 2P connector (B).


A

07XAZ-SZ30100 07SAZ-TB4011 A

A

~

0::

23-100

BACK

DTC 2-3: Short to another wire or decreased resistance in passenger's airbag inflator.



Does the SRS indicator light stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnectthe battery negative cable, and wait for 3 minutes. 12. Check resistance between the No.6 and No. 15 terminals and between the No.5 and No. 14 terminals of SRS unit connector A (18P). There should be 2.0-3.0 Q.


SRS UNIT CONNECTOR A 118P)

A


-07XAZ-SZ30100

Is the resistance as specified? YES - Faulty SRS unit or poor contact at the SRS unit connector; check the connection between the SRS main harness 18P connector and the SRS unit. If the connector is OK, replace the SRS unit (see page 23-296) .• NO-Open or increased resistance in the SRS main harness; replace the SRS main harness.•

5. Connect the special tool (2 Q connectors) to the SRS main harness 2P connector.

(cont'd)

BACK

23-101

SRS DTC Troubleshooting - '00 Model (cont'd) 11. Disconnect the special tool from the SRS main harness 2P connector.


12. Disconnect SRS unit connector A (18P) from the SRS unit.

8. Read the DTC.

A

Is DTC 2-3 indicated? YES-Go to step 9. NO-Short in the front passenger's airbag inflator; replace the front passenger's airbag (see page 23280) .• 9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the driver's airbag 2P connector (A) from the cable reel 2P connector (8).

13. Check resistance between the No.6 and No. 15 terminals and between the No.5 and No. 14 terminals of the SRS main harness 18P connector. There should be 1 M Q or more. SRS MAIN HARNESS 18P CONNECTOR

B


A

Is the resistance as specified? YES-Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO- Short in the SRS main harness; replace the SRS main harness .•

23-102

BACK


5. Connect the special tool (2 .Q connector) to the SRS main harness 2P connector.







YES - Go to step 3.

YES-Go to step 9.


NO- Short to power in the front passenger's airbag inflator; replace the front passenger's airbag (see page 23-280) .•




10. Disconnect the driver's airbag 2P connector (A) from the cable reel 2P connector (8), and disconnect the special tool from the SRS main harness 4P connector.

A

-07XAZ-SZ30100

A

(cont'd)

BACK

23-103

SRS DTC Troubleshooting - '00 Model (cont'd) DTC 2-5: Short to ground in passenger's airbag inflator


1. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (H),and check that the SRS indicator light comes on for about 6 seconds and then goes off.

Does the SRS indicator light stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.

12. Reconnect the battery negative cable. 13. Turn the ignition switch ON (II). 14. Check for voltage between the No.6 terminal of SRS unit connector A (18P) and body ground, between the No. 15 terminal and body ground, between the No.5 terminal and body ground, and between the No. 14 terminal and body ground. There should be 0.5 V or less.



-07XAZ-SZ30100


Is the voltage as specified? YES - Faulty SRS unit; replace the SRS unit (see page 23-296) .•


NO-Short to power in the SRS main harness; replace the SRS main harness .•

23-104

BACK



A

8. Read the DTC.

Is DTC 2-5 indicated? YES-Go to step 9. NO- Short to ground in the passenger's airbag inflator; replace the passenger's airbag (see page 23-280) .• 9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the driver's airbag 2P connector (A) from the cable reel 2P connector (B), and disconnect the special tool from the SRS main harness 2P connector.

12. Check resistance between the No.6 terminal of SRS unit connector A (18P) and body ground, between the No. 15 terminal and body ground, between the No.5 terminal and body ground, and between No. 14 terminal and body ground. There should be 1 M Q or more. SRS UNIT CONNECTOR A (18P)


-

=

B A

Is the resistance as specified? YES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO-Short to ground in the SRS main harness; replace the SRS main harness .•

BACK

23-105

SRS DTC Troubleshooting - '00 Model (cont'd) DTC 5-1, 5-2, 5-4, 5-5, 5-8, 6-1, 6-2, 6-3, 6-4, 6-7, 6-8, 7-1, 7-2, 7-3, 8-1 to 8-8, 9-1, 9-2: Internal Failure of the SRS unit

DTC 10-1, 10-2, 10-3, 10-4, 10-5, 10-6, 10-7: Airbags, side airbags and/or seat belt tensioners deployed

Note: Before Troubleshooting any of these DTCs, check the battery/system voltage. If the voltage is low, repair the charging system before troubleshooting the SRS. If the battery/system voltage is now OK, ask the customer if the battery ever went dead.

The SRS unit must be replaced after any airbags have deployed (see page 23-296).

,. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

Does the SRS indicator light stay on? YES - Replace the SRS unit (see page 23-296) .• NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).

23-106

BACK

DTC 13-1, 13-2: Internal Failure of the driver's side impact sensor

DTC 14-1, 14-2: Internal Failure of the front passenger's side impact sensor







YES-Replace the driver's side impact sensor (Sedan) (see page 23-297) (Coupe) (see page 23298) .•

YES - Replace the front passenger's side impact sensor (Sedan) (see page 23-297) (Coupe) (see page 23-298) .•

NO -Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).


BACK

23-107

SRS DTC Troubleshooting - '00 Sedan with Side Airbags DTC 11-1: Open or increased resistance in driver's side airbag inflator


1. Erase the DTC memory (see page 23-45). 8. Read the DTC. 2. Turn the ignition switch ON (11), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

/sDTC 11-1 indicated? YES- Go to step 9.

Does the SRS indicator light stay on? NO-Open or increased resistance in the driver's side airbag inflator; replace the driver's side airbag (see page 23-282) .•


9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the SRS floor harness 2P connector (A) from the front passenger's side airbag (B).

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the SRS floor harness 2P connector (A) from the driver's side airbag (B).

B

B

A A

j 07TAZ-SZ5011A

11. Disconnect SRS unit connector B (14P) from the SRS unit. Do not disconnect the special tool from the SRS floor harness 2P connector.

OTB40".

SAZ

-0

5. Connect the special tool (2 Q connector) to the SRS floor harness 2P connector.

23-108

BACK

DTC 11-3: Short to another wire or decreased

12. Check resistance between the No.4 and No. 13 terminals of SRS unit connector 8(14P). There should be 2.0-3.0 Q.

resistance in driver's side airbag inflator 1. Erase the DTC memory (see page 23-45).

SRS UNIT CONNECTOR B (14P)





Is the resistance as specified? YES-Faulty SRS unit or poor contact at SRS unit connector 8 (14P) and the SRS unit; check the connection. If the connector is OK, replace the SRS unit (see page 23-296) .•

4. Disconnect the SRS floor harness 2P connector (A) from the driver's side airbag (8).

NO-Open or increased resistance in the SRS floor harness; replace the SRS floor harness .•

A

07SAZ-TB4011A

/

07TAZ·SZ5011A

'-0

5. Connect the special tool (2 Q connector) to the SRS floor harness 2P connector. 6. Reconnect the battery negative cable. 7. Erase the DTC memory.

(cont'd)

BACK

23-109

SRS DTC Troubleshooting - '00 Sedan with Side Airbags (cont'd) 13. Check resistance between the No.4 and No. 13 terminals of SRS unit connector 8 (14P). There should be 1 M Q or more.

8. Read the DTC.

Is DTC 11-3 indicated? YES-Go to step 9.


NO- Short to another wire in the driver's side airbag inflator; replace the driver's side airbag (see page 23-282) .• 9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the SRS floor harness 2P connector (A) from the front passenger's side airbag (8).


Is the resistance as specified? YES-Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO- Short to another wire in the SRS floor harness; replace the SRS floor harness .•

A

11. Disconnect the special tool from the SRS floor harness 2P connector. 12. Disconnect SRS unit connector 8 (14P) from the SRS unit.

B

23-110

BACK

DTC 11-4: Short to power in driver's side airbag inflator


1. Erase the DTC memory (see page 23-45). 8. Read the DTC. 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

/sDTC 11-4 indicated? YES - Go to step 9.

Does the SRS indicator light stay on? NO-Shortto power in the driver's side airbag inflator; replace the driver's side airbag (see page 23-282) .•

YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the SRS floor harness 2P connector (A) from the driver's side airbag (B).

9. Disconnect the battery negative cable, and wait for 3 minutes .• 10. Disconnect the SRS floor harness 2P connector (A) from the front passenger's side airbag (B), and disconnect the special tool from the SRS floor harness 2P connector.

B

B

A

A

lSAZ.TIWl11

07TAZ-SZ5011A

A

-~

5. Connect the special tool (2 Q connector) to the SRS floor harness 2P connector. (cont'd)

BACK

23-111

SRS DTC Troubleshooting - '00 Sedan with Side Airbags (co nt'd) 11. Disconnect SRS unit connector 8 (14P) from the SRS unit.

DTC 11-5: Short to ground in driver's side airbag inflator 1. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

Does the SRS indicator light stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 12. Check resistance between the No. 13 and No.6 terminals of SRS unit connector 8 (14P), and between the No. 13 and No.7 terminals. There should be 1 M Q or more.

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the SRS floor harness 2P connector (A) from the driver's side airbag (8).

SRS UNIT CONNECTOR B (14PI



A

YES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO- Short to power in the SRS floor harness; replace the SRS floor harness .•

07SAZ-TB4011A

/

07T AZ-SZ5011 A

'-0


23-112

BACK

12. Check resistance between the No. 13 and No. 11 terminals of SRS unit connector 8 (14P), between the No. 13 and No. 12 terminals, and between the No. 13 terminal and body ground. There should be 1 MQ or more.

6. Reconnect the battery negative cable. 7. Erase the DTC memory. 8. Read the DTC. Is DTC 11-5 indicated?


YES-Go to step 9.

567 13 14

NO- Short to ground in the driver's side airbag inflator; replace the driver's side airbag (see page 23-282) .• 9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the SRS floor harness 2P connector (A) from the front passenger's side airbag (8), and disconnect the special tool from the SRS floor harness 2P connector.


.Q

= Is the resistance as specified? YES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO- Short to ground in the SRS floor harness; replace the SRS floor harness .•

A

11. Disconnect SRS unit connector 8 (14P) from the SRS unit.

B

BACK

23-113

SRS DTC Troubleshooting - '00 Sedan with Side Airbags (cont'd) DTC 12-1: Open or increased resistance in front passenger's side airbag inflator.








YES-Go to step 3.

YES - Go to step 9.


NO-Open or increased resistance in the front passenger's side airbag inflator, replace the front passenger's side airbag (see page 23-282) .•



4. Disconnect the SRS floor harness 2P connector (A) from the front passenger's side airbag (8).


A

A 07SAZ-TB4011A

~

H-

23-114

07TAZ-SZ5011A

BACK

11. Disconnect SRS unit connector 8 (14P) from the SRS unit. Do not disconnect the special tool from the SRS floor harness 2P connector.

DTC 12-3: Short to another wire or decreased resistance in front passenger's side airbag inflator. 1. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

Does the SRS indicator light stay on? YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). B


12. Check resistance between the No.5 and No. 14 terminals of SRS unit connector 8 (14P). There should be 2.0 - 3.0 Q.

4. Disconnect the SRS floor harness 2P connector (A) from the passenger's side airbag (8).

SRS UNIT CONNECTOR B 114P)

A Wire side of female terminals

Is the resistance as specified? YES - Faulty SRS unit or poor contact at SRS unit connector 8 (14P) and the SRS unit; check the connection. If the connector is OK, replace the SRS unit (see page 23-296) .•

07SAZ-TB4011A

~

NO-Open or increased resistance in the SRS floor harness; replace the SRS floor harness .•

0-

07TAZ-SZ50 11 A


BACK

23-115

SRS DTC Troubleshooting - '00 Sedan with Side Airbags (cont'd) 12. Disconnect SRS unit connector 8 (14P) from the SRS unit.

6. Reconnect the battery negative cable. 7. Erase the DTC memory. 8. Read the DTC.

Is DTC 12-3 indicated? YES-Go to step 9

NO - Short to another wire in the front passenger's side airbag inflator; replace the front passenger's side airbag (see page 23-282) .• 9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the SRS floor harness 2P connector (A) from the driver's side airbag (8).

B 13. Check resistance between the No.5 and No. 14 terminals of SRS unit connector 8 (14P). There should be 1 M Q or more.




VES- Faulty SRS unit; replace the SRS unit (see page 23-296) .•

11. Disconnect the special tool from the SRS floor harness 2P connector.

NO- Short to another wire in the SRS floor harness; replace the SRS floor harness .•

23-116

BACK

DTC 12-4: Short to power in front passenger's side airbag inflator




Does the SRS indicator light stay on? NO - Short to power in the front passenger's side airbag inflator; replace the front passenger's side airbag (see page 23-282) .•

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.

9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the SRS floor harness 2P connector (A) from the front driver's side airbag (8).


A

A

11. Disconnect SRS unit connector 8 (14P) from the SRS unit. 07SAZ-TB4011A

~

0-

07TAZ-SZ5011A


BACK

23-117

SRS DTC Troubleshooting - '00 Sedan with Side Airbags (cont'd) OTe 12-5: Short to ground in front passenger's side airbag inflator

12. Check resistance between the No. 14 and No.6 terminals of SRS unit connector 8 (14P), and between the No. 14 and No.7 terminals. There should be 1 M Q or more.

1. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (11), and check that the SRS indicator light comes on for about 6 seconds and then goes off.


Does the SRS indicator light stay on? YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). Wire side of female terminals

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the SRS floor harness 2P connector (A) from the front passenger's side airbag (8).

Is the resistance as specified? YES-Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO- Short to power in the SRS floor harness; replace the SRS floor harness.•

A

07SAZ-TB4011A

~

0-

07TAZ-SZ5011A


23-118

BACK


12. Check resistance between the No.1 4 and No.1 1 terminals of SRS unit connector 8 (14P), between the No. 14 and No. 12 terminals, and between the No. 14 terminal and body ground. There should be 1 M Q or more.



Is DTC 12-5 indicated? YES- Go to step 9.

5

6

14

NO- Short to ground in the front passenger's side airbag inflator, replace the front passenger's side airbag (see page 23-282) .• 9. Disconnect the battery negative cable, and wait for 3 minutes.

7


Q



NO - Short to ground in the SRS floor harness; replace the SRS floor harness .•

A


BACK

23-119

SRS DTC Troubleshooting - '00 Sedan with Side Airbags (cont'd) DTC 13-3: No signal from the driver's side impact sensor


1. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about six seconds and then goes off. Does the SRS indicator light stay on? YES - Go to step 3.

NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the negative battery cable, and wait for 3 minutes.

A


7. Disconnect the SRS floor harness 2P connector (A) from the driver's side impact sensor (8).

A

5. Check the connection at the SRS floor harness 2P connector and the driver'S side impact sensor. Is the connection OK?

/

YES - Go to step 6.

07XAZ-S1A0100

NO - Poor contact at the SRS floor harness 2P connector; reconnect or replace SRS floor harness .•

23-120

8. Connectthe special tool to the SRS floor harness 2P connector.

BACK

9. Disconnect SRS unit connector B (14P) from the SRS unit.

11. Check resistance between the No. 11 terminal of SRS unit connector B (14P) and the No.3 terminal ofthe special tool. There should be 0-1.0 Q. SRS UNIT CONNECTOR B (14P)

SPECIAL TOOL

B

10. Check resistance between the No.6 terminal of SRS unit connector B (14P) and the No.2 terminal of the special tool. There should be 0-1.0 Q. SRS UNIT CONNECTOR B (14P)

Is the resistance as specified? YES- Faulty driver's side impact sensor or SRS unit; replace the driver's side impact sensor (see page 23-297). If the problem is still present, replace the SRS unit (see page 23-296) .• NO- Open in the SRS floor harness; replace the SRS floor harness.•

Is the resistance as specified? YES-Go to step 11. NO-Open in the SRS floor harness; replace the SRS floor harness.•

BACK

23-121

SRS DTC Troubleshooting - '00 Sedan with Side Airbags (cont'd) OTC 13-4: Faulty power supply to the driver's

side impact sensor.

5. Disconnect the SRS floor harness 2P connector (A) from the driver's side impact sensor (8).



---~

.~--- -~.------------.

3. Turn the ignition switch OFF. Disconnect the negative battery cable, and wait for 3 minutes. 4. Disconnect the SRS floor harness 2P connectors (A) from the driver's and front passenger's side airbags (8).


B

A

B

A

23-122

BACK

7. Check resistance between the No.6 terminal of SRS unit connector B (14P) and body ground. There should be 1 M Q or more.

8. Check resistance between the No.6 and No. 11 terminals of SRS unit connector B (14P). There should be 1 M Q or more.



7 14



/s the resistance as specified? /s the resistance as specified? VES- Faulty driver's side impact sensor or SRS unit; replace the driver's side impact sensor (see page 23-297). If the problem is still present, replace the SRS unit (see page 23-296) .•

VES- Go to step 8. NO-Short to ground in the SRS floor harness; replace the SRS floor harness .•

NO - Short to another wire in the SRS floor harness; replace the SRS floor harness .•

BACK

23-123

SRS DTC Troubleshooting - '00 Sedan with Side Airbags (cont'd) DTC 14-3: No signal from the front passenger's side impact sensor.

6. Disconnect the SRS floor harness 2P connector (A) from the driver's side airbag (B).


Does the SRS indicator light stay on? YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the negative battery cable, and wait for 3 minutes. 4. Disconnect the SRS floor harness 2P connector (A) from the front passenger's side airbag (B).

A

7. Disconnect the SRS floor harness 2P connector (A) from the front passenger's side impact sensor (B).

B

A

5. Check the connection at the SRS floor harness 2P connector and the front passenger's side impact sensor.

Is the connection OK? YES-Go to step 6. NO - Poor contact at the SRS floor harness 2P connector; reconnect or replace SRS floor harness .•

23-124

07XAZ-S1A0100

8. Connect the SRS floor harness 2P connector to the special tool.

BACK

11. Check resistance between the No. 12 terminal of SRS unit connector B (14P) and the No.3 terminal of the special tool. There should be 0 -1.0 Q.



SPECIAL TOOL

10. Check resistance between the No.7 terminal of SRS unit connector B (14P) and the No.2 terminal of the special tool. There should be 0-1.0 Q. SRS UNIT CONNECTOR B (14P)

Is the resistance as specified? YES-Faulty front passenger's side impact sensor or SRS unit; replace the front passenger's side impact sensor (see page 23-297). If the problem is still present, replace the SRS unit (see page 23-296) .

•

NO-Open in the SRS floor harness; replace the SRS floor harness .•


Is the resistance as specified? YES-Go to step 11. NO-Open in the SRS floor harness; replace the SRS floor harness .•

BACK

23-125

SRS OTC Troubleshooting - '00 Sedan with Side Airbags (cont'd) DTC 14-4: Faulty power supply to the front passenger's side impact sensor

5. Disconnect the SRS floor harness 2P connector (A) from the front passenger's side impact sensor (8).



YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the negative battery cable, and wait for 3 minutes. 4. Disconnect the SRS floor harness 2P connectors from the driver's and front passenger's side airbags.


A

A

23-126

BACK









VES- Go to step 8.

VES- Faulty front passenger's side impact sensor or SRS unit; replace the front passenger's side impact sensor (see page 23-297). If the problem is still present, replace the SRS unit (see page 23-296) .

NO-Short to ground in the SRS floor harness; replace the SRS floor harness .•

•

NO-Shortto another wire in the SRS floor harness; replace the SRS floor harness .•

BACK

23-127

SRS DTC Troubleshooting - '00 Sedan with Side Airbags (cont'd) DTC 15-1: Faulty OPDS unit 1. Make sure nothing is on the front passenger's seat.

8. Check for voltage between the No.4 terminal of OPDS unit connector 0 (8P) and body ground. There should be battery voltage.

2. Initialize the OPDS unit (see page 23-46). OPDS UNIT CONNECTOR 0 (BPI

3. Erase the DTC memory (see page 23-45). 4. Read the DTC. /s DTC 15-1 indicated? YES-Go to step 5.

=



5. Check the No.7 (7.5A) fuse in the driver's underdash fuse/relay box.


/s the fuse OK?


YES-Go to step 6.


NO- Go to step 13. 6. Disconnect OPDS unit connector 0 (8P) from the OPDS unit (8).

10. Disconnect the SRS floor harness 6P connector C505 (A) from the dashboard wire harness A 6P connector (8).

o B

A

7. Turn the ignition switch ON (II). 11. Turn the ignition switch ON (II).

23-128

BACK

12. Check for voltage between the No.3 terminal of the dashboard wire harness 6P connector C505 and body ground. There should be battery voltage.

17. Disconnect dashboard wire harness connector I (18P) from the driver's under-dash fuse/relay box.

DASHBOARD WIRE HARNESS 6P CONNECTOR C505

2

6 Wire side of female terminals

=

Is there battery voltage? YES-Open in the SRS floor harness or OPDS unit harness; if the OPDS unit harness is OK, replace the SRS floor harness .•

18. Turn the ignition switch ON (II) for 30 seconds, then turn it off. 19. Check the No.7 (7.5A) fuse in driver's under-dash fuse/relay box.

NO-Open in dashboard wire harness A; replace dashboard wire harness A.

Is the fuse OK?

13. Replace the No.7 (7.5A) fuse in the driver's underdash fuse/relay box .•


NO-Shortto ground in the No.7 (7.5A) fuse circuit; refer to section 22 and continue troubleshooti ng .•

14. Turn the ignition switch ON (II) for 30 seconds, then turn it OFF. 15. Check the No.7 (7.5A) fuse in driver's under-dash fuse/relay box.


Is the fuse OK? YES- Finished .• NO-Gotostep 16. 16. Replace the No.7 (7.5 A) fuse in the driver's underdash fuse/relay box.

A

(cont'd)

BACK

23-129

SRS DTC Troubleshooting - '00 Sedan with Side Airbags (cont'd) 21. Connectthe dashboard wire harness 18P connector to the driver's under-dash fuse/relay box.

26. Turn the ignition switch ON (II) for 30 seconds. Then turn it OFF.

22. Turn ignition switch ON (II) for 30 seconds, then turn it OFF.

27. Check the No.7 (7.S A) fuse in the driver's underdash fuse/relay box. Is the fuse OK?

23. Check the No.7 (7.SA) fuse in driver's under-dash fuse/relay box.

YES-Faulty OPDS unit; replace the OPDS unit (see page 23-300) .•

Is the fuse OK?

NO-Short to ground in the SRS floor harness or OPDS unit harness; if the OPDS unit harness is OK, replace the SRS floor harness .•

YES- Go to step 24. NO- Short to ground in dashboard wire harness A; replace dashboard wire harness A..

28. Turn the ignition switch OFF. 24. Disconnect the OPDS unit harness 8P connector (A) from the OPDS unit (8).

29. Check resistance between the No.8 terminal of OPDS unit connector D (8P) and body ground. There should be 0 -1.0 Q. OPOS UNIT CONNECTOR 0

A

(BP)

B


2S. Reconnect the SRS floor harness 6P connector CSOS (A) to the dashboard wire harness A 6P connector (8).

Is the resistance as specified? YES-Go to step 30. NO-Open in the SRS floor harness or OPDS unit harness; if OPDS unit harness is OK, replace the SRS floor harness .•

A

23-130

BACK

30. Disconnect the side airbag connectors (A).

32. Check resistance between the No.1 terminal of SRS unit connector 8 (14P) and body ground. There should be 1 M Q or more.


4

5

6

7

11 12 13 14


Is the resistance as specified? YES- Go to step 33. NO-Short to ground in the SRS floor harness or the OPDS unit harness; if the OPDS unit harness is OK, replace the SRS floor harness.•


33. Check resistance between the No.1 terminal of SRS unit connector B (14P) and No.7 terminal of OPDS unit connector 0 (BP). There should be 0-1.0 Q. SRS UNIT CONNECTOR B (14PI

4

5

6

7

11 12 13 14

Q

Wire side of female terminals OPDS UNIT CONNECTOR D (SPI

4

8


B

Is the resistance as specified? YES- Go to step 34. NO-Open in the SRS floor harness or the OPDS unit harness; if the OPDS unit harness is OK, replace the SRS floor harness.•

(cont'd)

BACK

23-131

SRS DTC Troubleshooting - '00 Sedan with Side Airbags (cont'd) 34. Turn the ignition switch ON (II). 35. Check for voltage between the No.1 terminal of SRS unit connector B (14P) and body ground. There should be 0.5 V or less.

42. Turn the ignition switch ON (II), and check that the side airbag indicator light comes on for about 5 seconds, and then goes off.

YES - Faulty OPDS unit or SRS unit; replace the OPDS unit (see page 23-300). If the problem is still present, replace the SRS unit (see page 23-296) .•


4

5

6

NO-Faulty side airbag indicator light circuit; Go to troubleshooting DTC 15-2.•

7

11 12 13 14


Is the voltage as specified? YES - Go to step 36. NO- Short to power in the SRS floor harness or OPDS unit harness; if the OPDS unit harness is OK, replace the SRS floor harness .• 36. Turn the ignition switch OFF. 37. Install a known-good OPDS unit. 38. Reconnect all connectors. 39. Initialize the OPDS unit. 40. Erase the DTC memory. 41. Read the DTC.

Is DTC 15-1 indicated? YES - Go to step 42. NO- Finished .•

23-132

Does the side airbag indicator stay on?

BACK

DTC 15-2: Faulty side airbag indicator light circuit.

8. Check for a blown side airbag indicator bulb. Is the side airbag indicator bulb OK?

1. Make sure nothing is on the front passenger's seat. YES - Go to step 9. 2. Erase the DTC memory (see page 23-45). 3. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

NO- Blown side airbag indicator bulb; replace the bulb .• 9. Disconnect OPDS unit connector D (8P) from the OPDS unit (B).


o

B

4. Turn the ignition switch ON (II), and check that the side airbag indicator light comes on. Does the side airbag indicator light come on? YES-Go to step 5. NO - Go to step 6. 5. Make sure the side airbag indicator light comes on for 5 seconds and then goes off. Does the side airbag indicator light go off? YES- Faulty OPDS unit or SRS unit; replace the OPDS unit (see page 23-300). Ifthe problem is still present, replace the SRS unit (see page 23-296) .•

10. Turn the ignition switch ON (II). 11. Check for voltage between No.3 terminal of OPDS unit connector D (8P) and body ground. There should be battery voltage.

OPOS UNIT CONNECTOR 0 (8P)

NO- Go to step 36. 6. Turn the ignition switch OFF. 7. Check the No.9 (7.5A) fuse in the driver's underdash fuse/relay box.

=

Is the fuse OK? YES - Go to step 8.


NO - Short to ground in the No.9 (7.5 A) fuse circuit; refer to section 22 and continue troubleshooting .•

Is there battery voltage? YES-Go to step 12. NO - Go to step 24. (cont'd)

BACK

23-133

SRS DTC Troubleshooting - '00 Sedan with Side Airbags (cont'd) 12. Turn the ignition switch OFF.


13. Disconnect the dashboard wire harness connector I (18P) from the driver's under-dash fuse/relay box.

17. Disconnect gauge assembly connector B (22P) from the gauge assembly.

--

B

18. Turn the ignition switch ON (II). 19. Check for voltage between the No.3 terminal of OPDS unit connector 0 (8P) and body ground. There should be 0.5 V or less.

14. Turn the ignition switch ON (II). 15. Check for voltage between the No.3 terminal of OPDS unit connector D (8P) and body ground. There should be 0.5 V or less.

OPDS UNIT CONNECTOR D (8P)


= Wire side of female terminals Wire side offemale terminals

Is the voltage as specified? VES- Short to power in the gauge assembly; replace the gauge assembly.•

Is the voltage as specified? VES- Faulty OPOS unit; replace the OPOS unit (see page 23-300). NO-Go to step 16.

23-134

BACK

NO - Go to step 20.




25. 8ackprobe the No. 17 terminal of gauge assembly connector 8 (22P). Do not disconnect the connector from the gauge assembly. 26. Turn the ignition switch ON (II). 27. Check for voltage between the No. 17 terminal of gauge assembly connector 8 (22P) and body ground. There should be battery voltage.

GAUGE ASSEMBL V CONNECTOR B (22P)

11

A

2

7

12

19 20

8

9

10

21 22



=

23. Check for voltage between the No.3 terminal of OPDS unit connector D (8P) and body ground. There should be 0.5 V or less.



NO- Go to step 32. 28. Turn the ignition switch OFF. 29. Disconnect the SRS floor harness 6P connector C505 (A) from the dashboard wire harness A 6P connector (8).


Is the voltage as specified? YES- Short to power in dashboard wire harness A; replace dashboard wire harness A.. NO- Short to power in the SRS floor harness or the OPDS unit harness; if the OPDS unit harness is OK, replace the SRS floor harness.• A

30. Turn the ignition switch ON (II). (cont'd)

BACK

23-135

SRS DTC Troubleshooting - '00 Sedan with Side Airbags (cont'd) 31. Check for voltage between the No.4 terminal of the dashboard wire harness A 6P connector (CS51) and body ground. There should be battery voltage.

35. Check for voltage between the No. 11 terminal of gauge assembly connector B (22P) and body ground. There should be battery voltage.

DASHBOARD WIRE HARNESS A 6P CONNECTOR (CBS11

3

GAUGE ASSEMBlV CONNECTOR B (22P)

2

7

6

19 20 21 22

8

9

10



= Is there battery voltage? Is there battery voltage? YES - Poor contact at the dashboard wire harness A 6P and SRS floor harness 6P connectors or an open in the SRS floor harness. Check the connection between the dashboard wire harness A 6P and SRS floor harness 6P connectors; if the connection is OK, replace the SRS floor harness .• NO - Poor contact at gauge assembly connector B (22P) or an open in dashboard wire harness A. Check the connector; if the connection is OK, replace Tdashboard wire harness A .•

YES- Faulty side airbag indicator light circuit; replace the gauge assembly.• NO-Open in dashboard wire harness A; replace dashboard wire harness A .• 36. Turn the ignition switch OFF. 37. Disconnect the OPDS unit harness SP connector (A) from the OPDS unit (B).


A B


B

3S. Turn the ignition switch ON (II).

Does the side airbag indicator light stay off? YES- Faulty OPDS unit; replace the OPDS unit (see page 23-300) .• NO-Go to step 39. 34. Turn the ignition switch ON (II).

23-136

BACK


43. Disconnect gauge assembly connector 8 (22P) from the gauge assembly.

40. Disconnect the SRS floor harness 6P connector C505 (A) from the dashboard wire harness A 6P connector (8). B

44. Turn the ignition switch ON (II). A

Does the side airbag indicator light stay off? YES-Short to ground in dashboard wire harness A; replace dashboard wire harness A .•


Does the side airbag indicator light stay off?

NO - Short to ground in the gauge assembly; replace the gauge assembly.•

YES - Short to ground in the SRS floor harness or the OPDS unit harness; if the OPDS unit harness is OK. replace the SRS floor harness.•

NO - Go to step 42. 42. Turn the ignition switch OFF.

BACK

23-137

SRS DTC Troubleshooting - '00 Sedan with Side Airbags (cont'd) DTC 15-3: Faulty OPOS sensor

7. Replace the OPDS unit (see page 23-300), and reinitialize the OPDS unit (see page 23-46).

1. Erase the DTC memory (see page 23-45). 8. Erase the DTC memory. 2. Turn the ignition switch ON (11), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

9. Read the DTC.

Is 15-3 indicated? Does the SRS indicator light stay on? YES-Replace the SRS unit.• YES-Goto step 3. NO - The system is OK.• NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). NOTE: Aftermarket devices (fluorescent map lights, laptop computers, etc.) used near the front passenger's seat-back can interfere with the seat-back sensors and cause a false DTC 15-3. If one of these devices was used, erase the DTC, operate the device near the seat-back, and recheck for DTCs. If DTC 15-3 is reset, erase it, and do not use the device near the seat-back. 3. Check the connection at the OPDS sensor harness connector and the OPDS unit connector.

Are the connections OK? YES-Go to step 4. NO- Reconnect the OPDS sensor harness connector, and clear the DTC.• 4. Replace the OPDS sensor/seat back foam (see page 20-98), and reinitialize the OPDS system (see page 23-46). 5. Erase the DTC memory. 6. Read the DTC.

Is DTC 15-3 indicated? YES-Go to step 7. NO- The system is OK.•

23-138

BACK

DTC Troubleshooting - '00 Coupe with Side Airbags OTC 11-1: Open or increased resistance in


driver's side airbag inflator 8. Read the DTC. 1. Erase the DTC memory (see page 23-45).

Is DTC 11-1 indicated? 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

YES- Go to step 9. NO-Open or increased resistance in the driver's side airbag inflator, replace the driver's side airbag. (see page 23-282) .•


9. Disconnect the left side wire harness 4P connector C556 (A) from the SRS main harness 4P connector (8).

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the left side wire harness 2P connector from the driver's side airbag.

A

07\......11A

0::

A

07SAZ-TB4011A

/

07TAZ-SZ5011A

07TAZ-SZ5011A

10. Connect the special tool (2 Q connectors) to the SRS main harness 4P connector. 11. Erase the DTC memory.

'-0

12. Read the DTC.


5. Connect the special tool (2 Q connector) to the left side wire harness 2P connector.

NO-Open or increased resistance in the left side wire harness; replace the left side wire harness.• (cont'd)


BACK

23-139

SRS DTC Troubleshooting - '00 Coupe with Side Airbags (cont'd) 13. Disconnect the battery negative cable, and wait for 3 minutes.

16. Check resistance between the No.4 and No. 13 terminals of SRS unit connector 8 (14P). There should be 2.0-3.0 Q.

14. Disconnect the right side wire harness 2P connector (A) from the front passenger's side airbag (8).




B

YES-Faulty SRS unit or poor contact at SRS unit connector 8 (14P) and the SRS unit; check the connection. If the connector is OK, replace the SRS unit (see page 23-296) .•

A

15. Disconnect SRS unit connector 8 (14P) from the SRS unit. Do not disconnect the special tool from the SRS main harness 4P connector.

B

23-140

BACK

NO-Open or increased resistance in the SRS main harness; replace the SRS main harness.•

DTC "·3: Short to another wire or decreased resistance in driver's side airbag inflator



Is DTC 11-3 indicated? 2. Turn the ignition switch ON (11), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

YES -- Go to step 9. NO- Short to another wire in the driver's side airbag inflator; replace the driver's side airbag (see page 23-282) .•


9. Disconnect the left side wire harness 4P connector C556 (A) from the SRS main harness 4P connector (8).

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the left side wire harness 2P connector from the driver'S side airbag.

A

07SAZ-TB4011A

\

0::

A

07TAZ·SZS011A

10. Connect the special tool (2 Q connectors) to the SRS main harness 4P connector. 07SAZ-TB4011A


/

07TAZ-SZ5011A

12. Read the DTC.

-6


5. Connect the special tool (2 Q connector) to the left side wire harness 2P connector. 6. Reconnect the battery negative cable.

NO - Short to another wire or decreased resistance in the left side wire harness; replace the left side wire harness .•

(cont'd)

BACK

23-141


17. Check resistance between No.4 and No. 13 terminals of SRS unit connector B (14P). There should be 1 M Q or more.




Is the resistance as specified? YES - Faulty SRS unit; replace the SRS unit (see page 23-296) .• A

NO-Shortto another wire in the SRS main harness; replace the SRS main harness .•

15. Disconnect the special tool from the SRS main harness 4P connector. 16. Disconnect SRS unit connector 8 (14P) from the SRS unit.

B

23-142

BACK

DTC 11-4: Short to power in driver's side airbag inflator




YES-Go to step 9. NO- Short to power in the driver's side airbag inflator; replace the driver's side airbag (see page 23-282) .•


9. Disconnect the left side wire harness 4P connector C556 (A) from the SRS main harness 4P connector (B).

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the left side wire harness 2P connector from the driver's side airbag.

A 07SAZ-TB4011A

\

A

0=

07SAZ-TB4011A

/

07TAZ-SZ5011A

07TAZ-SZ5011A


-0

12. Read the DTC.



NO-Short to power in the left side wire harness; replace the left side wire harness.• (cont'd)

BACK

23-143

SRS DTC Troubleshooting - '00 Coupe with Side Airbags (cont'd) 13. Disconnect the battery negative cable, and wait for 3 minutes. 14. Disconnect the right side wi re harness 2P connector (A) from the front passenger's side airbag (B).

16. Check resistance between the No. 13 and No.6 terminals of SRS unit connector B (14P), and between the No. 13 and No. 7 te~minals. There should be 1 M Q or more. SRS UNIT CONNECTOR B (14PI


B


A

NO- Short to power in the SRS main harness; replace the SRS main harness .•


23-144

BACK

DTC 11-5: Short to ground in driver's side airbag inflator




YES- Go to step 9. NO-Short to ground in the driver's side airbag inflator; replace the driver's side airbag (see page 23-282) .•


9. Disconnect the left side wire harness 4P connector C556 (A) from the SRS main harness 4P connector (B).

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the left side wire harness 2P connector (A) from the driver's side airbag (B).

A

07SAZ-TB4011A

\

A

0=

07SAZ-TB4011A

/

07TAZ-SZ5011A

07TAZ-SZ5011 A

10. Connect the special tool (2 Q connectors) to the SRS main harness 4P connector. 11. Erace the DTC memory.

-0

12. Read the DTC.



NO-Short to ground in the left side wire harness; replace the left side wire harness.• (cont'd)

BACK

23-145


14. Disconnect the right side wi re harness 2P connector (A) from the front passenger's side airbag (8).

16. Check resistance between the No. 13 and No. 11 terminals of sRs unit connector B (14P), between the No. 13 and No. 12 terminals, and between the No. 13 terminal and body ground. There should be 1 M Q or more. SRS UNIT CONNECTOR B 114P)

567 14


Q

= Is this resistance as specified? YES-Faulty sRs unit; replace the page 23-296) .•

A 15. Disconnect sRs unit.

sRs unit connector 8 (14P) from the

NO-Short to ground in the sRs main harness; replace the sRs main harness .•

B

23-146

sRs unit (see

BACK

DTC 12-1: Open or increased resistance in front passenger's side airbag inflator




Does the SRS indicator light stay on? NO-Open or increased resistance in the front passenger's side airbag inflator; replace the front passenger's side airbag. (see page 23-282) .•


9. Disconnect the right side wire harness 4P connector C584 (A) from the SRS main harness 4P connector (8).

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the right side wire harness 2P connector (A) from the front passenger's side airbag (8).

r-

A

07XAZ-SZ30100

•

::0


07SAZ-TB4011A

~

0-

TB4011



I

YES-Go to step 13.

07TAZ-SZ5011A

NO-Open or increased resistance in the right side wire harness; replace the right side wire harness .• 5. Connect the special tool (2 Q connector) to the right side wire harness 2P connector.

(cont'd)

BACK

23-147


16. Check resistance between the No.5 and No. 14 terminals of SRS unit connector 8 (14P). There should be 2.0-3.0 Q.

14. Disconnect the left side wire harness 2P connector (A) from the driver's side airbag (8). SRS UNIT CONNECTOR B (14P)


Is the resistance as specified? YES - Faulty SRS unit or poor contact at SRS unit connector 8 (14P) and the SRS unit; check the connection. If the connector is OK, replace the SRS unit (see page 23-296) .•

A


B

23-148

BACK

NO-Open or increased resistance in the SRS main harness; replace the SRS main harness .•

DTe 12-3: Short to another wire or decreased


resistance in front passenger's side airbag inflator





YES - Go to step 9.


NO- Short to another wire in the front passenger's side airbag inflator; replace the front passenger's side airbag (see page 23-282) .•


9. Disconnect the right side wire harness 4P connector C584 (A) from the SRS main harness 4P connector (B).

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the right side wire harness 2P connector (A) from the front passenger's side airbag (B).

B

07SAZ-TB4011 B

A

/

07XAZ-SZ30100


07SAZ-TB4011 A

~

0-

11. Erase the DTC memory. 12. Read the DTC. Is DTC 12-3 indicated? YES - Go to step 13.

07TAZ-SZ5011 A

NO - Short to another wire or decreased resistance in the right side wire harness; replace the right side wire harness .•

5. Connect the special tool (2 Q connector) to the right side wire harness 2P connector.

(cont'd)

BACK

23-149


17. Check resistance between the No.5 and No. 14 terminals of SRS unit connector 8 (14P). There should be 1 M Q or more.

14. Disconnect the left side wire harness 2P connector (A) from the driver's side airbag (8). SRS UNIT CONNECTOR B (14P)

B


Is the resistance as specified? YES-Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO-Short to another wire in the SRS main harness; replace the SRS main harness.•

A

15. Disconnectthe special tool from the SRS main harness 4P connector. 16. Disconnect SRS unit connector 8 (14P) from the SRS unit.

B

23-150

BACK

DTC 12-4: Short to power in front passenger's side airbag inflator




Does the SRS indicator light stay on? NO- Short to power in the front passenger's side airbag inflator; replace the front passenger's side airbag (see page 23-282) .•



3. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the right side wire harness 2P connector from the front passenger's side airbag.

A

B

~07SAZ'TB4011A

07XAZ·SZ30100

07SAZ·TB4011A

~

0-

::0


I

12. Read the DTC.

07XAZ·S1A0200

Is DTC 12-4 indicated? YES-Gotostep 13.


NO- Short to power in the right side wire harness; replace the right side wire harness .• (cont'd)

BACK

23-151

SRS DTC Troubleshooting - '00 Coupe with Side Airbags (cont'd) 13. Disconnect the battery negative cable, and wait for 3 minutes. 14. Disconnect the left side wire harness 2P connector from the driver's side airbag.

16. Check resistance between the No. 14 and No.6 terminals of SRS unit connector B (14P), and between the No. 14 and No.7 terminals. There should be 1 M Q or more. SRS UNIT CONNECTOR B (14P)

B


Is the resistance as specified? YES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• A

NO-Short to power in the SRS main harness; replace the SRS main harness.•


B

23-152

BACK

DTC 12-5: Short to ground in front passenger's side airbag inflator




Does the SRS indicator light stay on? NO-Short to ground in the front passenger's side airbag inflator; replace the front passenger's side airbag (see page 23-282) .•

YES- Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).


3. Turn the ignition switch OFF. Disconnectthe battery negative cable, and wait for 3 minutes. 4. Disconnect the right side wire harness 2P connector (A) from the front passenger's side airbag (8).

B

A

~07SAZ-TB4011A

07XAZ-SZ30100

07SAZ-TB4011A


~

0-

::0



07TAZ-SZ5011A

YES-Go to step 13. 5. Connect the special tool (2 Q connector) to the right side wire harness 2P connector.

NO - Short to ground in the right side wire harness; replace the right side wire harness.• (cont'd)

BACK

23-153

SRS DTC Troubleshooting - '00 Coupe with Side Airbags (cont'd) 13. Disconnect the battery negative cable, and wait for 3 minutes. 14. Disconnect the left side wire harness 2P connector from the driver's side airbag.

16. Check resistance between the No. 14 and No. 11 terminals of SRS unit connector B (14P), between the No. 14 and No. 12 terminals, and between the No. 14 terminal and body ground. There should be 1 M Q or more. SRS UNIT CONNECTOR B (14P)

6

7 14

B Wire side of female terminals

Is the resistance as specified? YES-Faulty SRS unit; replace the SRS unit (see page 23-296) .•

A


NO-Shortto ground in the SRS main harness; replace the SRS main harness .•

B

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DTC 13-3: No signal from the driver's side

6. Disconnect the right side wire harness 2P connector from the front passenger's airbag.

impact sensor 1. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

Does the SRS indicator light stay on? VES- Go to step 3. NO -Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the negative battery cable, and wait for 3 minutes.

A

4. Disconnect the left side wire harness 2P connector from the driver's side airbag.

7. Disconnect the left side wire harness 2P connect (A) from the driver's side impact sensor (B).

B

A

07XAZ-S1A0100

5. Check the connection at the left side wire harness 2P connector and the driver's side impact sensor.

8. Connect the special tool to the left side wire harness 2P connector.

Is the connection OK? VES- Go to step 6. NO- Poor contact at the left side wire harness 2P connector; reconnect or replace the left side wire harness .•

(cont'd)

BACK

23-155

SRS DTC Troubleshooting - '00 Coupe with Side Airbags (cont'd) 9. Disconnect SRS unit connector B (14P) from the SRS unit.

11. Check resistance between the No. 11 terminal of SRS unit connector B (14P) and the No.3 terminal ofthe special tool. There should be 0-1.0 Q. SRS UNIT CONNECTOR B (14P)

SPECIAL TOOL

Is the resistance as specified? 10. Check resistance between the No.6 terminal of SRS unit connector B (14P) and the No.2 terminal of the special tool. There should be 0 -1.0 Q.

YES- Faulty driver's side impact sensor or SRS unit; replace the driver's side impact sensor (see page 23-298). If the problem is still present, replace the SRS unit (see page 23-296) .•


NO-Open between the SRS main harness and the left side wire harness; replace the harness .•

Is the resistance as specified? YES- Go to step 11. NO- Open in the SRS main harness or in the left side wire harness; replace the faulty harness .•

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DTC 13-4: Faulty power supply to the driver's side impact sensor

5. Disconnect the left side wire harness 2P connector (A) from the driver's side impact sensor (8).


Does the SRS indicator light stay on? YES - Go to step 3.


B

3. Turn the ignition switch OFF. Disconnect the negative battery cable, and wait for 3 minutes. 4. Disconnect the side wire harness 2P connectors from the driver's and front passenger's side airbags.


A

B

A

(cont'd)

BACK

23-157

SRS DTC Troubleshooting - '00 Coupe with Side Airbags (cont'd) 7. Check resistance between the No.6 terminal of SRS unit connector B (14P) and body ground. There should be 1 M Q or more.








YES - Go to step 8.

YES-Faulty driver's side impact sensor or SRS unit; replace the driver'S side impact sensor (see page 23-298). If the problem is still present, replace the SRS unit (see page 23-296) .•

NO-Short to ground in the SRS main harness or in the left side wire harness; replace the faulty harness .•

NO- Short to another wire in the SRS main harness or in the left side wire harness; replace the faulty harness .•

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DTC 14-3: No signal from the front passenger's side impact sensor

6. Disconnect the left side wire harness 2P connector (A) from the driver's side airbag (8).


Does the SRS indicator light stay on? YES- Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the negative battery cable, and wait for 3 minutes. 4. Disconnect the right side wire harness 2P connector (A) from the front passenger's side airbag (8).

A

7. Disconnect the right side wire harness 2P connector (A) from the front passenger's side impact sensor (8).

A

5. Check the connection at the right side wire harness 2P connector and the front passenger's side impact sensor.

8. Connect the special tool to the left side wire harness 2P connector.

Is the connection OK?

YES - Go to step 6. NO-Poor contact at the right side wire harness 2P connector; reconnect or replace the right side wire harness.•

(cont'd)

BACK

23-159

SRS DTC Troubleshooting - '00 Coupe with Side Airbags (cont'd) 11. Check resistance between the No. 12 terminal of SRS unit connector B (14P) and the No.3 terminal ofthe special tool. There should be 0-1.0 Q.



SPECIAL TOOL

B


10. Check resistance between the No.7 terminal of SRS unit connector B (14P) and the No.2 terminal of the special tool. There should be 0 - 1.0 Q.

YES-Faulty front passenger's side impact sensor or SRS unit; replace the front passenger's side impact sensor (see page 23-298). If the problem is still present, replace the SRS unit (see page 23-296).

•


NO-Open in the SRS main harness or in the right side wire harness; replace the faulty harness .•

Is the resistance as specified? YES - Go to step 11. NO-Open in the SRS main harness or in the right side wire harness; replace the faulty harness .•

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DTC 14-4: Faulty power supply to the front passenger's side impact sensor



A

Does the SRS indicator light stay on? YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the negative battery cable, and wait for 3 minutes. 4. Disconrfect the side wire harness 2P connector (A) from the driver's and front passenger's side airbags (8).


B

A

B A

(cont'd)

BACK

23-161

SRS DTC Troubleshooting - '00 Coupe with Side Airbags (cont'd) 7. Check resistance between the No.7 terminal of SRS unit connector B (14P) and body ground. There should be 1 M Q or more.








YES-Go to step 8.

YES- Faulty front passenger's side impact sensor or SRS unit; replace the front passenger's side impact sensor (see page 23-298). If the problem is still present, replace the SRS unit (see page 23-296).

NO-Short to ground in the SRS main harness or in the right side wire harness; replace the faulty harness.•

•

NO- Short to another wire in the SRS main harness or in the right side wire harness; replace the faulty harness .•

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DTC 15-1: Faulty OPDS unit 1. Make sure nothing is on the front passenger's seat.

B. Check for voltage between the No.4 terminal of OPDS unit connector D (BP) and body ground. There should be battery voltage.

2. Initialize the OPDS unit (see page 23-46).


3. Erase the DTC memory (see page 23-45). 4. Read the DTC. Is DTe 15-1 indicated? YES - Go to step 5.

=



5. Check the No.7 (7.5 A) fuse in the driver's underdash fuse/relay box.

Is there battery voltage? YES-Go to step 2B.

Is the fuse OK? NO- Go to step 9. YES - Go to step 6. 9. Turn the ignition switch OFF. NO- Go to step 13. 6. Disconnect OPDS unit connector D (BP) from the OPDS unit (8).

B

10. Disconnect the right side wire harness 16P connector C5B2 (A) from the dashboard wire harness A 16P connector (8).

D

A



(cont'd)

BACK

23-163

SRS DTC Troubleshooting - '00 Coupe with Side Airbags (co nt'd) 12. Check for voltage between the No.9 terminal of the dashboard wire harness A 16P connector C582 and body ground. There should be battery voltage.

17. Disconnectthe dashboard wire harness connector I (18P) from the driver's under-dash fuse/relay box.

DASHBOARD WIRE HARNESS A 16P CONNECTOR IC582)


Is there battery voltage? YES-Open in the right side wire harness or OPDS unit harness: if the OPDS unit harness is OK, replace the SRS floor harness ••

18. Turn the ignition switch ON (II) for 30 seconds, then turn it off. 19. Check the No.7 (7.5A) fuse in the driver's underdash fuse/relay box.

NO-Open in dashboard wire harness A: replace dashboard wire harness A .•

Is the fuse OK? 13. Replace the No.7 (7.5A) fuse in the driver's underdash fuse/relay box.

YES- Go to step 20.

14. Turn the ignition switch ON (II) for 30 seconds, then turn it OFF.

NO-Short to ground in the No.7 (7.5A) circuit; refer to section 22 and continue troubleshooting .•

15. Check the No.7 (7.5A) fuse in driver's under-dash fuse/relay box.

20. Disconnect the right side wire harness 16P connector C582 (A) from the dashboard wire harness A 16P connector (B).

Is the fuse OK? YES- Finished .• NO-Go to step 16. 16. Replace the No.7 (7.5A) fuse in the driver's underdash fuse/relay box.•

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21. Connect dashboard wire harness connector I (18P) to the driver's under-dash fuse/relay box.

26. Turn the ignition switch ON (II) for 30 seconds, then turn it OFF.

22. Turn ignition switch ON (II) for 30 seconds, then turn it OFF.



Is the fuse OK? YES - Faulty OPDS unit; replace the OPDS unit (see page 23-300) .•

Is the fuse OK? YES-Go to step 24.

NO- Short to ground in the right side wire harness or OPDS unit harness; If the OPDS unit harness is OK, replace the right side wire harness .•

NO-Short to ground in dashboard wire harness A; replace dashboad wire harness A. •

28. Turn the ignition switch OFF. 24. Disconnect OPDS unit connector D (8P) from the OPDS unit (B).

29. Check resistance between the No.8 terminal of OPDS unit connector D (8P) and body ground. There should be 0 -1.0 Q.

OPDS UNIT CONNECTOR D (SP)

B

D


Is the resistance as specified? 25. Reconnect the right side wire harness 16P connector C582 (A) to the dashboard wire harness A 16P connector (B).

YES- Go to step 30. NO- Open in the right side wire harness or OPDS unit harness; if the OPDS unit harness is OK, replace the right side wire harness .•

B

(cont'd)

BACK

23-165

SRS DTC Troubleshooting - '00 Coupe with Side Airbags (cont'd) 30. Disconnect the side airbag connectors (A).

32. Check resistance between the No.1 terminal of SRS unit connector B (14P) and body ground. There should be 1 M Q or more. SRS UNIT CONNECTOR B (14P)

4

5

6

7

11

12 13 14


Is the resistance as specified? YES - Go to step 33. NO- Short to ground in the SRS main harness or in the OPDS unit harness; replace the faulty harness.•


33. Check resistance between the No.1 terminal of SRS unit connector B (14P) and the No.7 terminal of the OPDS unit connector D (8P). There should be 0-1.0 Q. SRS UNIT CONNECTOR B (14P)

4

5

6

7

11 12 13 14

Wire side of female terminals OPDS UNIT CONNECTOR D ISP)

Wire side of female terminals B

Is the resistance as specified? YES-Go to step 34. NO-Open in the SRS main harness and the OPDS unit harness; replace the faulty harness .•

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34. Turn the ignition switch ON (II). 35. Check for voltage between the No.1 terminal of SRS unit connector B (14P) and body ground. There should be 0.5 V or less.

42. Turn the ignition switch ON (II), and check that the side airbag indicator light comes on for about 5 seconds, and then goes off.

YES- Faulty OPDS unit or SRS unit; replace the OPDS unit (see page 23-300). If the problem is still present, replace the SRS unit (see page 23-296) .•


456

Does the side airbag ingicator stay on?

NO- Faulty side airbag indicator light circuit; go to troubleshooting DTC 15-2.•

7

11 12 13 14



YES - Go to step 36. NO- Short to power in the SRS main harness or in the OPDS unit harness; replace the faulty harness.• 36. Turn the ignition switch OFF. 37. Install a known-good OPDS unit. 38. Reconnect all connectors. 39. Initialize the OPDS unit. 40. Erase the DTC memory. 41. Read the DTC.

Is OTe 15-1 indicated?

YES - Go to step 42. NO-Finished.•

BACK

23-16~

SRS DTC Troubleshooting - '00 Coupe with Side Airbags (cont'd) DTC 15-2: Faulty side airbag indicator light circuit

S. Check for a blown side airbag indicator bulb.

Is the side airbag indicator bulb OK? 1. Erace the OTC memory (see page 23-45). YES - Go to step 9. 2. Turn the ignition switch ON (11), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

NO- Blown side airbag indicator bulb; replace the bulb.• 9. Disconnect OPOS unit connector 0 (SP) from the OPOS unit (B).

Does the SRS indicator light stay on? YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to troubleshooting Intermittent Failures (see page 23-45).

D

B

3. Make sure nothing is on the front passenger's seat. 4. Turn the ignition switch ON (11), and check that the side airbag indicator light comes on.

Does the side airbag indicator light come on? YES - Go to step 5. NO- Go to step 6. 5. Make sure the side airbag indicator light comes on for 5 seconds and then goes off.

10. Turn the ignition switch ON (II). 11. Check for voltage between the No.3 terminal of OPOS unit connector 0 (SP) and body ground. There should be battery voltage.

Does the side airbag indicator light go off? YES - Faulty OPOS unit or SRS unit; replace the OPOS unit. If the problem is still present, replace the SRS unit.•

OPDS UNIT CONNECTOR D (BP)

NO - Go to step 36. 6. Turn the ignition switch OFF. 7. Check the No.9 (7.5A) fuse in the driver's underdash fuse/relay box.

Is the fuse OK?


YES - Go to step S. NO-Short to No.9 (7.5A) fuse related circuit; refer to section 22 and continue troubleshooting .•

Is there battery voltage? YES-Go to step 12. NO - Go to step 24.

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13. Disconnect dashboard wire harness A 18P connector I (18P) from the driver's under-dash fuse! relay box.


B

18. Turn the ignition switch ON (II). 19. Check for voltage between the No.3 termi nal of the OPDS unit connector D (8P) and body ground. There should be 0.5 V or less.





Is the voltage as specified? Wire side of female terminals

YES - Short to power in the gauge assembly; replace the gauge assembly.• Is the voltage as specified? NO- Go to step 20. YES- Faulty OPDS unit; replace the OPDS unit (see page 23-300) .• NO- Go to step·16.

(cont'd)

BACK

23-169

SRS DTC Troubleshooting - '00 Coupe with Side Airbags (cont'd) 20. Turn the ignition switch OFF.



25. Backprobe the No. 17 terminal of gauge assembly connector B (22P). Do not disconnect the connector from the gauge assembly. 26. Turn the ignition switch ON (II). 27. Check for voltage at the No. 17 terminal of gauge assembly connector B (22P) and body ground. There should be battery voltage.

GAUGE ASSEMBL V CONNECTOR B (22PI

2 11

7

12

8

9

10

19 20

21

22



Is there battery voltage? OPDS UNIT CONNECTOR D (8PI

YES- Go to step 28. NO-Go to step 32. 28. Turn the ignition switch OFF. 29. Disconnect the right side wire harness 16P connector C582 (A) from the dashboard wire harness A 16P connector (B).


Is the voltage as specified? YES - Short to power in dashboard wire harness A; replace dashboard wire harness A .• NO- Short to power in the right side wire harness or the OPDS unit harness; if the OPDS unit harness is OK, replace the right side wire harness .•

23-170

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31. Check for voltage between the No. 13 terminal of the dashboard wire harness A 16P connector (C582) and body ground. There should be battery voltage.

35. Check for voltage between the No. 11 terminal of gauge assembly connector 8 (22P) and body ground. There should be battery voltage.

DASHBOARD WIRE HARNESS A 16P CONNECTOR (C5821

GAUGE ASSEMBLY CONNECTOR B (22P)

7

8

19 20

9

10

21 22



= Is there battery voltage? Is there battery voltage? YES-Poor contact atthe dashboard wire harness A 16P and right side wire harness 16P connectors or an open in the right side wire harness. Check the connection between the dashboard wire harness A 16P and right side wire harness 16P connectors; if the connection is OK, replace the right side wire harness.• NO- Poor contact at gauge assembly connector 8 (22P) or an open in the dashboard wire harness A. Check gauge assembly connector 8 (22P) and the gauge assembly; if the connection is OK, replace dashboard wire harness A..

YES- Faulty side airbag indicator light circuit; replace the gauge assembly.• NO-Open in dashboard wire harness A; replace dashboard wire harness A .• 36. Turn the ignition switch OFF. 37. Disconnect OPDS unit connector 0 (8P) from the OPDS unit (8).


B

D


B

(cont'd)

BACK

23-171

SRS DTC Troubleshooting - '00 Coupe with Side Airbags (cont'd) 43. Disconnect gauge assembly connector 8 (22P) from the gauge assembly.


Does the side airbag indicator light stay off? YES- Faulty OPDS unit; replace the OPDS unit.• B

NO-Go to step 39.

39. Turn the ignition switch OFF. 40. Disconnect the right side wire harness 16P connector C582 (A) from the dashboard wire harness A 16P connector (8).


Does the side airbag indicator light stay off? YES-Short to ground in dashboard wire harness A; replace dashboard wire harness A.. NO-Short to ground in the gauge assembly; replace the gauge assembly .•


Does the side airbag indicator light stay off? YES - Short to ground in the right side wire harness or the OPDS unit harness; if the OPDS unit harness is OK, replace the right side wire harness .•


23-172

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DTC 15-3: Faulty OPDS sensor

7. Replace the OPOS unit (see page 23-300), and reinitialize the OPOS unit (see page 23-46).

1. Erase the DTC memory (see page 23-45). 8. Erase the OTC memory. 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

9. Read the OTC.

Is 15-3 indicated? Does the SRS indicator light stay on? YES - Replace the SRS unit.• YES - Go to step 3. NO- The system is OK.• NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). NOTE: Aftermarket devices (fluorescent map lights, laptop computers, etc.) used near the front passenger's seat-back can interfere with the seatback sensors and cause a false DTC 15-3. If one of these devices was used, erase the DTC, operate the device near the seat-back, and recheck for DTCs. If DTC 15-3 is reset, erase it, and do not use the device near the seat-back. 3. Check the connection at the OPOS sensor harness connector and the OPOS unit connector.

Are the connections OK? YES - Go to step 4. NO- Reconnect the OPDS sensor harness connector, and clear the OTC .• 4. Replace the OPDS sensor/seat back foam (see page 20-97), and reinitialize the OPOS unit (see page 2346). 5. Erase the DTC memory. 6. Read the DTC.

Is DTC 15-3 indicated? YES -- Go to step 7. NO- The system is OK.•

BACK

23-173

SRS DTC Troubleshooting - '01-02 Models DTC 1-1: Open in driver's airbag inflator


DTC 1-2: Increased resistance in driver's


airbag inflator 8. Read the DTC. 1. Erase the DTC memory (see page 23-45).


YES-Go to step 9. NO-Open or increased resistance in the driver's airbag inflator; replace the driver's airbag (see page 23-278) .•

Does the SRS indicator light stay on? YES - Go to step 3. NO -Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).



A

/07SAZ-TB4011A

:::6 5. Connect the special tool (2 Q connectors) to the cable reel 4P connector.

23-174

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10. Disconnect the front passenger's airbag 4P connector (A) from the SRS main harness 4P connector (B).


13. Check resistance between the No.7 and the No. 16 terminals and between the No.2 and the No. 11 terminals of SRS connector A (18P). There should be 2.0-3.0 Q. B


11. Disconnect both seat belt tensioner 2P connectors (A) from the side wire harness 2P connectors (B). 345

6

7

8

9

12 13 14 15 16 17 18

B


Is the resistance as specified? YES - Faulty SRS unit or poor contact at SRS unit connector A (18P) and the SRS unit. Check the connection. If the connection is OK, replace the SRS unit (see page 23-296) .• NO-Open or increased resistance in the SRS main harness or cable reel; replace the SRS main harness or cable reel (see page 23-292) .•

BACK

23-175

SRS DTC Troubleshooting - '01-02 Models (cont'd) DTC 1-3: Short to another wire or decreased resistance in driver's airbag inflator

8. Read the DTC.


NO-Short in the driver's airbag; replace the driver's airbag (see page 23-278) .• 9. Disconnect the battery negative cable, and wait for 3 minutes.

Does the SRS indicator light stay on? YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the driver's airbag 4P connector from the cable reel 4P connector (A).

A

"::::~=9Lj...t--_-07XAZ-SZ30100 /07SAZ-TB4011A

::0 5. Connect the special tool (2 Q connectors) to the cable reel 4P connector. 6. Reconnect the battery negative cable. 7. Erase the DTC memory.

23-176

BACK



14. Check resistance between the No.7 and the No. 16 terminals and between the No.2 and No. 11 terminals of SRS unit connector A (18P). There should be 1 M Q or more. A SRS UNIT CONNECTOR A (18P)

11. Disconnect both seat belt tensioner 2P connectors (A) from the side wire harness 2P connectors (8).

3

4

5

6

789

12 13 14 15 16 17 18

A

B


Is the resistance as specified? YES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• 12. Disconnect the special tool from the cable reel 4P connector.

BACK

NO-Short in the SRS main harness or cable reel; replace the SRS main harness or cable reel (see page 23-292) .•

23-177

SRS DTC Troubleshooting - '01-02 Models (cont'd) DTC 1-4: Short to power in driver's airbag inflator

8. Read the DTC.



Does the SRS indicator light stay on? YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnectthe battery negative cable, and wait for 3 minutes. 4. Disconnect the driver's airbag 4P connector from the cable reel 4P connector (A).

A

~:::::::~~_~_--07XAZ-SZ30100 /07SAZ-TB4011A

::6 5. Connect the special tool (2 Q connectors) to the cable reel 4P connector. 6. Reconnect the battery negative cable. 7. Erase the DTC memory.

23-178

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10. Disconnect the front passenger's airbag 4P connector (A) from the SRS main harness 4P connector (8), and disconnect the special tool from the cable reel 4P connector.


B


A


15. Check for voltage between the No.7 terminal of SRS unit connector A (18P) and body ground, between the No. 16 terminal and body ground, between the No.2 terminal and body ground, and between the No. 11 terminal and body ground. There should be 0.5 V or less. SRS UNIT CONNECTOR A (18P)

234

5

6

789

12 13 14 15 16 17 18

=

=

=

=


Is the voltage as specified? YES - Faulty SRS unit; replace the SRS unit (see

page 23-296) .• NO-Short to power in the SRS main harness or cable reel; replace the SRS main harness or cable reel (see page 23-292) .•

BACK

23-179

SRS DTC Troubleshooting - '01-02 Models (cont'd) DTC 1-5: Short to ground in driver's airbag inflator

8. Read the DTC.



NO- Short to ground in the driver's airbag inflator; replace the driver's airbag (see page 23-278) .• 9. Disconnect the battery negative cable, and wait for 3 minutes.

YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the driver's airbag 2P connector from the cable reel 2P connector (A).

A

/07SAZ-TB4011A

::iO 5. Connect the special tool (2 Q connectors) to the cable reel 4P connector. 6. Reconnect the battery negative cable. 7. Erase the DTC memory.

23-180

BACK

10. Disconnect the front passenger's airbag 4P connector (A) from the SRS main harness 4P connector (B), and disconnect the special tool from the cable reel 4P connector.


13. Check resistance between the No.7 terminal of SRS unit connector A (18P) and body ground, between the No. 16 terminal and body ground, between the No.2 terminal and body ground, and between the No. 11 terminal and body ground. There should be 1 M Q or more.

A


11. Disconnect both belt tensioner 2P connectors (A) from the side wire harness 2P connectors (B).

3

4

5

6

7

8

9

12 13 14 15 16 17 18

=


Is the resistance as specified? YES - Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO - Short to ground in the SRS main harness or cable reel; replace the SRS main harness or cable reel (see page 23-292) .•

BACK

23-181

SRS DTC Troubleshooting - '01-02 Models (cont'd) DTC 2-1: Open in passenger's airbag inflator

8. Read the DTC.

DTC 2-2: Increased resistance in passenger's airbag inflator

Is DTC 2-1 or 2-2 indicated? YES--Go to step 9.

1. Erase the DTC memory (see page 23-45). NO- Open or increased resistance in the front passenger's airbag inflator; replace the front passenger's airbag (see page 23-280) .•



Does the SRS indicator light stay on? YES-Go to step 3.

10. Disconnect the driver's airbag 4P connector (A) from the cable reel 4P connector (B).

NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the front passenger's airbag 4P connector from the SRS main harness 4P connector (A).

A

A

11. Disconnect both seat belt tensioner 2P connectors (A) from the side wire harness 2P connectors (B). -07XAZ-SZ30100 07SAZ-TB4011A

~

0:

5. Connect the special tool (2 Q connectors) to the SRS main harness 2P connector. 6. Reconnect the battery negative cable. 7. Erase the DTC memory.

23-182

BACK

DTC 2-3: Short to another wire or decreased resistance in passenger's airbag inflator



Does the SRS indicator light stay on? YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.

13. Check resistance between the No.6 and No. 15 terminals and between the No.5 and No. 14 terminals of SRS unit connector A (18P). There should be 2.0-3.0 Q.



/ /

J

,I 6

7

2

3

4

5

11

12

13

14 15

I

8

9

16 17 18

I

A

?1

Wire side of female terminals -07XAZ-SZ30100


07SAZ-TB4011A

~

YES- Faulty SRS unit or poor contact at the SRS unit connector; check the connection between the SRS main harness 18P connector and the SRS unit. If the connector is OK, replace the SRS unit (see page 23-296) .• NO-Open or increased resistance in the SRS main harness; replace the SRS main harness .•

0::


(cont'd)

BACK

23-183

SRS DTC Troubleshooting - '01-02 Models (cont'd) 13. Disconnect SRS unit connector A (18P) from the SRS unit.

6. Reconnect the battery negative cable. 7. Erase the DTC memory. 8. Read the DTC. Is DTC 2-3 indicated? YES-Go to step 9. NO-Short in the front passenger's airbag inflator; replace the front passenger's airbag (see page 23280) .• 9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the driver's airbag 4P connector (A) from the cable reel 4P connector (8).

14. Check resistance between the No.6 and No. 15 terminals and between the No.5 and No. 14 terminals of SRS unit connector A (18P). There should be 1 M Q or more. SRS UNIT CONNECTOR A (18P)

7

/

4

,I

5

6

7

8

9

11 12 13 14 15 16 T

17

18

2

3

r T

?1

A



Is the resistance as specified? VES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO- Short in the SRS main harness; replace the SRS main harness .•


23-184

BACK


8. Read the DTC.

Is OTe 2-4 indicated? 1. Erase the DTC memory (see page 23-45). VES-Goto step 9. 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

NO-Short to power in the front passenger's airbag inflator; replace the front passenger's airbag (see page 23-280) .•

Does the SRS indicator light stay on? 9. Disconnect the battery negative cable, and wait for 3 minutes.

VES- Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).

10. Disconnect the driver's airbag 4P connector (A) from the cable reel 4P connector (8), and disconnect the special tool from the SRS main harness 4P connector.


A

A

11. Disconnect both seat belt tensioner 2P connectors (A) from the side wire harness 2P connectors (8). -07XAZ-SZ30100 07SAZ-TB4011A

~

A

U::

B

5. Connect the special tool (2 Q connectors) to the SRS main harness 2P connector. 6. Reconnect the battery negative cable. 7. Erase the DTC memory.

(cont'd)

BACK

23-185

SRS DTC Troubleshooting - '01-02 Models (cont'd) DTC 2-5: Short to ground in passenger's airbag inflator


1. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off. Does the SRS indicator light stay on? YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 13. Reconnect the battery negative cable.

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and waitfor 3 minutes.

14. Turn the ignition switch ON (II). 15. Check for voltage between the No.6 terminal of SRS unit connector A (18P) and body ground, between the No. 15 terminal and body ground, between the No.5 terminal and body ground, and between the No. 14 terminal and body ground. There should be 0.5 V or less.


/


234 11

5

678

9

12 13 14 15 16 17 18 07XAZ-SZ30100


Is the voltage as specified? YES- Faulty SRS unit; replace the SRS unit (see page 23-296) .•



23-186

BACK




Is DTC 2-5 indicated? YES-Go to step 9. NO-Short to ground in the passenger's airbag inflator; replace the passenger's airbag (see page 23-280) .• 9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the driver's airbag 4P connector (A) from the cable reel 4P connector (B), and disconnect the special tool from the SRS main harness 4P connector.

13. Check resistance between the No.6 terminal of SRS unit connector A (18P) and body ground, between the No. 15 terminal and body ground, between the No.5 terminal and body ground, and between No. 14 terminal and body ground. There should be 1 M Q or more. SRS UNIT CONNECTOR A (18P)

234 11

5

678

9

12 13 14 15 16 17 18

=

A

=

=


11. Disconnect both seat belt tensioner 2P connectors (A) from the side wire harness 2P connectors (B).

Is the resistance as specified? YES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO-Short to ground in the SRS main harness; replace the SRS main harness .•

BACK

23-187

SRS DTC Troubleshooting - '01-02 Models (co nt'd) DTC 3-1: Open in left side seat belttensioner


DTC 3-2: Increased resistance in left side seat belt tensioner



Is ore 3-1 or ore 3-2 indicated?

2. Turn the ignition switch ON (11), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

YES-Go to step 9. NO-Open or increased resistance in left side seat belt tensioner; replace the left side seat belt (see page 23-4) .•


9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the left side wire harness 4P connector C557 (A) from the SRS main harness 4P connector.

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the left side seat belt tensioner 2P connector from the left side wire harness 2P connector (A).

~/07XAZ_SZ30100

A 07SAZ-TB4011A

~

~::

A

11. Connect the special tool (2 Q connectors) to the SRS main harness 4P connector. /07TAZ-SZ5011A


07SAZ-TB4011A

~


0.-

14. Read the DTC.

Is ore 3-1 or ore 3-2 indicated?


YES-Go to step 15. NO- Open or increased resistance in left side wire harness; replace the left side wire harness .• 15. Disconnect the battery negative cable, and wait for 3 minutes.

23-188

BACK

16. Disconnect the driver's airbag connector (A), front passenger's airbag connector (8), and right side seat belt tensioner connector (C).


A

18. Check resistance between the No.8 terminal and the No. 17 terminal of SRS unit connector A (18P). There should be 2.0-3.0 Q. SRS UNIT CONNECTOR A (18P)

234 B

11

5

678

9

12 13 14 15 16 17 18

C Wire side of female terminals

Is the resistance as specified? YES - Faulty SRS unit or poor contact at SRS unit connector A (18P) and at the SRS unit. Check the connection. If the connection is OK, replace the SRS unit (see page 23-296) .• NO-Open or increased resistance in the SRS main harness; replace the SRS main harness .•

BACK

23-189

SRS DTC Troubleshooting - '01-02 Models (cont'd) DTC 3-3: Short to another wire or decreased


resistance in left side seat belt tensioner 7. Erase the DTC memory. 1. Erase the DTC memory (see page 23-45). 8. Read the DTC. 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.


Does the SRS indicator light stay on? NO- Short in the left side seat belt tensioner; replace the left side seat belt (see page 23-4) .•

VES- Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).


3. Turn the ignition switch OFF. Disconnectthe battery negative cable, and wait for 3 minutes. 4. Disconnect the left side seat belt tensioner 2P connector from the left side wire harness 2P connector (A).

.P"'''''''''~ ~/07XAZ_SZ30100

A 07SAZ-TB4011A

~Fni

0=

A

/

07TAZ-SZ5011 A

07SAZ-TB4011A

11. Connect the special tool (2 Q connectors) to the SRS main harness 4P connector. 12. Reconnect the battery negative cable.

~

O~


Is DTC 3-3 indicated? 5. Connect the special tool (2 Q connector) to the left side wire harness 2P connector.

YES - Go to step 15. NO- Short in left side wire harness; replace the left side wire harness .• 15. Disconnect the battery negative cable, and wait for 3 minutes.

23-190

BACK

16. Disconnect the driver's airbag connector (A), front passenger's airbag connector (8), and right side seat belt tensioner connector (C).


A

18. Disconnect the special tool from the SRS main harness 4P connector. 19. Check resistance between the No.8 terminal and the No. 17 terminal of SRS unit connector A (18P). There should be 1 M Q or more. SRS UNIT CONNECTOR A (18P)

B 234 11

5

678

9

12 13 14 15 16 17 18

C



VES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO- Short in the SRS main harness; replace the SRS main harness .•

BACK

23-191

SRS DTC Troubleshooting - '01-02 Models (cont'd) DTC 3-4: Short to power in left side seat belt tensioner




Does the SRS indicator light stay on? NO- Short to power in left side seat belt tensioner; replace the left side seat belt (see page 23-4).•



3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the left side seat belt tensioner 2P connector from the left side wire harness 2P connector (A).

~/07XAZ_SZ30100

A 07SAZ-TB4011A

~

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A

/07TAZ-SZ5011A 07SAZ-TB4011 A

11. Connect the special tool (2 Q connectors) to the SRS main harness 4P connector. 12. Reconnect the battery negative cable.

~

0.,


Is DTC 3-4 indicated? 5. Connect the special tool (2 Q connector) to the left side wire harness 2P connector.

YES - Go to step 15. NO-Short to power in left side wire harness; replace the left side wire harness .• 15. Disconnect the battery negative cable, and wait for 3 minutes.

23-192

BACK

16. Disconnectthe driver's airbag connector (A), front passenger's airbag connector (B), and right side seat belt tensioner connector (C).


A

A

18. Disconnect the special tool from the SRS main harness 4P connector. 19. Reconnect the battery negative cable. 20. Turn the ignition switch ON (II).

21. Check for voltage between the No.8 terminal of SRS unit connector A (18P) and body ground, and between the No. 17 terminal and body ground. There should be 0.5 V or less. B SRS UNIT CONNECTOR A (18P)

C

234 11

5

6

789

12 13 14 15 16 17 18


Is the voltage as specified? YES- Faulty SRS unit; repiace the SRS unit (see page 23-296) .• NO-Short to power in SRS main harness; replace the SRS main harness .•

BACK

23-193

SRS DTC Troubleshooting - '01-02 Models (cont'd) DTC 3·5: Short to ground in left side seat belt tensioner


,. Erase the DTC memory (see page 23-45).

8. Read the DTC. 2. Turn the ignition switch ON (11), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

Is DTC 3-5 indicated? YES-Goto step 9.

Does the SRS indicator light stay on? NO- Short to ground in left side seat belt tensioner; replace the left side seat belt (see page 23-4) .•

YES- Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.


4. Disconnect the left side seat belt tensioner 2P connector from the left side wire harness 2P connector (A).

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A 07SAZ·TB4011A

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A


07SAZ·TB4011A

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NO - Short to ground in the left side wire harness; replace the left side wire harness.• 15. Disconnect the battery negative cable, and wait for 3 minutes.

23-194

BACK

16. Disconnect the driver's airbag connector (A), front passenger's airbag connector (B), and right side seat belt tensioner connector (C).


A

A

18. Disconnect the special tool from the SRS main harness 4P connector. 19. Check resistance between the No.8 terminal of SRS unit connector A (18P) and body ground, and between the No. 17 terminal and body ground. There should be 1 M Q or more. SRS UNIT CONNECTOR A (18P)

B

23456789 11

12 13 14 15

16 17 18

C



VES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO- Short to ground in SRS main harness; replace the SRS main harness .•

BACK

23-195

SRS DTC Troubleshooting· '0'·02 Models (cont'd) DTC 4-1: Open in right side seat belt tensioner DTC 4-2: Increased resistance in right side seat belt tensioner

8. Read the DTC.

Is DTC 4-1 or DTC 4-2 indicated? YES-Goto step 9.

1. Erase the DTC memory (see page 23-45). NO-Open or increased resistance in right side seat belt tensioner; replace the right side seat belt (see page 23-4) .•




10. Disconnect the driver'S airbag connector (A), front passenger's airbag connector (B), and left side seat belt tensioner connector (e).

3. Turn the ignition switch OFF. Disconnectthe battery negative cable, and wait for 3 minutes. 4. Disconnect the right side seat belt tensioner 2P connector from the right side wire harness 2P connector (A). A

A---I-/:.Hl;l

B

c

5. Connect the special tool (2 Q connector) to the right side wire harness 2P connector. 6. Reconnect the battery negative cable. 7. Erase the DTC memory.

23-196

BACK

DTC 4-3: Short to another wire or decreased resistance in right side seat belt tensioner



A

Does the SRS indicator light stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 12. Check resistance between the No.9 terminal and the No. 18 terminal of SRS unit connector A (18P). There should be 2.0-3.0 Q.

4. Disconnect the right side seat belt tensioner 2P connector from the right side wire harness 2P connector (A).


234 11

5

6

789

12 13 14 15 16 17 18


Q


Is the resistance as specified? YES - Faulty SRS unit or poor contact at the SRS unit connector. Check the connection between the SRS main harness 18P connector and the SRS unit. If the connection is OK, replace the SRS unit (see page 23-296) .•

5. Connect the special tool (2 Q connector) to the right side wire harness 2P connector. 6. Reconnect the battery negative cable.

NO-Open or increased resistance in the SRS main harness or rightside wire harness; replace the faulty harness.•


(cont'd)

BACK

23-197

SRS DTC Troubleshooting - '01-02 Models (cont'd) 11. Disconnect SRS unit connector A (18P) from the SRS unit.

8. Read the DTC.

Is DTC 4-3 indicated? YES- Go to step 9. NO-Short in the right side seat belttensioner; replace the right side seat belt (see page 23-4) .•

A

9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the driver's airbag connector (A), front passenger's airbag connector (8), and left side seat belt tensioner connector (C).

12. Disconnect the special tool (2 Q) from the right side wire harness 2P connector. 13. Check resistance between the No.9 terminal and the No. 18 terminal of SRS unit connector A (18P). There should be 1 M Q or more. SRS UNIT CONNECTOR A (18P) A

234 11

5

678

12 13 14 15 16 17


B


C

NO- Short in the SRS main harness or the right side wire harness; replace the faulty harness .•

23-198

BACK

DTC 4-4: Short to power in right side seat belt tensioner

8. Read the DTC.


NO - Short to power in the right side seat belt tensioner; replace the right side seat belt (see page 23-4) .•

Does the SRS indicator light stay on? 9. Disconnect the battery negative cable, and wait for 3 minutes.


10. Disconnect the driver's airbag connector (A), front passenger's airbag connector (8), and left side seat belt tensioner connector (C).

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the right side seat belt tensioner 2P connector from the right side wire harness 2P connector (A).

A A----i-I'~

~

.7SAZ-T84011A

/01TAZ-SZ5011A

~

~~

B


c 6. Reconnect the battery negative cable. 7. Erase the DTC memory.

(cont'd)

BACK

23-199

SRS DTC Troubleshooting - '01-02 Models (cont'd) DTC 4-5: Short to ground in right side seat belt tensioner



A

Does the SRS indicator light stay on? YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 12. Disconnect the special tool from the right side wire harness 2P connector.



4. Disconnect the right side seat belt tensioner 2P connector from the right side wire harness 2P connector (A).

14. Turn the ignition switch ON (II). 15. Check for voltage between the No.9 terminal of SRS unit connector A (18P) and body ground, and between the No. 18 terminal and body ground. There should be 0.5 V or less. SRS UNIT CONNECTOR A (18P)

A---I44~~~

'-

234 11

5

6

7

/07TAZ-SZ5011A

~ ~.-

8

'7SAZ·TB4011A

12 13 14 15 16 17

5. Connect the special tool (2 Q connector) to the right side wire harness 2P connector. Wire side of female terminals


Is the voltage as specified? 7. Erase the DTC memory. YES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO- Short to power in the SRS main harness or the right side wire harness; replace the faulty harness.•

23-200

BACK


8. Read the DTC.

Is DTC 4-5 indicated? YES-Go to step 9. NO- Short to ground in right side seat belt tensioner; replace the right side seat belt (see page 23-4) .•

A

9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the driver's airbag connector (A), front passenger's airbag connector (8), and left side seat belt tensioner connector (C). 12. Disconnect the special tool from the right side wire harness 2P connector. 13. Check resistance between the No.9 terminal of SRS unit connector A (18P) and body ground, and between the No. 18 terminal and body ground. There should be 1 M Q or more. SRS UNIT CONNECTOR A (18P)

A

234

~~~~~-~-.~~~£?

11

5

678

12 13 14 15 16 17

(<< \

"

... --='

B


Is the resistance as specified? C

YES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO-Short to ground in the SRS main harness or the right side wire harness; replace the faulty harness .•

BACK

23-201

SRS DTC Troubleshooting - '0'·02 Models (cont'd) DTC 5-1, 5-2, 5-4, 5-8, 6-1, 6-2, 6-3, 6-4, 6-7, 6-8, 7-1,7-2,7-3,8-1,8-2,8-3,8-4,8-5,8-6,8-7,8-8, 9-1,9-2: Internal Failure of the SRS unit

DTC 10-1, 10-2, 10-3, 10-4, 10-5, 10-6, 10-7: Airbags, side airbags and/or seat belt tensioners deployed

Note: Before troubleshooting any of these DTCs, check the battery/system voltage. If the voltage is low, repair the charging system before troubleshooting the SRS. If the battery/system voltage is now OK, ask the customer if the battery ever went dead.

The SRS unit must be replaced after any airbags have deployed (see page 23-296).


Does the SRS indicator light stay on? YES- Replace the SRS unit (see page 23-296) .• NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).

23-202

BACK

OTC 13-1, 13-2: Internal Failure of the driver's

OTC 14-1, 14-2: Internal Failure of the front

side impact sensor

passenger's side impact sensor



2. Turn the ignition switch ON (11), and check that the SRS indicator light comes on for about 6 seconds and then goes off.




YES - Replace the SRS unit (see page 23-299) .•

YES- Replace the SRS unit (see page 23-299) .•



BACK

23-203

SRS DTC Troubleshooting - '00-02 Models DTC 9-3: Faulty driver's seat belt buckle switch

7. Disconnect the driver's power seat wire harness 3P connector (with power seat) or left side wire harness 3P connector (without power seat) (A) from the driver's seat belt buckle switch 3P connector (B).

1. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (II), then buckle and unbuckle the driver's seat belt several times. 3. Read the DTC.

Is DTC 9-3 indicated? YES-Go to step 4. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 4. Check the No.9 (7.5A) fuse in the driver's under-dash fuse/relay box.

B

8. Buckle the driver's seat belt. Check resistance between the No.1 and No.3 terminals of the driver's seat belt buckle switch 3P connector. There should be 0-1 Q.

Is the fuse blown? YES- Go to step 5. NO-Goto step 6.

Check resistance between the No. 1 and No.2 terminals of the same connector. There should be 1 MQ or more.

5. Replace the No.9 (7.5A) fuse in the under-dash fuse/relay box, and turn the ignition switch ON (II) for 30 seconds.

DRIVER'S SEAT BELT BUCKLE SWITCH 3P CONNECTOR

Did the fuse blow-out again? YES- Locate and repair the short to ground on the No.9 fuse circuit, and clear the DTC.• NO- Go to step 6.




Are the resistance readings as specified? YES-Go to step 9. NO-Replace the driver's seat belt buckle assembly, and clear the DTC .•

23-204

BACK

9. Unbuckle the driver's seat belt. Check resistance between the No.1 and No.2 terminals of the driver's seat belt buckle switch 3P connector. There should be 0 -1 Q.

10. Check resistance between the No.1 terminal of the driver's seat wire harness 3P connector and body ground. There should be 0--1 Q. DRIVER'S SEAT WIRE HARNESS 3P CONNECTOR

Check resistance between the No.1 and No.3 terminals of the same connector. There should be 1 MQ or more. DRIVER'S SEAT BELT BUCKLE SWITCH 3P CONNECTOR


Is the resistance as specified? Terminal side of male terminals

YES-Gotostep 11.

NO - Open in the driver's seat wire harness or poor ground connection at G551. If G551 is OK, replace the faulty harness .• 11. Turn the ignition switch ON (II). Terminal side of male terminals

Does the seat belt reminder stay on?

Are the resistance readings as specified? YES-Go to step 16. YES-Goto step 10. NO-Gotostep 12. NO- Replace the driver's seat belt buckle assembly, and clear the DTC .•

(cont'd)

BACK

23-205

SRS DTC Troubleshooting - '00-02 Models (cont'd) 12. Connect No.2 terminal ofthe driver's seat wire harness 3P connector to body ground with a jumper wire.

15. Connect the No.4 terminal of SRS unit connector C (BP) to body ground with a jumper wire. Turn the ignition switch ON (II).

DRIVER'S SEAT WIRE HARNESS 3P CONNECTOR

SRS UNIT CONNECTOR C (BPI JUMPER WIRE

~

I

1

JUMPER WIRE

1 5

c;----?

I

2

3

4

6

7

8

-Wire side of female terminals


Does the seat belt reminder come on?

Does the seat belt reminder come on?

YES-Go to step 13.

YES- Disconnect the jumper wire, then go to step 1B.

NO- Open in the driver's seat wire harness, driver's under-dash fuse/relay box, or dashboard wire harness A. Isolate the faulty harness, and replace the harness or component as necessary.• 13. Turn the ignition switch OFF, and disconnect the negative cable from the battery. 14. Disconnect all SRS unit connectors from the SRS unit, and reconnect the battery.

NO- Open in dashboard wire harness A. Replace dashboard wire harness A.• 16. Turn the ignition switch OFF, and disconnect the negative cable from the battery. 17. Disconnect SRS unit connector C (BP), reconnect the battery, and turn the ignition switch ON (II).

Does the seat belt reminder come on? YES- Short to ground in the dashboard wire harness A, driver'S under-dash fuse/relay box (without heated seat), driver's multiplex control unit (without heated seat), left side wire harness, driver's power seat wire harness (with power seat), or gauge assembly/circuit board. Replace the faulty harness or component.. NO- Replace the SRS unit (see page 23-296) .•

23-206

BACK

18. Turn the ignition switch OFF. 19. Check resistance between the No.3 terminal of the driver's seat wire harness 3P connector and body ground. There should be 1 M Q or more. DRIVER'S SEAT WIRE HARNESS 3P CONNECTOR

20. Check resistance between the No.8 terminal of the dashboard wire harness A 8P connector and the No.3 terminal of the driver's power seat wire harness 3P connector (with power seat) or left side wire harness 3P connector (without power seat). There should be 0 -1 Q.

DRIVER'S POWER SEAT WIRE HARNESS 3P CONNECTOR

SRS UNIT CONNECTOR C (BP)

5

=

L----{Ql--------' Wire side of female terminals


Is the resistance as specified? Is the resistance as specified?

YES - Go to step 20. YES - Replace the SRS unit.. NO-Short to ground in dashboard wire harness A, left side wire harness, or driver's seat wire harness. Replace the faulty harness .•

BACK

NO- Open in the dashboard wire harness A, left side wire harness or driver's power seat wire harness (with power seat). Replace the faulty harness .•

23-207

SRS DTC Troubleshooting - '00-02 Models (cont'd) DTC 9-4: Faulty front passenger's seat belt buckle switch

6. Buckle the front passenger's seat belt. Check resistance between the No. 1 and No.3 terminals of the front passenger's seat belt buckle switch 3P connector. There should be 0-1 Q.

1. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (II), then buckle and unbuckle the front passenger's seat belt several times.

Check resistance between the No.1 and No.2 terminals of the same connector. There should be 1 MQ or more.

3. Read the DTC.

FRONT PASSENGER'S SEAT BELT BUCKLE SWITCH 3P CONNECTOR

Is DTC 9-4 indicated? YES-Go to step 4. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-451. 4. Turn the ignition switch OFF.


5. Disconnect the front passenger's seat belt buckle switch 3P connector (AI from the passenger's power seat wire harness 3P connector (B). BLU/GRN (BLUI


Are the resistance readings as specified? YES-Goto step 7. NO - Replace the front passenger's seat belt buckle assembly, and clear the DTC (see page 23-9) .•

23-208

BACK

7. Unbuckle the front passenger's seat belt. Check resistance between the No.1 and No.2 terminals of the front passenger's seat belt buckle switch 3P connector. There should be 0 -1 Q.

8. Check resistance between the No.1 terminal of the passenger's power seat wire harness 3P connector (with power seat) or right side wire harness 3P connector (without power seat) and body ground. There should be 0-1 Q.

Check resistance between the No.1 and No.3 terminals of the same connector. There should be 1 MQ or more.

PASSENGER'S POWER SEAT WIRE HARNESS 3P CONNECTOR OR RIGHT SIDE WIRE HARNESS 3P CONNECTOR

r

FRONT PASSENGER'S SEAT BELT BUCKLE SWITCH 3P CONNECTOR

BLK

Q

23


Is the resistance reading as specified? Terminal side of male terminals

YES- Go to step 9. NO-Open in the passenger's power seat wire harness (with power seat), open in the right side wire harness, or poor ground connection at G581. If G581 is OK, replace the faulty harness .• 9. Disconnect the negative cable from the battery. Disconnect the dashboard wire harness A 8P connector from the SRS unit.


Are the resistance readings as specified?

YES-Go to step 8. NO- Replace the front passenger's seat belt buckle assembly (see page 23-9), and clear the DTC .•

10. Check resistance between the No.2 terminal ofthe passenger's power seat wire harness 3P connector (with power seat) or right side wire harness 3P connector (without power seat) and body ground. There should be 1 M Q or more. PASSENGER'S POWER SEAT WIRE HARNESS 3P CONNECTOR OR RIGHT SIDE WIRE HARNESS 3P CONNECTOR

~

~ BLU/GRN


Is the resistance reading as specified?

YES-Gotostep 11. NO-Shortto ground in dashboard wire harness A, right side wire harness, or passenger's power seat wire harness (with power seat). Replace the faulty harness .• (cont'd)

BACK

23-209

SRS DTC Troubleshooting - '00-02 Models (cont'd) 11. Check resistance between the No.3 terminal of the passenger's seat wire harness 3P connector and body ground. There should be 1 M Q or more.

13. Check resistance between the No.3 terminal of SRS unit connector C (BP) and the No.2 terminal of the passenger's seat wire harness 3P connector. There should be 0-1 Q.

PASSENGER'S SEAT WIRE HARNESS 3P CONNECTOR PASSENGER'S SEAT WIRE HARNESS 3P CONNECTOR

SRSUNIT CONNECTOR C (BP)

BLU/WHT (VEL/BLU)

234

=

567






NO - Short to ground in the dashboard wire harness A, right side wire harness or passenger's power seat wire harness (with power seat). Isolate the faulty harness, and replace as necessary.•

YES-Replace the SRS unit.•

12. Check resistance between the No.7 terminal of SRS unit connector C (BP) and the No.3 terminal of the passenger's seat wire harness 3P connector. There should be 0 -1 Q.

PASSENGER'S SEAT WIRE HARNESS 3P CONNECTOR

SRSUNIT CONNECTOR C (BP)



YES- Go to step 13. NO-Open in the dashboard wire harness A, right side wire harness, or passenger's seat wire harness. Isolate the faulty harness, and replace as necessary.•

23-210

8

BACK

NO-Open in the dashboard wire harness A, right side wire harness, or passenger's seat wire harness. Isolate the faulty harness, and replace as necessary.•

OTe Troubleshooting - '01-02 Models with Side Airbags DTC 11-1: Open or increased resistance in driver's side airbag inflator




Does the SRS indicator light stay on? NO- Open or increased resistance in the driver's side airbag inflator; replace the driver's side airbag (see page 23-282) .•


9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the right side wire harness 2P connector (A) from the front passenger's side airbag (8).


A A

lSAZ-TB4011 A

07XAZ-S1A0200

--0


(cont'd)

BACK

23-211

SRS DTC Troubleshooting - '01-02 Models with Side Airbags (cont'd) DTC 11-3: Short to another wire or decreased

11. Disconnect SRS unit connector 8 (14P) from the SRS unit. Do not disconnect the special tool from the left side wire harness 2P connector.

resistance in driver's side airbag inflator 1. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (11), and check that the SRS indicator light comes on for about 6 seconds and then goes off. Does the SRS indicator light stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).

12. Check resistance between the No.4 and No. 13 terminals of SRS connector 8 (14P). There should be 2.0-3.0 Q.

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the left side wire harness 2P connector (A) from the driver'S side airbag (8).


Wire side of female terminals A

Is the resistance as specified? YES-Faulty SRS unit or poor contact at the SRS main harness 14P connector and the SRS unit; check the connection at the SRS main harness 14P connector and SRS unit. If the connector is OK, replace the SRS unit (see page 23-296) .•

07SAZ-TB4011A

/

'-0

NO-Open or increased resistance in the SRS main harness or left side wire harness; replace the faulty harness .•

5. Connect the special tool (2 Q connector) to the left side wire harness 2P connector. 6. Reconnect the battery negative cable. 7. Erase the DTC memory.

23-212

BACK

8. Read the DTC.

13. Check resistance between the No.4 and No. 13 terminals of SRS unit connector 8 (14PI. There should be 1 M Q or more.



NO-Short to another wire in the driver's side airbag inflator; replace the driver's side airbag (see page 23-2821 .• 9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the right side wire harness 2P connector (AI from the front passenger's side airbag (81.


Is the resistance as specified? YES-Faulty SRS unit; replace the SRS unit (see page 23-2961 .• NO-Short to another wire in the SRS main harness or left side wire harness; replace the faulty harness.•

A

11. Disconnect the special tool from the left side wire harness 2P connector. 12. Disconnect SRS unit connector 8 (14PI from the SRS unit.

BACK

23-213

SRS DTC Troubleshooting - '01-02 Models with Side Airbags (cont'd) DTC 11-4: Short to power in driver's side airbag inflator




Does the SRS indicator light stay on? NO- Short to power in the driver's side airbag inflator; replace the driver's side airbag (see page 23-282) .•

YES - Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnectthe battery negative cable, and wait for 3 minutes. 4. Disconnect the left side wire harness 2P connector (A) from the driver's side airbag (B).

9. Disconnect the battery negative cable, and wait for 3 minutes.• 10. Disconnect the right side wire harness 2P connector (A) from the front passenger's side airbag (B), and disconnect the special tool from the left side wire harness 2P connector.

B

A

A

lSAZ 07XAZ-S1A0200

O

lB4011A

'-6


23-214

BACK


B

12. Check resistance between the No. 13 and No.6 terminals of SRS unit connector B (14P), and between the No. 13 and No.7 terminals. There should be 1 M Q or more.




YES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO- Short to power in the SRS main harness or left side wire harness; replace the faulty harness .•

BACK

23-215

SRS DTC Troubleshooting - '01-02 Models with Side Airbags (cont'd) DTC 11-5: Short to ground in driver's side airbag inflator




Does the SRS indicator light stay on? NO- Short to ground in the driver's side airbag inflator; replace the driver'S side airbag (see page 23-282) .•

YES-Goto step 3. NO -Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the left side wire harness 2P connector (A) from the driver's side airbag (B).

9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the right side wire harness 2P connector (A) from the front passenger's side airbag (B), and disconnect the special tool from the left side wire harness 2P connector.

B A

A

07SAZ-TB4011A

I

07XAZ-S1A0200

--0

5. Connect the special tool (2 .Q connector) to the left side wire harness 2P connector.

23-216

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11. Disconnect SRS unit connector B (14P) from the

SRS unit.

12. Check resistance between the No. 13 and No. 11 terminals of SRS unit connector B (14P), between the No. 13 and No. 12 terminals, and between the No. 13 terminal and body ground. There should be

1 MQ or more. SRS UNIT CONNECTOR B (14P)

567 14



VES- Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO- Short to ground in the SRS main harness or the left side wire harness; replace the faulty harness.•

BACK

23-217

SRS DTC Troubleshooting· '01·02 Models with Side Airbags (cont'd) DTC 12-1: Open or increased resistance in front passenger's side airbag inflator




Does the SRS indicator light stay on? NO-Open or increased resistance in the front passenger's side airbag inflator; replace the front passenger's side airbag (see page 23-282) .•


9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnectthe right side wire harness 4P connector C583 (A) from the SRS main harness 4P connector (8).


A

/07SAZ-TB4011A

::0

A

11. Connect the special tool (2 Q connectors) to the SRS main harness 4P connector. 12. Reconnectthe battery negative cable. 13. Erase the DTC memory. 14. Read the DTC.

07SAZ-TB4011A

~

0-


I

07XAZ-S1A0200

NO-Open or increased resistance in the right side wire harness; replace the right side wire harness.• 15. Disconnect the battery negative cable, and wait for 3 minutes.


23-218

BACK


18. Check resistance between the No.5 and No. 14 terminals of SRS unit connector 8 (14P). There should be 2.0 - 3.0 Q. SRS UNIT CONNECTOR B (14P)

6

7

13 14

Q




YES- Faulty SRS unit or poor contact at SRS unit connector 8 (14P) and atthe SRS unit. Check the connection. If the connection is OK, replace the SRS unit (see page 23-296) .• NO- Open or increased resistance in the SRS main harness; replace the SRS main harness .•

B

BACK

23-219

SRS OTe Troubleshooting - '01-02 Models with Side Airbags (cont'd) DTe 12-3: Short to another wire or decreased resistance in front passenger's side airbag inflator

6. Reconnect the battery negative cable. 7. Erase the DTC memory. 8. Read the DTC.




YES- Go to step 9. NO- Short to another wire in the front passenger's side airbag inflator; replace the front passenger's side airbag (see page 23-282) .•

Does the SRS indicator light stay on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.

9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the right side wire harness 4P connector C583 (A) from the SRS main harness 4P connector (B).

4. Disconnect the right side wire harness 2P connector (A) from the front passenger's side airbag (B).

A

/07SAZ-TB4011A

::0

A

11. Connect the special tool (2 Q connectors) to the SRS main harness 4P connector. 12. Reconnectthe battery negative cable. 13. Erase the DTC memory. 14. Read the DTC.

07SAZ-TB4011A

~

u-

Is DTC 12-3 indicated? YES-Goto step 15.

!

07XAZ-S1A0200

NO-Short in the right side wire harness; replace the right side wire harness .• 15. Disconnect the battery negative cable, and wait for 3 minutes.


23-220

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19. Check resistance between the No.5 and No. 14 terminals of SRS unit connector 8 (14P). There should be 1 M Q or more. SRS UNIT CONNECTOR B (14P)

6

7

13 14

Q


Is the resistance as specified? YES- Faulty SRS unit; replace the SRS unit (see page 23-296) .•

A


NO- Short to another wire in the SRS main harness; replace the SRS main harness .•

B


BACK

23-221

SRS DTC Troubleshooting - '01-02 Models with Side Airbags (cont'd) DTC 12-4: Short to power in front passenger's side airbag inflator



Is DrC 12-4 indicated? YES- Go to step 9.

Does the SRS indicator light stay on? NO-Short to power in the front passenger's side airbag inflator; replace the front passenger's side airbag (see page 23-282) .•


9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the right side wire harness 4P connector C583 (A) from the SRS main harness 4P connector (8).


/07SAZ-TB4011A

::0

A

11. Connect the special tool (2 Q connectors) to the SRS main harness 4P connector. 12. Reconnect the battery negative cable. 13. Erase the DTC memory. 14. Read the DTC.

07SAZ-TB4011A

~

Is DrC 12-4 indicated?

0- I

07XAZ-S1A0200

YES-Gotostep 15. NO-Shortto power in the right side wire harness; replace the right side wire harness.• 15. Disconnect the battery negative cable, and wait for 3 minutes.


23-222

BACK


18. Check resistance between the No. 14 and No.6 terminals of SRS unit connector 8 (14P), and between the No. 14 and No.7 terminals. There should be 1 M Q or more. SRS UNIT CONNECTOR B (14P)



YES - Faulty SRS unit; replace the SRS unit (see page 23-296) .•



B

BACK

23-223

SRS DTC Troubleshooting - '01-02 Models with Side Airbags (cont'd) DTC 12-5: Short to ground in front passenger's side airbag inflator




Does the SRS indicator light stay on? NO - Short to ground in the front passenger's side airbag inflator; replace the front passenger's side airbag (see page 23-282) .•


9. Disconnect the battery negative cable, and wait for 3 minutes. 10. Disconnect the right side wire harness 4P connector C583 (A) from the SRS main harness 4P connector (B).

3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes. 4. Disconnect the right side wire harness 2P connector (A) from the front passenger's side airbag (B).

A

/07SAZ-TB4011A

::0

A

11. Connect the special tool (2 Q connectors) to the SRS main harness 4P connector. 12. Reconnect the battery negative cable. 13. Erase the DTC memory. 14. Read the DTC.

07SAZ-TB4011A

~

H-

Is DTC 12-5 indicated? YES - Go to step 15. NO- Short to ground in the right side wire harness; replace the right side wire harness.•

I

07XAZ-S1 A0200



23-224

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16. Disconnect the left side wire harness 2P connector (A) from the driver's side airbag (B).

18. Check resistance between the No. 14 and No. 11 terminals of SRS unit connector B (14P), between the No. 14 and No. 12 terminals, and between the No. 14 terminal and body ground. There should be 1 MQ or more. SRS UNIT CONNECTOR B (14P)



A

17. Disconnect SRS unit connector B(14P) from the SRS unit.

YES-Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO- Short to ground in the SRS main harness; replace the SRS main harness.•

BACK

23-225

SRS DTC Troubleshooting - '01-02 Models with Side Airbags (cont'd) DTC 13-3: No signal from the driver's side impact sensor

6. Disconnect the left side wi re harness 2P connector (A) from the driver's side impact sensor (8).

'~B


A------- \~


07SAZ-TB4011A

~

3. Turn the ignition switch OFF. Disconnectthe battery negative cable, and wait for 3 minutes.

ti~

4. Check the connection between the left side wire harness 2P connector and the driver's side impact sensor.

7. Connect the special tool (jumper connector) to the left side wire harness 2P connector.

Is the connection OK? YES- Go to step 5.


NO- Poor contact between the left side wire harness 2P connector and the driver's side impact sensor; reconnect or replace the driver'S side impact sensor.• 5. Disconnect the driver's side airbag and front passenger's side airbag 2P connectors (A).

A

23-226

BACK

DTC 13-4: Faulty power supply to the driver's side impact sensor

9. Check resistance between the No.6 and No. 11 terminals of SRS unit connector B (14P). There should be 0-1.0 Q.

1. Erase the DTC memory (see page 23-45). SRS UNIT CONNECTOR B (14P)

7

14



Q




Is the resistance as specified? YES-Faulty driver's side impact sensor or SRS unit; replace the driver's side impact sensor (see page 23-299). If the problem is still present, replace the SRS unit (see page 23-296) .•

4. Disconnect the driver's side airbag and front passenger's side airbag 2P connectors (A).

NO-Open in the SRS main harness or left side wire harness; replace the faulty harness .•

(cont'd)

BACK

23-227

SRS OTe Troubleshooting - '01-02 Models with Side Airbags (cont'd) 5. Disconnect the left side wire harness 2P connector (A) from the driver's side impact sensor (8).

7. Check resistance between the No.6 terminal of SRS unit connector 8 (14P) and body ground. There should be 1 M Q or more. SRS UNIT CONNECTOR B /14P)

7

14

= A




YES-Go to step 8. NO-Short to ground in the SRS main harness or left side wire harness; replace the faulty harness .• 8. Check resistance between the No.6 and No. 11 terminals of SRS unit connector 8 (14P). There should be 1 M Q or more. SRS UNIT CONNECTOR B (14P)

7 14


Is the resistance as specified? YES- Faulty driver's side impact sensor or SRS unit; replace the driver's side impact sensor (see page 23-299). If the problem is still present, replace the SRS unit (see page 23-296) .• NO-Short in the SRS main harness or left side wire harness; replace the faulty harness.•

23-228

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DTC 14-3: No signals from the front


passenger's side impact sensor 1. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.

Does the SRS indicator light stay on? YES- Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Turn the ignition switch OFF. Disconnect the battery negative cable, and wait for 3 minutes.

07SAZ-TB4011A

~

ti11~

4. Check the connection between the right side wire harness 2P connector and the front passenger's side impact sensor.

7. Connect the special tool (jumper connector) to the right side wire harness 2P connector.

Is the connection OK? YES - Go to step 5. NO - Poor contact between the right side wi re harness 2P connector and the front passenger's side impact sensor; reconnect or replace the sensor (see page 23-299) .•


5. Disconnect the driver's side airbag and front passenger's side airbag 2P connectors (A).

A

(cont'd)

BACK

23-229

SRS DTC Troubleshooting - '01-02 Models with Side Airbags (cont'd) DTC 14-4: Faulty power supply to the front

9. Check resistance between the No.7 and No. 12 terminals of SRS unit connector B (14P). There should be 0-1.0 Q.

passenger's side impact sensor 1. Erase the DTC memory (see page 23-45).


6


7


13 14




Is the resistance as specified? YES - Faulty front passenger's side impact sensor or SRS unit; replace the front passenger's side impact sensor (see page 23-299). If the problem is still present, replace the SRS unit (see page 23-296) .

4. Disconnectthe driver's side airbag and front passenger's side airbag 2P connectors (A).

•

NO-Open in the right side wire harness or SRS main harness; replace the faulty harness .•

A

23-230

BACK

5. Disconnectthe right side wire harness 2P connector (A) from the front passenger's side impact sensor (8).

7. Check resistance between the No.7 terminal of SRS unit connector 8 (14P) and body ground. There should be 1 M Q or more. SRS UNIT CONNECTOR B (14PI

4

5

6

7

11

12 13 14

Q =




YES-Go to step 8. NO- Short to ground in the SRS main harness or right side wire harness; replace the faulty harness.• 8. Check resistance between the No.7 and No. 12 terminals of SRS unit connector 8 (14P). There should be 1 M Q or more. SRS UNIT CONNECTOR B (14PI

6

7

13 14


Is the resistance as specified? YES- Faulty front passenger's side impact sensor or SRS unit; replace the front passenger's side impact sensor (see page 23-299). If the problem is still present, replace the SRS unit (see page 23-296) .

•

NO-Short in the SRS main harness or right side wire harness; replace the faulty harness.•

BACK

23-231

SRS DTC Troubleshooting - '01-02 Models with Side Airbags (cont'd) DTC 15-1: Faulty OPOS unit 1. Make sure nothing is on the front passenger's seat.

8. Check for voltage between the No.4 terminal of OPDS unit connector 0 (8P) and body ground. There should be battery voltage.

2. Initialize the OPDS unit (see page 23-46). OPDS UNIT CONNECTOR D (8PI

3. Erase the DTC memory (see page 23-45). 4. Read the DTC.


=





Is the fuse OK? NO-Go to step 9. YES - Go to step 6. 9. Turn the ignition switch OFF. NO-Goto step 13. 6. Disconnect OPDS unit connector 0 (8P) from the OPDS unit (B).

B


D

11. Turn the ignition switch ON (II). 7. Turn the ignition switch ON (II).

23-232

BACK

12. Check for voltage between the No.6 terminal of the dashboard wire harness A 6P connector (C5B2) and body ground. There should be battery voltage.

17. Disconnect OPDS unit connector D (BP) from the OPDS unit (B).

DASHBOARD WIRE HARNESS A 6P CONNECTOR (C582)

B

D


Is there battery voltage? YES - Open in the right side wire harness or OPDS unit harness; if the OPDS unit harness is OK, replace the right side wire harness.• NO - Open in dashboard wire harness A; replace dashboard wire harness A..

1B. Turn the ignition switch ON (II) for 30 seconds, then

turn it off. 19. Check the No.7 (7.5A) fuse in the driver's underdash fuse/relay box. Is the fuse OK?

13. Replace the No.7 (7.5A) fuse in the driver's underdash fuse/relay box.

YES- Short to ground in the OPDS unit; replace the OPDS unit (see page 23-300) .•

14. Turn the ignition switch ON (II) for 30 seconds, then turn it OFF. 15. Check the NO.7 (7.5A) fuse in driver's under-dash fuse/relay box.

NO-Short to ground in the No.7 (7.5A) circuit; refer to section 22 and continue troubleshooting .• 20. Turn the ignition switch OFF.

Is the fuse OK? YES -Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). NO- Go to step 16. 16. Replace the No.7 (7.5A) fuse in the driver's underdash fuse/relay box.

(cont'd)

BACK

23-233

SRS DTC Troubleshooting - '01-02 Models with Side Airbags (cont'd) 24. Disconnect SRS unit connector B (14P) from the SRS unit.

21. Check resistance between the No.8 terminal of OPDS unit 0 (8P) connector and body ground. There should be 0 -1.0 Q. OPDS UNIT CONNECTOR D (SPI

B



Is the resistance as specified? YES-Go to step 22.


NO-Open in the right side wire harness or OPDS unit harness, or poor ground (GS81). If GS81 is OK, replace the faulty harness .• 22. Disconnect the battery negative cable, and wait for 3 minutes.

4

5

6

7

11 12 13 14

23. Disconnect the side airbag connectors (A).


Is the resistance as specified? YES-Go to step 26. NO- Short to ground in the SRS main harness, in the right side wire harness, or in the OPDS unit harness; replace the faulty harness .•

23-234

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26. Check resistance between the No.1 terminal of SRS unit connector B (14P) and the No.7 terminal of OPDS unit connector D (8P). There should be 0-1.0 Q.

27. Disconnect the SRS main harness 2P connector N from the driver's under-dash fuse/relay box.

SRS UNIT CONNECTOR B 114P)

I

V" L 5 6 7 V V/ Wire side of female terminals 1

4

11

12

13

14

OPDS UNIT CONNECTOR D (8 PI

Q

I

c:;---;:>

1

2

3

4

5

6

7

8


N

Is the resistance as specified? 28. Reconnect the negative battery cable. YES - Go to step 27. 29. Turn the ignition switch ON (II). NO-Open in the SRS main harness, in the right side wire harness or in the OPDS unit harness; replace the faulty harness.•

30. Check for voltage between the No.1 terminal of SRS unit connector B (14P) and body ground. There should be 0.5 V or less. SRS UNIT CONNECTOR B (14PI

4

5

6

7

11

12

13 14


Is the voltage as specified? YES- Faulty OPDS unit or SRS unit. Replace the OPDS unit (see page 23-300). Ifthe problem is still present, replace the SRS unit (see page 23-296) .• NO-Short to power in the SRS main harness, in the right side wire harness or in the OPDS unit harness; replace the faulty harness.•

BACK

23-235

SRS DTC Troubleshooting - '01-02 Models with Side Airbags (cont'd) OTC 15-2: Faulty side airbag indicator light

8. Check for a blown side airbag indicator bulb.

circuit Is the side airbag indicator bulb OK? 1. Erase the DTC memory (see page 23-45). YES- Go to step 9. 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off.


NO- Blown side airbag indicator bulb; replace the bulb .• 9. Disconnect OPDS unit connector D (8P) from the OPDS unit (B).


D

B

3. Make sure nothing is on the front passenger's seat. 4. Turn the ignition switch ON (II), and check that the side airbag indicator light comes on.

Does the side airbag indicator light come on? YES-Go to step 5. NO- Go to step 6. 5. Make sure the side airbag indicator light comes on for 5 seconds and then goes off.

Does the side airbag indicator light go off? YES - Faulty OPDS unit or SRS unit; replace the OPDS unit (see page 23-300).If the problem is still present, replace the SRS unit (see page 23-296) .•

10. Turn the ignition switch ON (II). 11. Check for voltage between the No.3 terminal of OPDS unit connector D (8P) and body ground. There should be battery voltage.

OPOS UNIT CONNECTOR D (8P)

NO- Go to step 36. 6. Turn the ignition switch OFF. 7. Check the No.9 (7.5A) fuse in the driver's underdash fuse/relay box.

=

Is the fuse OK?


YES-Go to step 8. NO-Short to ground in the No.9 (7.5A) fuse circuit; refer to section 22, and continue troubleshooting .•

Is there battery voltage? YES - Go to step 12. NO- Go to step 24.

23-236

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13. Disconnect dashboard wire harness connector I (1BP) from the driver's under-dash fuse/relay box.


B

1B. Turn the ignition switch ON (II). 19. Check for voltage between the No.3 terminal of OPDS unit connector D (BP) and body ground. There should be 0.5 V or less.

14. Turn the ignition switch ON (II). 15. Check for voltage between the No.3 terminal of OPDS unit connector D (BP) and body ground. There should be 0.5 V or less.





Is the voltage as specified? YES - Short to power in the gauge assembly; replace the gauge assembly.•

Is the voltage as specified? YES- Faulty OPDS unit; replace the OPDS unit (see page 23-300) .•

NO - Go to step 20.

NO-Go to step 16.

(cont'd)

BACK

23-237

SRS DTC Troubleshooting - '01-02 Models with Side Airbags (cont'd) 20. Turn the ignition switch OFF.


21. Disconnect the right side wire harness 6P connector C582 (A) from the dashboard wire harness A 6P connector (8).

25. 8ackprobe the No. 17 terminal of gauge assembly connector 8 (22P). Do not disconnect gauge assembly connector 8 (22P) from the gauge assembly. 26. Turn the ignition switch ON (II). 27. Check for voltage between the No. 17 terminal of gauge assembly connector 8 (22P) and body ground. There should be battery voltage. GAUGE ASSEMBLY CONNECTOR B (22P)

11

2

6

8

9

10

12

18 19 20

21

22

7


=

23. Check for voltage between the No.3 terminal of OPDS unit connector D (8P) and body ground. There should be 0.5 V or less.




YES- Go to step 28. NO- Go to step 32. 28. Turn the ignition switch OFF. 29. Disconnect the right side wire harness 6P connector C582 (A) from the dashboard wire harness A 6P connector (8).


Is the voltage as specified? YES - Short to power in dashboard wire harness A; replace dashboard wire harness A .• NO- Short to power in the right side wire harness or the OPDS unit harness; if the OPDS unit harness is OK, replace the right side wire harness .• A

23-238

BACK



31. Check for voltage between the No.5 terminal of the dashboard wire harness A 6P connector (C582) and body ground. There should be battery voltage.


--------

DASHBOARD WIRE HARNESS A 6P CONNECTOR IC582)

B

2 6

3



Is there battery voltage? YES- Poor contact at the dashboard wire harness A 6P connector and right side wire harness 6P connector or an open in the right side wire harness. Check the connection between the dashboard wire harness A 6P connector and right side wire harness 6P connector; if the connection is OK, replace the right side wire harness .•

35. Check for voltage between the No. 11 terminal of gauge assembly connector B (22P) and body ground. There should be battery voltage.

NO-Poor contact atthe dashboard wire harness A 22P connector and gauge assembly connector C (22P), or an open in dashboard wire harness A. Check gauge assembly connector B (22P) and gauge assembly connections; if the connections are OK, replace dashboard wire harness A .•


6

7

8

9

10

18 19 20 21 22


Is there battery voltage? YES-Faulty side airbag indicator light circuit; replace the gauge assembly.• NO- Open in dashboard wire harness A; replace dashboard wire harness A .•

(cont'd)

BACK

23-239

SRS DTC Troubleshooting - '01-02 Models with Side Airbags (cont'd) 41. Check resistance between the No. 17 terminal of gauge assembly connector B (22P) and body ground. There should 1 M Q or more.

36. Turn the ignition switch OFF. 37. Disconnect OPDS unit connector D (8P) from the OPDS unit (B).

GAUGE ASSEMBLV CONNECTOR B (22P)

D

B

11

2

678910

12

18 19 20

21

22



YES - Short to ground in the side airbag indicator light circuit; replace the gauge assembly.• 38. Turn the ignition switch ON (II).

NO- Short to ground in dashboard wire harness A, right side wire harness, or OPDS unit harness; replace the faulty harness .•

Does the side airbag indicator light stay off?

YES - Go to step 39. NO- Faulty OPDS unit; replace the OPDS unit (see page 23-300) .• 39. Turn the ignition switch OFF. 40. Disconnect gauge assembly connector B (22P) from the gauge assembly.

B

23-240

BACK

DTC 15-3: Faulty OPDS sensor

7. Replace the OPDS unit (see page 23-300), and reinitialize the OPDS system.

1. Erase the DTC memory (see page 23-45). 8. Erase the DTC memory. 2. Turn the ignition switch ON (11), and check that the SRS indicator light comes on for about 6 seconds, and then goes off.

9. Read the DTC.

Is

orc 15-3 indicated?

Does the SRS indicator light stay on? YES- Replace the SRS unit.• YES - Go to step 3. NO-The system is OK.• NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). NOTE: Aftermarket devices (fluorescent map lights, laptop computers, etc.) used nearthe front passenger's seat-back can interfere with the seat-back sensors and cause a false DTC 15-3. If one ofthese devices was used, erase the DTC, operate the device near the seat-back, and recheck for DTCs. If DTC 15-3 is reset, erase it, and do not use the device near the seat-back. 3. Check the connection at the OPDS sensor harness connector and the OPDS unit connector.

Are the connections OK? YES-Go to step 4. NO-Reconnectthe OPDS sensor harness connector, and clear the DTC.• 4. Replace the OPDS sensor/seat back foam (Sedan) (see page 20-98), (Coupe) (see page 20-97), and reinitialize the OPDS system (see page 23-46). 5. Erase the DTC memory. 6. Read the DTC.

Is

orc 15-3 indicated?

YES-Go to step 7. NO- The system is OK.•

BACK

23-241

SRS SRS Indicator Light Circuit Troubleshooting - '98-99 Models The SRS Indicator Light Doesn't Come On

7. Check for a blown SRS indicator bulb.

1. Turn the ignition switch ON (II), and check to see if

Is the SRS indicator bulb OK?

the other indicator lights come on (brake system, etc).

YES-Go to step 9.

Do the other indicator lights come on?

NO - Go to step 8.

YES-Go to step 5.

8. Replace the bulb, and reconnect the gauge assembly connectors. Then turn the ignition switch ON (II).

NO-Goto step 2. 2. Check the No.9 (7.5A) fuse in the driver's underdash fuse/relay box.

Does the SRS indicator light come on? YES- The system is OK.•

Is the fuse OK? NO-Go to step 9. YES - Go to step 4. 9. Turn the ignition switch OFF, and disconnect gauge assembly connector C (16P) from the gauge assembly.

NO- Go to step 3. 3. Replace the No.9 (7.5A) fuse, and check to see if the SRS indicator light comes on.

c

Does the SRS indicator light come on? YES- The system is OK.• NO - Go to step 4. 4. Check for an open in the wire harness between fuse No.9 (7.5A) and the gauge assembly, and repair. Check that the SRS indicator light comes on. Does the SRS indicator light come on? YES-The system is OK.• NO - Go to step 5.

10. Connect a voltmeter between the No.9 terminal of the 16P connector and body ground.

5. Turn the ignition switch OFF. GAUGE ASSEMBLY CONNECTOR C (16PI

6. Remove the gauge assembly.

1

2

8

3

4

5

6

14 15 16


=

23-242

BACK

7

15. Turn the ignition switch ON (II), and measure voltage.

11. Turn the ignition switch ON (II), and measure voltage. Is there 8.5 V or less within the first 6 seconds after turning the ignition switch ON (II)?

Is there 8.5 V or more within the first 6 seconds after turning the ignition switch ON (II)?

YES-Faulty sRS indicator light circuit in the gauge assembly; replace the sRs indicator circuit board in the gauge assembly.•

YES-Short to power in the BLU wire ofthe dashboard wire harness; repair the harness.• NO- Go to step 16.

NO-Go to step 12. 16. Turn the ignition switch OFF. 12. Turn the ignition switch OFF. 17. Disconnect the battery negative cable, and wait 3 minutes.

13. Disconnect the dashboard wire harness 3P connector C503 (A) from the sRs main harness.

18. Disconnect the driver's and front passenger's airbag connectors (A).

A

14. Connect a voltmeter between the No.1 terminal of the dashboard wire harness 3P connector (C503) and body ground. DASHBOARD WIRE HARNESS 3P CONNECTOR IC503)


A

(cont'd)

BACK

23-243

SRS SRS Indicator Light Circuit Troubleshooting - '98-99 Models (cont'd) The "SRS" Indicator Light Stays On When In


"ses" Menu Method

NOTE: • Inability to retrieve DTCs with the PGM Tester. Retrieve the flash codes with the SCS mode (see page 23-42). • A new SRS unit must sense the entire system is OK before completing its initial self-test. The most common cause of an incomplete self-test is the failure to replace all deployed parts after a collision, in particular, and seat belt tensioners. • An incomplete self-test prevents the PGM Tester from retrieving DTCs, although flash codes are available in the Tester's SCS mode. A

1. Erase the DTC memory (see page 23-45). 20. Connect a voltmeter between the No.6 terminal of the SRS main harness 18P connector and ground.

2. Turn the ignition switch ON (II), and check the SRS indicator light.


Does the SRS indicator light stay on? YES - Go to step 3.

7

NO-Intermittent failure, system is OK at this time. Recheck for an intermittent failure (see page 23-45).

8 9

16 17 18 3. Turn the ignition switch OFF. Wire side of female terminals

4. Check for blown No.2 (10 A) fuse in the driver's under-dash fuse/relay box.

Is the fuse OK? 21. Turn the ignition switch ON (II), and measure voltage. There should be 0.5 V or less.

YES - Go to step 5.

Is the voltage as specified? YES-Faulty SRS unit; replace the unit (see page 23-295).•

NO - Replace the No.2 (1 OA) fuse, and recheck the system.• 5. Disconnect the battery negative cable, and wait for 3 minutes.

NO- Short to power in the BLU wire ofthe SRS main harness; replace the harness.•

23-244

BACK


9. Connect a voltmeter between the No.3 terminal of the SRS main harness 18P connector and body ground.


6

7

8

9

16 17 18 = Wire side of female terminals.


A

Is there battery voltage? YES-Go to step 11. NO-Open in the SRS main harness (VB line); replace the harness.• 11. Connectthe SRS main harness 18P connector terminals No.6 and No.3 with a jumper wire and backprobe adapters. SRS MAIN HARNESS 18P CONNECTOR

JUMPER WIRE

A

I


1 10

I

1/ 3 1/1/ 6 V 1/ 13 14 15

7 8 9 16 17 18


Does the SRS indicator light go off? YES- Faulty SRS unit, or poor contact at the SRS main harness 18P connector; check the connector. If the connector is OK, replace the SRS unit (see page 23-295) .• A

NO-Go to step 12. 8. Reconnect the battery negative cable. (cont'd)

BACK

23-245

.I

SRS SRS Indicator Light Circuit Troubleshooting - '98-99 Models (cont'd) 12. Check the No.2 (10A) fuse in the driver's underdash fuse/relay box.


Is the fuse blown?

17. Remove the gauge assembly. Do not disconnect the connector from the gauge assembly.

YES-Go to step 13.


NO-Go to step 16.

19. Connect the No.9 terminal of gauge assembly connector C (16P) and No. 11 terminal of gauge assembly connector B (22P) with a jumper wire.


GAUGE ASSEMBLV CONNECTOR C (16P)

14. Disconnect gauge assembly connector C (16P) from the gauge assembly. C

2 3 8

9 10

14 15 16 Wire side of female terminals.

GAUGE ASSEMBLV CONNECTOR B (22P)

7

8

9 10

19 20 21 22 JUMPER WIRE

Does the SRS indicator light go off? YES-Go to step 20. NO- Faulty SRS indicator light circuit in the gauge assembly; replace the SRS printed circuit board in the gauge assembly.•

15. Check resistance between the No.9 terminal of gauge assembly connector C (16P) and ground. There should be 1 M Q or more.

20. Turn the ignition switch OFF. GAUGE ASSEMBLV CONNECTOR C (16P)

2

3

21. Disconnect gauge assembly connector C (16P) from the gauge assembly. C

567

8

14 15 16


Is the resistance as specified? YES - Short to ground in the gauge assembly; replace the gauge assembly.• NO - Go to step 23.

23-246

BACK

22. Check resistance between the No.6 terminal of the SRS main harness 18P connector and No.9 terminal of gauge assembly connector C (16P). There should be 0 - 1.0 Q.

24. Check resistance betweeen the No.1 terminal of the SRS main harness 3P connector C503 and ground. There should be 1 M Q or more. SRS MAIN HARNESS 3P CONNECTOR 1C503,

GAUGE ASSEMBLY CONNECTOR C (16P)

1

2

5

3

8

6

7

14 15 16




789

YES-Short to ground in the dashboard wire harness; repair the dashboard wire harness.•

16 17 18

NO - Short to ground in the SRS main harness; replace the SRS main harness .•



25. Reconnect the SRS main harness 18P connector to the SRS unit.

NO-Go to step 28. 23. Disconnect the SRS main harness 3P connector C503 (A) from the dashboard wire harness.

26. Connect a voltmeter between the No.9 terminal of gauge assembly connector C (16P) and ground. GAUGE ASSEMBLY CONNECTOR C 116P'


27. Turn the ignition switch ON (II), wait for 6 seconds, then measure voltage.


YES - The problem corrected itself after disconnecting and connecting the connectors. Be sure all terminals make good contact, and recheck the system for an intermittent failure (see page 2345) .•

A

NO-Poor contact at the SRS main harness 18P connector; check the connector. If the connector is OK, substitute a known-good SRS unit, and recheck. lfthe connector is damaged, replace the SRS main harness .• (cont'd)

BACK

23-247

SRS SRS Indicator Light Circuit Troubleshooting - '98-99 Models (cont'd) 28. Disconnect the SRS main harness 3P connector (A) from the dashboard wire harness.

The SRS Indicator Light Comes On for the Bulb Check, Goes Off, then Comes Back On After Self- Diagnosis, but no DTCs are stored (NEC SRS unit only) 1. Erase the DTC memory (see page 23-45). 2. Turn the ignition switch ON (II), and check that the SRS indicator light comes on for about 6 seconds and then goes off. Does the SRS indicator light come on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).

A

29. Check resistance between the No.6 terminal of the SRS main harness 18P connector and the No.1 terminal of the SRS main harness 3P connector; there should be 0 -1.0 Q.

3. Check for blown No.1 (15A) fuse in the driver'S under-dash fuse/relay box. Is the fuse OK? YES-Go to step 12.


NO- Go to step 4. 4. Replace the fuse. Turn the ignition switch ON (II), and check that the fuse doesn't blow. SRS MAIN HARNESS 18P CONNECTOR


7

10

8

Is the fuse OK? YES-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45) .•

9

16 17 18

NO-Go to step 5. Is the resistance as specified?


YES-Open in the BLU wire ofthe dashboard wire harness; repair the dashboard wire harness.•


NO-Open in the SRS main harness; replace the SRS main harness .•

23-248

BACK


9. Check resistance between the No.7 terminal of the SRS main harness 18P connector and body ground. There should be 1 M Q or more.


8 9 17 18 Wire side of female terminals


A

YES-Faulty SRS unit; replace the SRS unit (see page 23-295) .• NO-Gotostep 10. 10. Disconnect the SRS main harness 2P connector (A) from the driver's under-dash fuse/relay box.

A


A

A

(cont'd)

BACK

23-249

SRS SRS Indicator Light Circuit Troubleshooting - '98-99 Models (cont'd) 11. Check resistance between the No.7 terminal of the SRS main harness 18P connector and ground. There should be 1.0 M Q or more.

12. Disconnect the battery negative cable, and wait for 3 minutes. 13. Disconnect the driver's airbag and front passenger's airbag connectors (A).


~

1 10

/ / V / / 13 14 3

I 7

8 9 15 16 17 18 6


Is the resistance as specified? VES- Short to ground in the driver's under-dash fuse/relay box; replace the driver's under-dash fuse/relay box .•

A

NO- Short to ground in the SRS main harness; replace the SRS main harness .•

A

23-250

BACK


19. Disconnect the SRS main harness 2P connector (A) from the driver's under-dash fuse/relay box.

A

15. Reconnectthe battery negative cable. A

16. Connect a voltmeter between the No.7 terminal of the SRS main harness 18P connector and ground. 20. Check resistance between the No.1 terminal of the SRS main harness 2P connector and No.7 terminal ofthe SRS main harness 18P connector. There should be 0-1.0 Q.



8 9 10

17 18

= Wire side of female terminals.


8

10


15

9

16 17 18



/s the resistance as specified?

YES-Poor contact at the SRS main harness 18P connector; check the connector. If the connector is OK, substitute a known-good SRS unit, and recheck. If the connector is damaged, replace the SRS main harness.•

YES - Poor contact at the SRS main harness 2P connector; check the connector. Ifthe connector is OK, substitute a known-good under-dash fuse/relay box, and recheck. Ifthe connector is damaged, replace the SRS main harness .•

NO-Goto step 18.

NO- Open in the SRS main harness, replace the SRS main harness .•


BACK

23-251

SRS SRS Indicator Light Circuit Troubleshooting - '00 Sedan The SRS Indicator Light Doesn't Come On

8. Disconnect gauge assembly connector C (16P) from the gauge assembly.

1. Turn the ignition switch ON (11), and check to see if the other indicator lights come on (brake system, etc).

::::=:==--:==----

Do the other indicator lights come on? VES- Go to step 5.

NO - Go to step 2.

2. Turn the ignition switch OFF, and check the No.9 (7.5A) fuse in the driver's under-dash fuse/relay box.

Is the fuse OK? VES-Gotostep 14.

9. Connect a voltmeter between the No.9 terminal of gauge assembly connector C (16P) and body ground.

NO-Go to step 3. 3. Replace the No.9 (7.5A) fuse, and check to see if the SRS indicator light comes on.


Does the SRS indicator light come on?

567

VES- The system is OK.•

8

14 15 16

NO-Goto step 4. Wire side offemale terminals.

4. Check for a short to ground between fuse No.9 (7.5A) and the gauge assembly, and repair. Check to see if the SRS indicator light comes on.

=

Does the SRS indicator light come on? 10. Turn the ignition switch ON (II), and mea!;ure voltage.

VES- The system is OK.• NO- Short to ground in the gauge assembly; replace the circuit board in the gauge assembly.•

Is there 8.5 V or less within the first 6 seconds after turning the ignition switch ON (/I)?

5. Turn the ignition switch OFF. 6. Remove the gauge assembly.

VES- Faulty SRS indicator light circuit in the gauge assembly; replace the SRS indicator circuit board in the gauge assembly.•

7. Check for a blown SRS indicator bulb.

NO-Go to step 11.

Is the SRS indicator bulb OK?


VES- Go to step 8. NO- Blown SRS indicator bulb; replace the bulb.•

23-252

BACK

12. Disconnect SRS unit connector C (8P) from the SRS unit.


B

13. Connect a voltmeter between the No.5 terminal of SRS unit connector C (8P) and body ground. Turn the ignition switch ON (II), and measure voltage. There should be 0.5 V or less.

15. Connect a voltmeter between the No. 11 terminal of gauge assembly connector B (22P) and body ground. Turn the ignition switch ON (II), and measure voltage. There should be battery voltage.


5


234

7

6

19 20 21 22

7

8


8

9 10


Is voltage as specified?


YES - Faulty SRS unit; replace the SRS unit (see page 23-296) .•

YES-Go to step 16.

NO-Short to power in the BLU wire of dashboard wire harness A; replace dashboard wire harness

NO-Open in dashboard wire harness A; repair or replace dashboard wire harness A .•

A..

(cont'd)

BACK

23-253

SRS SRS Indicator light Circuit Troubleshooting - '00 Sedan (cont'd) 16. Turn the ignition switch OFF. Check resistance between the No. 16 terminal of gauge assembly connector 8 (22P) and body ground. There should beO-1.0 Q. GAUGE ASSEMBLY CONNECTOR B 122P)

11

2

7

12

19 20 21 22

8

9

10

Wi re side of female terminals.

The SRS Indicator Light Stays On When In

"ses" Menu Method

NOTE: • Inability to retrieve DTCs with the PGM Tester. Retrieve the flash codes with the SCS mode (see page 23-43). • A new SRS unit must sense the entire system is OK before completing its initial self-test. The most common cause of an incomplete self-test is the failure to replace all deployed parts after a collision, in particular, the seat belt tensioners. • An incomplete self-test prevents the PGM Tester from retrieving DTCs, although flash codes are available in the Tester's SCS mode. 1. Check for a blown No.2 (10A) fuse in the driver'S under-dash fuse/relay box.

= Is the resistance as specified?

Is the fuse OK?

YES-Faulty SRS indicator light circuit in the gauge assembly; replace the SRS indicator circuit board in the gauge assembly.•

YES-Go to step 2. NO- Replace the No.2 fuse. Turn the ignition switch ON (II), and check for a blown No.2 fuse. If the fuse is blown; replace the SRS main harness. If the fuse is OK; replace the SRS unit.•

NO-Open in dashboard wire harness A or bad body ground; check the body ground connection. If it is OK, repair or replace dashboard wire harness

A.•

2. Disconnectthe driver's airbag 2P connector (A) and front passenger's airbag 4P connector (8).

A

B

23-254

BACK

3. Disconnect SRS unit connector A (1BP) from the SRS unit.

6. Turn the ignition switch OFF. Disconnect SRS unit connector C (BP) from the SRS unit.

A

4. Connect a voltmeter between the No.4 terminal of SRS unit connector A (1BP) and body ground. SRS UNIT CONNECTOR A 118P)

7. Connect a jumper wire between the No.4 terminal of SRS unit connector A (1BP) and the No.5 terminal of SRS unit connector C (BP). Turn the ignition switch ON (II). SRS UNIT CONNECTOR A118P)

JUMPER WIRE

I

/ / / /

567 14 15 16

4

3

5

6

7

12 13 14 15 16

/ / / /

Wire side of female t erminals SRS UNIT CONNECTOR CI8P)


Ie;----?

=

1

2

3

4

5

6

7

8

I



Is there battery voltage? Does the SRS indicator light go off? YES-Go to step 6. YES- Faulty SRS unit, poor contact at the SRS main harness 1BP connector, or poor contact at the dashboard wire harness A BP connector; check the connectors. If the connectors are OK, replace the SRS unit (see page 23-296) .•

NO-Open in the SRS main harness (VB line); replace the SRS main harness.•

NO- Go to step B.

(cont'd)

BACK

23-255

SRS SRS Indicator Light Circuit Troubleshooting - '00 Sedan (cont'd) B. Turn the ignition switch OFF. Check the No.2 (10 A) fuse in the driver's under-dash fuse/relay box.


Is the fuse blown? YES-Goto step 9. NO-Go to step 11. 9. Disconnect gauge assembly connector C (16P) from the gauge assembly.

=

12. Check resistance between the No.5 terminal of SRS unit connector C (BP) and the No.9 terminal of gauge assembly connector C (16P). There should beO-1.0Q. GAUGE ASSEMBLY CONNECTOR C (16P)

2 10. Check resistance between the No.5 terminal of SRS unit connector C (BP) and body ground. There should be 1 M Q or more.

3

567

8

14 15 16 Wire side of female terminals SRS UNIT CONNECTOR CI8P)

SRS UNIT CONNECTOR C (8P)

234 5

4


8 Is the resistance as specified? Wire side of female terminals


=

NO-Open in dashboard wire harness A; replace dashboard wire harness A..

Is the resistance as specified? YES - Short to ground in the gauge assembly; replace the gauge assembly.• NO-Short to ground in dashboard wire harness A; repair or replace dashboard wire harness A .•

23-256

BACK

SRS Indicator Light Circuit Troubleshooting - '00 Model without Side Airbags The SRS Indicator Light Comes On for the Bulb Check, Goes Off, then Comes Back On After Self-Diagnosis, but no DTCs are stored (NEC SRS unit only)

7. Disconnect the driver'S and front passenger's airbag connectors.


Does the SRS indicator light come on? YES - Go to step 3.

A

NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45). 3. Check for a blown No.1 (15A) fuse in the driver's under-dash fuse/relay box.

Is the fuse OK? YES-Goto step 11. NO-Goto step 4. 4. Replace the fuse. Turn the ignition switch ON (II), and check that the fuse doesn't blow. 8. Disconnect SRS unit connector A (18P) from the SRS unit.

Is the fuse OK? YES-Intermittent failure, system is OK this time. Go to Troubleshooting Intermittent failures (see page 23-45).

A

NO - Go to step 5. 5. Turn the ignition switch OFF. 6. Disconnect the battery negative cable, and wait for 3 minutes.

(cont'd)

BACK

23-257

SRS SRS Indicator Light Circuit Troubleshooting - '00 Model without Side Airbags (cont'd) 9. Disconnect SRS main harness 2P connector N from the driver'S under-dash fuse/relay box.

11. Disconnect the battery negative cable, and wait for 3 minutes. 12. Disconnect the driver's airbag and front passenger's airbag connectors (A).

A

N

10. Check resistance between the No.3 terminal of SRS unit connector A (18P) and body ground. There should be 1 M Q or more. SRS UNIT CONNECTOR A (18PI

456

7

13 14 15 16 A Wire side of female terminals

= Is the resistance as specified? YES-Short to ground in the No.1 (15A) fuse circuit, or faulty SRS unit; check the No.1 (15 A) fuse circuit. If the circuit is OK, replace the SRS unit (see page 23-296) .• NO-Short to ground in the SRS main harness; replace the harness.•

23-258

BACK


14. Reconnect the battery negative cable. 15. Connect a voltmeter between the No.3 terminal of SRS unit connector A (18P) and body ground. SRS UNIT CONNECTOR A (18P)

4

5

6

7


= 16. Turn the ignition switch ON (II), and measure voltage.

Is there battery voltage? VES- Poor contact at the SRS main harness 18P connector, or faulty SRS unit; check the connector. If the connector is OK, replace the SRS unit (see page 23-296) .• NO- Poor contact at the SRS main harness 2P connector, or open in the SRS main harness; check the connector. If the connector is OK, replace the SRS main harness.•

BACK

23-259

SRS SRS Indicator Light Circuit Troubleshooting - '00 Coupe The SRS Indicator Light Doesn't Come On


1. Turn the ignition switch ON (II), and check to see if the other indicator lights come on (brake system, etc).

Do the other indicator lights come on? YES - Go to step 5. NO - Go to step 2. 2. Turn the ignition switch OFF, and check the No.9 (7.5 A) fuse in the driver's under-dash fuse/ relay box.

Is the fuse OK? YES - Go to step 14.

9. Connect a voltmeter between the No.9 terminal of gauge assembly connector C (16P) and body ground.

NO-Go to step 3. 3. Replace the No.9 (7.5A) fuse, and check to see if the SRS indicator light comes on.

GAUGE ASSEMBLY CONNECTOR C (16PI


2

YES-The system is OK.•

3

567

8

14 15 16

NO- Go to step 4. Wire side offemale terminals.

4. Check for a short to ground in the wire harness between fuse No.9 (7.5A) and the gauge assembly, and repair. Check to see if the SRS indicator light comes on.



YES-The system is OK.•

Is there 8.5 V or less within the first 6 seconds after turning the ignition switch ON (II)?

NO - Short to ground in the gauge assembly; replace the circuit board in the gauge assembly.•

YES- Faulty SRS indicator light circuit in the gauge assembly; replace the SRS indicator circuit board in the gauge assembly.•

5. Turn the ignition switch OFF. 6. Remove the gauge assembly.

NO-Gotostep 11. 7. Check for a blown SRS indicator bulb. 11. Turn the ignition switch OFF.

Is the SRS indicator bulb OK? YES- Go to step 8. NO- Blown SRS indicator bulb; replace the bUlb.•

23-260

BACK



B

c 13. Connect a voltmeter between the No.5 terminal of SRS unit connector C (8P) and body ground. Turn the ignition switch ON (11), and measure voltage. There should be 0.5 V or less.

15. Connect a voltmeter between the No. 11 terminal of gauge assembly connector B (22P) and body ground. Turn the ignition switch ON (11), and measure voltage. There should be battery voltage. GAUGE ASSEMBLV CONNECTOR B 122P)

SRS UNIT CONNECTOR C 18P)

7

4

8

9 10

19 20

21 22

8 Wire side of female terminals.

=





YES - Faulty SRS unit; replace the SRS unit (see page 23-296).

NO-Open in dashboard wire harness A; repair or replace dashboard wire harness A.•

NO-Short to power in the BLU wire of dashboard wire harness A or the SRS main harness; replace dashboard wire harness A or the SRS main harness.

(cont'd)

BACK

23-261

SRS SRS Indicator Light Circuit Troubleshooting - '00 Coupe (cont'd) 16. Turn the ignition switch OFF. Check resistance between the No. 16 terminal of gauge assembly connector 8 (22P) and body ground. There should be 0-1.0 Q. GAUGE ASSEMBLY CONNECTOR B (22P)

2 11

7

12

8

19 20

9

10

21 22


The SRS Indicator Light Stays On When In "ses" Menu Method NOTE: • Inability to retrieve DTCs with the PGM Tester. Retrieve the flash codes with the SCS mode (see page 23-43). • A new SRS unit must sense the entire system is OK before completing its initial self-test. The most common cause of an incomplete self-test is the failure to replace all deployed parts after a collision, in particular, and seat belt tensioners. • An incomplete self-test prevents the PGM Tester from retrieving DTCs, although flash codes are available in the Tester's SCS mode. 1. Check for a blown No.2 (1 OA) fuse in the driver's u nder-dash fuse/relay box.

= Is the resistance as specified?

Is the fuse OK?


YES-Go to step 2.

NO - Replace the No.2 fuse. Turn the ignition switch ON (II), and check for a blown No.2 fuse. If the fuse is blown; replace the SRS main harness. If the fuse is OK; replace the SRS unit .•

NO-Open in dashboard wire harness A or body ground; check the body ground connection. )f it is OK, repair or replace dashboard wire harness A..

2. Disconnect the driver's airbag 2P connector (A) and front passenger's airbag 4P connector (8).

A

B

23-262

BACK


6. Turn the ignition switch OFF. Disconnect SRS unit connector C (8P) from the SRS unit.

C

4. Connect a voltmeter between the No.4 terminal of SRS unit connector A (18P) and body ground. SRS UNIT CONNECTOR A 118P)

7. Connect the No.4 terminal of SRS unit connector A (18P) and the No.5 terminal of SRS unit connector C (8P) with a jumper wire and backprobe adapters. Turn the ignition switch ON (II). SRS UNIT CONNECTOR A118P)

JUMPER WIRE

I 4

5

6

LJ/

7

/V

14 15 16

4

3

5

6

7

12 13 14 15 16

/ / / /

Wire side of female t erminals SRS UNIT CONNECTOR CI8P)


,e;--?

=

1

2

3

4

5

6

7

8

J



Is there battery voltage? Does the SRS indicator light go off? YES - Go to step 6. YES- Faulty SRS unit, poor contact at SRS unit connector A (18P), or poor contact at SRS unit connector C (8P); check the connectors. If the connectors are OK, replace the SRS unit (see page 23-296) .•

NO-Open in the SRS main harness (VB line); replace the SRS main harness.•

NO- Go to step 8.

(cont'd)

BACK

23-263

SRS SRS Indicator Light Circuit Troubleshooting - '00 Coupe (cont'd) s.

Turn the ignition switch OFF. Check the No.2 (10 A) fuse in the driver's under-dash fuse/relay box. Is the fuse blown?


--:::=:---------

YES- Go to step 9. NO-Go to step 11. 9. Disconnect gauge assembly connector C (16P) from the gauge assembly.

12. Check resistance between the No.5 terminal of SRS unit connector C (SP) and the No.9 terminal of gauge assembly connector C (16P). There should beO-1.0 Q. GAUGE ASSEMBLY CONNECTOR C (16P)

567 10. Check resistance between the No.5 terminal of SRS unit connector C (ap) and body ground. There should be 1 M Q or more.

8

14 15 16 Wire side offemale terminals SRS UNIT CONNECTOR C (8P)

SRS UNIT CONNECTOR C (8P)

4

8

4


8

Is the resistance as specified? YES- Faulty SRS indicator light circuit in the gauge assembly; replace the SRS indicator circuit board in the gauge assembly.•


NO-Open in the BLU wire of dashboard wire harness A or the SRS main harness; replace dashboard wire harness A or the SRS main harness.•

Is the resistance as specified? YES-Short to ground in the gauge assembly; replace the gauge assembly .• NO-Short to ground in the BLU wire of dashboard wire harness A or the SRS main harness; replace the dashboard wire harness or the SRS main harness .•

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SRS Indicator Light Circuit Troubleshooting - '01-02 Models The SRS Indicator Light Doesn't Come On


1. Turn the ignition switch ON (II), and check to see if the other indicator lights come on (brake system, etc).

Do the other indicator lights come on? YES-Go to step 2. NO - Go to step 9. 2. Turn the ignition switch OFF, then disconnect gauge assembly connector B (22P) from the gauge assembly.

5. Check for voltage between the No.9 terminal of gauge assembly connector C (16P) and body ground for 6 seconds after turning the ignition switch ON (II). There should be 8.5 V or less. GAUGE ASSEMBLV CONNECTOR C (16P)

567 14 15 16

8 3. Check resistance between the No. 16 terminal of gauge assembly connector B (22P) and body ground. There should be 0 -1.0 Q. GAUGE ASSEMBLY CONNECTOR B I22P)

6

2

7

8


Is voltage as specified?

9 10

18 19 20 21 22

11 12

YES- Blown SRS indicator bulb or faulty SRS indicator light circuit in the gauge assembly. Check for a blown SRS indicator bulb. Ifthe SRS indicator bulb is OK, replace the gauge assembly.•

=

NO - Go to step 6.



Is resistance as specified? YES-Go to step 4. NO - Open in the BLK wire of dashboard wire harness A, or faulty body ground terminal. If the body ground terminal is OK, replace dashboard wire harness A.. (cont'd)

BACK

23-265

SRS SRS Indicator Light Circuit Troubleshooting - '01-02 Models (cont'd) 7. Disconnect SRS unit connector C (BP) from the SRS unit.

9. Turn the ignition switch OFF. Check the No.9 (7.5A) fuse in the driver's under-dash fuse/relay box.

Is the fuse blown? YES-Go to step 12. NO-Go to step 10. 10. Disconnect gauge assmbly connector B (22P) from the gauge assembly.

C

~--------

B. Connect a voltmeter between the No.9 terminal of gauge assembly connector C (16P) and body ground. Turn the ignition switch ON (Ill, and measure voltage. There should be 0.5 V or less. GAUGE ASSEMBLY CONNECTOR C (16P)

567

8

14 15 16


Is the voltage as specified? YES-Faulty SRS unit; replace the SRS unit.• NO-Short to power in the BLU wire of dashboard wire harness A; replace dashboard wire harness A .

•

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11. Connect a voltmeter between the No. 11 terminal of gauge assembly connector B (22P) and body ground. Turn the ignition switch ON (II), and measure voltage. There should be battery voltage.

12. Replace the No.9 (7.SA) fuse, and check to see if the SRS indicator light comes on.

YES- The system is OK at this time .•


6

7

8

9


NO-Short to ground in the driver's under-dash fuse/relay box No.9 (7.SA) fuse Ii ne; refer to the "Electrical" section, then continue troubleshooting.•

10

18 19 20 21 22


Is there battery voltage? YES-Faulty SRS indicator light circuit in the gauge assembly, or poor contact at gauge assembly connector B (22P) and the gauge assembly; if the connection is OK, replace the gauge assembly.• NO-Open in the driver's under-dash fuse/relay box No.9 (7.5 A) fuse line, open in the VEL wire of dashboard wire harness A. If the driver's underdash fuse/relay box is OK, replace dashboard wire harness A..

(cont'd)

BACK

23-267

SRS SRS Indicator Light Circuit Troubleshooting - '01-02 Models (co nt'd) The SRS Indicator Light Stays On When In ··SCS" Menu Method

8. Disconnect the driver's airbag 4P connector.

NOTE: • Inability to retrieve DTCs with the PGM Tester. Retrieve the flash codes with .the SCS mode (see page 23-43). • A new SRS unit must sense the entire system is OK before completing its initial self-test. The most common cause of an incomplete self-test is the failure to replace all deployed parts after a collision, in particular, and seat belt tensioners. • An incomplete self-test prevents the PGM Tester from retrieving DTCs, although flash codes are available in the Tester's SCS mode. 1. Erase the DTC memory (see page 23-45).

9. Disconnect the front passenger's airbag 4P connector.

Does the SRS indicator light go off while the DTC memory is being erased? YES-Go to step 42. NO-Goto step 2. 2. Check the No.2 (10A) fuse in the driver's underdash fuse/relay box.

Is the fuse OK? YES-Go to step 19. NO - Go to step 3. 3. Replace the No.2 (10A) fuse in the driver's underdash fuse/relay box. 4. Turn the ignition switch ON (II), and wait for 30 seconds. Then turn the ignition switch OFF. 5. Check the No.2 (10A) fuse in the driver's underdash fuse/relay box.

Is the fuse OK? YES- The system is OK at this time.• NO- Go to step 6. 6. Replace the No.2 (10A) fuse in the driver's underdash fuse/relay box. 7. Disconnect the battery negative cable, and wait for 3 minutes.

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10. Disconnect both seat belt tensioner 2P connectors.

12. Reconnect the negative battery cable. 13. Turn the ignition switch ON (II) and wait for 30 seconds. Then turn the ignition switch OFF. 14. Check the No.2 (1 OA) fuse in the driver's underdash fuse/relay box. Is the fuse OK? YES - Short to ground in the SRS unit; replace the

SRS unit (see page 23-296) .• NO-Goto step 15.


15. Replace the No.2 (10A) fuse in the driver's underdash fuse/relay box. 16. Disconnect SRS main harness 2P connector N from the driver's under-dash fuse/relay box. N

A

17. Turn the ignition switch ON (II) and waitfor 30 seconds. Then turn the ignition switch OFF. 18. Check the No.2 (10A) fuse in the driver's underdash fuse/relay box. Is the fuse OK? YES-Short to ground in dashboard wire harness A; replace dashboard wire harness A .• NO- Short to ground in the driver'S under-dash fuse/relay box No.2 (10A) fuse line; replace the driver's under-dash fuse/relay box.•

(cont'd)

BACK

23-269

SRS SRS Indicator Light Circuit Troubleshooting· '01·02 Models (cont'd) 19. Disconnect the battery negative cable, and wait for 3 minutes.

22. Disconnect both seat belt tensioner 2P connectors (A).

20. Disconnect the driver's airbag 4P connector (A).

23. Disconnect SRS unit connector A (1SP) from the SRS unit. 21. Disconnect the front passenger's 4P connector (A).

A

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BACK

24. Reconnect the battery negative cable. 25. Connect a voltmeter between the NO.4 terminal of SRS unit connector A (18P) and body ground. Turn the ignition switch ON (II), and measure voltage. There should be battery voltage.

28. Check resistance between the No.4 terminal of SRS unit connector A (18P) and the No.2 terminal of SRS main harness 2P connector N. There should be 0-1.0 Q. SRS MAIN HARNESS 2P CONNECTOR N


V 1/ 11 2

I 7

8

9

12 13 14 15 16

17

18

3

4

5

6


5

':L

678

9

14 15 16 17 18 Wire side of female terminals


Is the resistance as specified? YES-Open in the driver's under-dash fuse/relay box, or poor contact at the SRS main harness 2P connector; check the connection. If the connection is OK, replace the driver's under-dash fuse/relay box .•


NO - Go to step 26.

NO- Open in the SRS main harness; replace the SRS main harness .•

26. Turn the ignition switch OFF. 27. Disconnect SRS main harness 2P connector N from the under-dash fuse/relay box.

29. Turn the ignition switch OFF. 30. Disconnect SRS unit connector C (8P) from the SRS unit.

C

N

(cont'd)

BACK

23-271

SRS SRS Indicator Light Circuit Troubleshooting - '01-02 Models (cont'd) 31. Connect the No.4 terminal of SRS unit connector A (18P) and the No.5 terminal of SRS unit connector C (8P) with a jumper wire.


SRS UNIT CONNECTOR C (8P) ,e;---';)

1

2

3

4

5

6

7

8

Wire side of female term inals JUMPER SRS UNIT CONNECTOR WIRE A 118P)

V

2

1/ 11

3

4

5

6

7

8

9

12 13 14 15 16 17 18


32. Turn the ignition switch ON (II). 39. Check resistance between the No.5 terminal of SRS unit connector C (8P) and body ground. There should be 1 M Q or more.

33. Check the SRS indicator light.

Does the SRS indicator light go off? SRS UNIT CONNECTOR C (8P)

YES-Faulty SRS unit; replace the SRS unit (see page 23-296) .• NO-Go to step 34.

5

34. Turn the ignition switch OFF. 35. Disconnect the jumper wire between the No.4 terminal of SRS unit connector A (18P) and the No. 5 terminal of SRS unit connector C (8P).

2

3

4

6

7

8


36. Check the No.2 (10 A) fuse in the driver's underdash fuse/relay box.

Is the resistance as specified? Is the fuse OK? YES- Faulty SRS indicator light circuit in the gauge assembly; replace the gauge assembly.•

YES-Go to step 40. NO-Go to step 37.

NO- Short to ground in dashboard wire harness A; replace dashboard wire harness A..

37. Replace the No.2 (10A) fuse in the driver's underdash fuse/relay box.

23-272

BACK



C

41. Check resistance between the No.9 terminal of gauge assembly connector 8 (22P) and the No.5 terminal of SRS uint connector C (8P). There should be 1 Q or less.

43. Connect the Honda PGM Tester (A) to the Data Link Connector (16 P) (8) and follow the Tester's prompts in the "SCS" menu.


2

5

3

4



1

2

6

8

9

10

11

12

18 19 20

21

22

7

A


Is the resistance as specified? YES - Faulty SRS indicator light circuit in the gauge assembly or poor contact at gauge assembly connector 8 (22P). Check the connection. If the connection is OK, replace the gauge assembly .• NO- Open in dashboard wire harness A; replace dashboard wire harness A .•

(cont'd)

BACK

23-273

SRS SRS Indicator Light Circuit Troubleshooting - '01-02 Models (cont'd) 44. Check resistance between the No.6 terminal of SRS unit connector C (8P) and body ground. There should be 0-1.0 Q.

The SRS Indicator Light Comes On for the Bulb Check, Goes Off, then Comes Back On After Self-Diagnosis, but no DTCs are stored (NEC SRS unit only)



4

5

8

Does the SRS indicator light come on? YES-Go to step 3. NO-Intermittent failure, system is OK at this time. Go to Troubleshooting Intermittent Failures (see page 23-45).



YES - Faulty SRS unit, or poor contact at the dashboard wire harness A 8P connector; check the connection at the dashboard wire harness A 8P connector and the SRS unit. If the connection is OK, replace the SRS unit (see page 23-296) .• NO- Open in the SCS line between the No.6 terminal of the dashboard wire harness A 8P connector and the No.9 terminal (brown wire) of the Data Link Connector (DLC) (16P), or open between the No.4 terminal of the Data Link Connector (DLC) (16P) and body ground; refer to the "Electrical" section, then continue troubleshooting .•

3. Check for a blown No.1 (15A) fuse in the driver's under-dash fuse/relay box.

Is the fuse OK? YES-Go to step 11. NO-Go to step 4. 4. Replace the fuse. Turn the ignition switch ON (II), and check that the fuse doesn't blow.

Is the fuse OK? YES- The problem is gone. Test-drive the vehicle, and see Troubleshooting Intermittent Failures (see page 23-45). NO-Go to step 5. 5. Turn the ignition switch OFF. 6. Disconnect the battery negative cable, and wait for 3 minutes.

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BACK

7. Disconnect the driver's airbag, front passenger's airbag, and seat belt tensioner connectors (A).


A

9. Disconnect SRS main harness 2P connector N from the driver's under-dash fuse/relay box.

A

N

(cont'd)

BACK

23-275

SRS SRS Indicator Light Circuit Troubleshooting· '01·02 Models (cont'd) 10. Check resistance between the No.3 terminal of SRS unit connector A (18) and body ground. There should be 1 M Q or more.

12. Disconnect the driver'S airbag, front passenger's airbag, and seat belt tensioner connectors (A).


456

7


= Is the resistance as specified? YES-Short to ground in the No.1 (15A) fuse circuit, or faulty SRS unit; check the No.1 fuse circuit. If the circuit is OK, replace the SRS unit (see page 23296) .•

NO-Short to ground in the SRS main harness; replace the harness .• 11. Disconnect the battery negative cable, and wait for 3 minutes. A

23-276

BACK

Component Replacement/ Inspection After Deployment 13. Disconnect SRS unit connector A (18P) from the SRS unit. NOTE: Before doing any SRS repairs, use the PGM Tester SRS menu method to check for DTCs; refer to the DTC Troubleshooting Index for the less obvious deployed parts (seat belt tensioners, OPDS sensor, side airbag sensors, etc.)

A

'98-00 Models: After a collision where the frontal airbags deployed, replace these items: • SRS unit • Deployed airbag(s) '01-02 Models: After a collision where the seat belt tensioners deployed, replace these items: • Seat belt tensioners • SRS unit

14. Reconnect the battery negative cable. 15. Connect a voltmeter between the No.3 terminal of SRS unit connector A (18P) and body ground. SRS UNIT CONNECTOR A (18P)

I

/ /

2

3

4

5

6

7

8

9

After a collision where the front airbag(s) deployed, replace these items: • SRS unit • Deployed airbag(s) • Seat belt tensioners '00-02 Models: After a collision where the side airbag(s) deployed, replace these items: • SRS unit • Deployed side airbag(s) • Side impact sensor(s) for side(s) deployed

11 12 13 14 15 16 17 18

)L

= '98-02 Models: During the repair process, inspect these areas: • Inspect all the SRS wire harnesses. Replace, don't repair, any damaged harnesses. • Inspect the cable reel for heat damage. If there is any damage, replace the cable reel.


16. Turn the ignition switch ON (II), and measure voltage. Is there battery voltage? VES- Poor contact at SRS unit connector A (18P) or faulty SRS unit; check the connector. If the connector is OK, replace the SRS unit (see page 23296) .• NO-Poor contact at SRS main harness 2P connector N or open in the SRS main harness; check the connector. Ifthe connector is OK, replace the SRS main harness.•

After the vehicle is completely repaired, turn the ignition switch ON (II). If the SRS indicator comes on for about 6 seconds and then goes off, the SRS airbag system is OK. If the indicator does not function properly, use the PGM Tester SRS Menu Method to read the DTC (s). If this doesn't retrieve any codes, use the Tester's SCS menu method. If the SCS method doesn't work, you may need to install a known-good SRS unit to read the DTC(s). If you still cannot retrieve a code, go to SRS Indicator Circuit Troubleshooting.

BACK

23-277

SRS Driver's Airbag Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work.

3. Remove the covers (A, B) from the steering wheel, then remove the two Torx bolts (C) using a Torx T30 bit. Remove the driver's airbag (D).

o

2. Remove the access panel (A) from the steering wheel, then disconnect the connector between the cable reel 2P (or 4P) connector (B) and driver's airbag 2P (or 4P) connector (C).

4. Disconnect the horn connector from the steering wheel. A

23-278

BACK

Installation 1. Place the new driver's airbag (AI in the steering wheel, and secure it with new Torx bolts (81. Install the covers (CI.

2. Connect the cable reel 2P (or 4PI connector (AI to the driver's airbag 2P (or 4PI connector (8), then install the access panel (CIon the steering wheel.

B

c

3. Connect the battery negative cable. A

4. After installing the airbag, confirm proper system operation: o

o

BACK

Turn the ignition switch ON (II); the SRS indicator light should come on for about 6 seconds and then go off. Make sure both horn buttons work.

23-279

SRS Front Passenger's Airbag Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work.

3. Remove the four mounting nuts (A) from the bracket. Cover the lid and dashboard with a cloth, and pry carefully with a screwdriver to lift the front passenger's airbag (8) out of the dashboard.

2. Remove the glove box (see page 20-87), then disconnect the connector between the SRS main harness 2P (or 4P) connector (A) and front passenger's airbag 2P (or 4P) connector (8). Then remove the harness clamp (C). A

B

A

23-280

BACK

Installation 1. Place the new front passenger's airbag (A) into the dashboard. Tighten the front passenger's airbag mounting nuts (B), and install the harness clip (C). A

2. Connect the front passenger's airbag 2P (or 4P) connector (A) to the SRS main harness 2P (or 4P) connector (B). Attach the front passenger's airbag connector to the connector holder (C), then reinstall the glove box.

c

L

c

A

B 9.8 N·m (1.0 kgf·m, 7.2 Ibf·ft)

3. Reconnect the battery negative cable. 4. After installing the airbag, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator light should come on for about 6 seconds and then go off.

BACK

23-281

SRS Side Airbag Replacement NOTE: Review the seat replacement procedure in the body section before performing repairs or service.

Installation

INOTICE I

Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work.

Be sure to install the harness wires so that they are not pinched or interfering with other parts. NOTE: • If the side airbag lid is secured by a tape, remove the tape. • Do not open the lid of the side airbag cover. • Use new mounting nuts tightened to the specified torque when you replace a side airbag. • Make sure that the seat-back cover is installed properly. Improper installation may prevent proper deployment.

2. Disconnect the side airbag harness 2P connector (A).

1. Place the new side airbag on the seat back-frame (A). Tighten the side airbag mounting nuts (B). A

A

3. Remove the seat assembly (Sedan) (see page 2098), (Coupe) (see page 20-97), and seat-back cover (Sedan) (see page 20-98), (Coupe) (see page 20-97). 4. Remove the two mounting nuts (A) and the side airbag (B).

2. Install the new seat-back cover (Sedan) (see page 20-98), (Coupe) (see page 20-97). 3. Install the seat assembly(Sedan) (see page 20-98), (Coupe) (see page 20-97), then connect the side airbag harness 2P connector. 4. Move the front seat and the seat-back through their full ranges of movement, making sure the harness wires are not pinched or interfering with other parts. 5. Reconnect the battery negative cable. A

23-282

6. After installing the side airbag, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator light should come on for about 6 seconds and then go off.

BACK

Airbag Disposal - '98-99 Models Special Tool Required Deployment tool 07HAZ-SG00500 Before scrapping any airbags (including those in a whole vehicle to be scrapped), the airbags must be deployed. If the vehicle is still within the warranty period, before you deploy the airbags, the Honda District Service Manager must give approval and/or special instructions. Only after the airbags have been deployed (as the result of vehicle collision, for example), can they be scrapped. If the airbags appear intact (not deployed), treat them with extreme caution. Follow this procedure:

Front Passenger's Airbag: 5. Remove the glove box, then disconnect the 2P connector between the front passenger's airbag (A) and SRS main harness (B).

Deploying Airbags In the vehicle If an SRS equipped vehicle is to be entirely scrapped, its airbags should be deployed while still in the vehicle. The airbags should not be considered as salvageable parts and should never be installed in another vehicle. 1. Turn the ignition switch OFF, then disconnect the battery negative cable, and wait at least 3 minutes. 2. Confirm that each airbag is securely mounted. 3. Confirm that the special tool is functioning properly by following the check procedure on the tool label.

A

6. Cut off the airbag connector, strip the ends of the airbag wires, and connect the deployment tool alligator clips (A) to the airbag. Place the deployment tool at least 30 feet (10 meters) away from the airbag.

Driver's Airbag: 4. Remove the access panel (A), then disconnect the 2P connector between the driver's airbag (B) and the cable reel (C).

DRIVER'S AIRBAG

FRONT PASSENGER'S AIRBAG A

(cont'd)

BACK

23-283

SRS Airbag Disposal - '00 Model

Airbag Disposal - '98-99 Models (cont'd)

Special Tool Required

7. Connect a 12 volt battery to the tool.

Deployment tool 07HAZ-SG00500 • If the green light on the tool comes on, the airbag igniter circuit is defective and cannot deploy the airbag. Go to Damaged Airbag Special Procedure. • If the red light on the tool comes on, the airbag is ready to be deployed. 8. Push the tool's deployment switch. The airbag should deploy (deployment is both highly audible and visible: a loud noise and rapid inflation ofthe bag, followed by slow deflation). • If the airbags deploy and the green light on the tool comes on, continue with this procedure. • If an airbag doesn't deploy, yet the green light comes ON, its igniter is defective. Go to Disposal of Damaged Components. • During deployment the airbag can become hot enough to burn you. Wait 30 minutes after deployment before touching the airbag. 9. Dispose of the complete airbag. No part of it can be reused. Place it in a sturdy plastic bag (A), and seal it securely. A

/

Before scrapping any airbags or side airbags (including those in a whole vehicle to be scrapped), the airbags or side airbags must be deployed. Ifthe vehicle is still within the warranty period, before deploying the airbags or side airbags, the Honda District Service Manager must give approval and/or special instruction. Only after the airbags or side airbags have been deployed (as the result of vehicle collision, for example), can they be scrapped. Ifthe airbags or side airbags appear intact (not deployed), treat them with extreme caution. Follow this procedure.

Deploying Airbags In the vehicle If an SRS equipped vehicle is to be entirely scrapped, its airbags or side airbags should be deployed while still in the vehicle. The airbags or side airbags should not be considered as salvageable parts and should never be installed in another vehicle. 1. Turn the ignition switch OFF, and disconnect the battery negative cable and wait at least 3 minutes. 2. Confirm that each airbag or side airbag are securely mounted. 3. Confirm that the special tool is functioning properly by following the check procedure on the tool label.

Driver's Airbag: 4. Remove the access panel (A), then disconnect the 2P connector between the driver's airbag (B) and the cable reel (C).

B

c

23-284

BACK

Front Passenger's Airbag: 5. Remove the glove box, then disconnect the 4P connector between the front passenger's airbag (A) and SRS main harness (8).

7. Cut off the ai rbag connector, strip the ends of the airbag wires, and connect the deployment tool alligator clips (A) to the airbag. Place the deployment tool at least 30 feet (10 meters) away from the airbag. NOTE: The front passenger's airbag has 4 wires, 2 yellow and 2 red. Twist each pair of unlike color wires together, and connect one alligator clip to each pair.

A

B

Side Airbag: 6. Disconnect the 2P connector between the side airbag (A) and the SRS floor harness (8) or side wire harness (8).

B

A

(cont'd)

BACK

23-285

SRS Airbag Disposal- '00 Model (cont'd)

Airbag Disposal - '01-02 Models Special Tool Required Deployment tool 07HAZ-SG00500

8. Connect a 12 volt battery to the tool. • If the green light on the tool comes on, the airbag igniter circuit is defective and cannot deploy the airbag. Go to Damaged Airbag Special Procedure. • If the red light on the tool comes on, the airbag is ready to be deployed. 9. Push the tool's deployment switch. The airbag should deploy (deployment is both highly audible and visible: a loud noise and rapid inflation of the bag, followed by slow deflation). • If the airbags deploy and the green light on the tool comes on, continue with this procedure. • If an airbag doesn't deploy, yet the green light comes ON, its igniter is defective. Go to Disposal of Damaged Components. • During deployment the airbag can become hot enough to burn you. Wait 30 minutes after deployment before touching the airbag. 10. Dispose of the complete airbag. No part of it can be reused. Place it in a sturdy plastic bag (A), and seal it securely.

Before scrapping any airbags, side airbags, or seat belt tensioners (including those in a whole vehicle to be scrapped), the airbags, side airbags, or seat belt tensioners must be deployed. If the vehicle is still within the warranty period, the Honda District Service Manager must give approval and/or special instruction before deploying the airbags, side airbags, or seat belt tensioners. Only after the airbags, side airbags, or seat belt tensioners have been deployed (as the result of vehicle collision, for example), can they be scrapped. Ifthe airbags, side airbags, or seat belttensioners appear intact (not deployed), treat them with extreme caution. Follow this procedure.

Deploying Airbags In the vehicle If an SRS equipped vehicle is to be entirely scrapped, its airbags, side airbags, or seat belt tensioners should be deployed while still in the vehicle. The airbags, side airbags, or seat belt tensioners should not be considered as salvageable parts and should never be installed in another vehicle. 1. Turn the ignition switch OFF, then disconnect the battery negative cable, and wait at least 3 minutes. 2. Confirm that each airbag, side airbag, and seat belt tensioner is securely mounted. 3. Confirm that the special tool is functioning properly by following the check procedure on the tool label. Driver's Airbag: 4. Remove the access panel (A), then disconnect the 4P connector between the driver's airbag (B) and the cable reel (C).

c

23-286

BACK

Front Passenger's Airbag: 5. Remove the glove box, then disconnect the 4P connector between the front passenger's airbag (A) and SRS main harness (8).

Seat belt tensioner: 7. Disconnect the 2P connector between the seat belt tensioner (A) and side wire harness (8).

B

8. Pull the seat belt out all the way and cut it. 9. Cut off each airbag connector, strip the ends of the wires, and connect the deployment tool alligator clips (A) to the wires. Place the deployment tool at least 30 feet (10 meters) away from the vehicle. NOTE: The driver's airbag and front passenger's airbag have four wires, two yellow (1 st inflator) and 2 red (2nd inflator). Twist each pair of unlike colored wires together, and connect an alligator clip to each pair.

Side Airbag: 6. Disconnect the 2P connector between the side airbag (A) and the side wire harness (8).

A

B

A

(cont'd)

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23-287

SRS Airbag Disposal - '01-02 Models (cont'd) Deploying the Components Out of the Vehicle

10. Connect a 12 volt battery to the tool. • If the green light on the tool comes on, the igniter circuit is defective and cannot deploy the component. Go to Disposal of Damaged Airbag. • If the red light on the tool comes on, the component is ready to be deployed.

If an intact airbag has been removed from a scrapped vehicle, or has been found defective or damaged during transit, storage, or service, it should be deployed as follows:

11. Push the tool's deployment switch. The airbags and tensioners should deploy (deployment is both highly audible and visible: a loud noise and rapid inflation of the bag, followed by slow deflation). • If the components deploy and the green light on the tool comes on, continue with this procedure. • If an component doesn't deploy, yet the green light comes ON, its igniter is defective. Go to Disposal of Damaged Components. • During deploymentthe airbag can become hot enough to burn you. Wait 30 minutes after deployment before touching the airbag. 12. Dispose of the complete airbag. No part of it can be reused. Place it in a sturdy plastic bag (A), and seal it securely. A

/

1. Confirm that the special tool is functioning properly by following the check procedure on this page or on the tool label. 2. Position the airbag face up, outdoors, on flat ground, at least 30 feet (10 meters) from any obstacles or people. 3. Follow steps 6, 7, 8, and 9 or 7,8,9 and 10 or 9,10, 11 and 12 of the in-vehicle deployment procedure.

Disposal of Damaged Components 1. If installed in a vehicle, follow the removal procedure of driver's airbag (see page 23-278), front passenger's (see page 23-280), and side airbag (see page 23-282), and seat belt tensioner (see page 23-4). 2. In all cases, make a short circuit by twisting together the two inflator wires. 3. Package the component in exactly the same packaging that the new replacement part came in. 4. Mark the outside ofthe box "DAMAGED AIRBAG NOT DEPLOYED", "DAMAGED SIDE AIRBAG NOT DEPLOYED" or "DAMAGED SEAT BELT TENSIONER NOT DEPLOYED" so it does not get confused with your parts stock. 5. Contact your Honda District Service Manager for how and where to return it for disposal.

Deployment Tool Check 1. Connect the yellow clips to both switch protector handles on the tool; connect the tool to a battery. 2. Push the operation switch: green means the tool is OK; red means the tool is faulty. 3. Disconnect the battery and the yellow clips.

23-288

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Cable Reel Replacement - '98-00 Models Removal

6. Remove the dashboard lower cover (A).

1. Make sure the front wheels are aligned straight ahead. 2. Disconnect the battery negative cable, and wait at least 3 minutes. 3. Remove the driver's airbag (see page 23-278). 4. Disconnect the connector (A) from the cruise control set/resume switch, then remove the steering wheel bolt (B).

B

A

7. Remove the column cover screws (A), then remove the column covers (B, C).

5. Align the front wheels straight ahead, then remove the steering wheel (see page 17-22).

(cont'd)

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23-289

SRS Cable Reel Replacement - '98-00 Models (cont'd) 8. Disconnect the SRS main harness 2P connector (A) from the cable reel 2P connector (B), then disconnect the dashboard harness 4P connector (C) from the cable reel (D).

Installation 1. Before installing the steering wheel, the front wheels should be aligned straight ahead.

D

2. Disconnect the battery negative cable, and wait at least 3 minutes. 3. Set the cancel sleeve (A) so that the projections (B) are aligned vertically.

B

9. Remove the screws (A) from the cable reel, then remove the cable reel from the column.

23-290

4. Carefully install the cable reel (A) on the steering column shaft. Then connect the 4P connector (B) to the cable reel, and connect the 2P connector (C) to the SRS main harness 2P connector (D).

BACK

8. Install the driver's airbag (see step 1 on page 23279).

5. Install the steering column covers. 6. If necessary, center the cable reel. (New replacement cable reels come centered.) Do this by first rotating the cable reel clockwise until it stops. Then rotate it counterclockwise (about 2 1/2 turns) until the arrow mark on the cable reel label points straight up.

9. Reconnect the battery negative cable. 10. After installing the cable reel, confirm proper system operation: • Turn the ignition switch ON (II); the SRS indicator light should come on for about 6 seconds and then go off. • After the SRS indicator light has come off, turn the steering wheel fully left and right to confirm the SRS indicator light does not come on. • Make sure both horn buttons work.

7. Align the projections on the cable reel with the holes on the steering wheel, and install the steering wheel with a new steering wheel bolt. A


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23-291

SRS Cable Reel Replacement· '01·02 Models Removal

6. Remove the dashboard lower cover (A).

1. Make sure the front wheels are aligned straight ahead. 2. Disconnect the battery negative cable, and wait at least 3 minutes. 3. Remove the driver's airbag (see page 23-278). 4. Disconnect the connectors (A) from the cruise control set/resume switch and radio remote switch, then remove the steering wheel bolt (B). A

7. Remove the column cover screws (A), then remove the column covers (B, C).

5. Align the front wheels straight ahead, then remove the steering wheel (see page 17-22).

23-292

BACK

8. Disconnect the SRS main harness 4P connector (A) from the cable reel 4P connector (B), and dashboard wire harness B 4P connector (C) from the cable reel 4P connector (D).

Installation 1. Before installing the steering wheel, the front wheels should be aligned straight ahead. 2. Disconnect the battery negative cable, and wait at least 3 minutes. 3. Set the cancel sleeve (A) so that the projections (B) are aligned vertically.

t c 9. Remove the tab (A), then remove the cable reel from the column. A

4. Carefully install the cable reel (A) on the steering column shaft. Then connect dashboard wire harness B 4P connector (B) to the cable reel 4P connector (C), and connect the cable reel connector (D) to the SRS main harness 4P connector (E).

B

(cont'd)

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23-293

SRS Cable Reel Replacement - '01-02 Models (cont'd) 5. Install the steering column covers.

8. Install the driver's airbag (see step 1 on page 23279).

6. If necessary, center the cable reel. (New replacement cable reels come centered.) Do this by first rotating the cable reel clockwise until it stops. Then rotate it counterclockwise (about 2 1/2 turns) until the arrow mark on the cable reel label points straight up.

9. Reconnect the battery negative cable. 10. After installing the cable reel, confirm proper system operation: o

o

o

7. Align the projections on the cable reel with the holes on the steering wheel, and install the steering wheel with a new steering wheel bolt. A 38 Nm 13.9 kgf·m, 28 Ibf.ft)

23-294

BACK

Turn the ignition switch ON (II); the SRS indicator light should come on for about 6 seconds and then go off. After the SRS indicator light has come off, turn the steering wheel fully left and rightto confirm the SRS indicator light does not come on. Make sure both horn buttons work.

SRS Unit Replacement - '98-99 Models Removal

Installation

1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work (see page 23-28).

1. Install the new SRS unit (A) with Torx bolts (B), then connect the SRS main harness lSP connector (e) to the SRS unit; push it into position until it clicks. NOTE: When tightening the Torx bolts to the specified torque after replacement, be careful to turn them in so that their heads rest squarely on the brackets.

2. Disconnect the airbag connectors.

3. Remove the center console (see page 20-83). 4. Disconnect the SRS main harness 18P connector (A) from the SRS unit (B). A

B

5. Remove the three Torx bolts (A) from the SRS

9.8 N·m (1.0 kgf·m, 7.2Ibf·ft)

unit (B), then pull out the SRS unit from the bracket. A

2. Install the center console (see page 20-83). 3. Reconnect the airbag connectors. 4. Reconnect the battery negative cable. 5. After installing the SRS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator light should come on for about 6 seconds and then go off.

BACK

23-295

SRS SRS Unit Replacement - '00-02 Models Installation

Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work (see page 23-28).

1. Install the new SRS unit (A) with Torx bolts (B), then connect the connectors (e) to the SRS unit; push it into position until it clicks.

2. Disconnect the airbag connectors (see page 23-39).

NOTE: • When tightening the Torx bolts to the specified torque after replacement, be careful to turn them in so that their heads rest squarely on the brackets.

3. Disconnect the side airbag connectors (see page 23-39). 4. Remove the center console (see page 20-83).

A

5. Disconnect the connectors (A) from the SRS unit (B).

A

B

B 9.S N·m (1.0 kgf·m, 7.2Ibf·ft)

2. Install the center console (see page 20-83). 6. Remove the three Torx bolts (A) from the SRS unit (B), than pull out the SRS unit from the bracket. B

3. Reconnect the airbag connectors. (see page 23-39). 4. Reconnect the side airbag connectors (see page 2339). 5. Reconnect the battery negative cable. 6. Initialize the OPOS unit (see page 23-46). 7. After installing the SRS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator light should come on for about 6 seconds and then go off.

23-296

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Side Impact Sensor Replacement - '00 Sedan Removal

Installation

INOTICE I

INOTICE I

• Removal of the side impact sensor must be performed according to the precautions/ procedures described before. • Before disconnecting the side impact sensor 2P connector(s), disconnect the side airbag 2P connector(s). • Do not turn the ignition switch ON (II) and do not connect the battery cable while exchanging the side impact sensor.

• Be sure to install the harness wires so that they are not pinched or interfering with other parts. • Do not turn the ignition switch ON (II) and do not connect the battery cable while exchanging the side impact sensor.

1. Disconnect the negative battery cable, and wait at least 3 minutes before beginning work.

1. Install the new side impact sensor with new Torx bolts (A) then connect the SRS floor harness 2P connector (B) to the side impact sensor (C). 2. Reinstall the plate. A

9.8 N·m (1.0 kgf·m, ______ ---~ 7.2 Ibf.ft) _________-----

2. Remove the seat assembly (see page 20-83).

------~

3. Remove the front door sill trim (see page 20-75). 4. Remove the center pillar trim (see page 20-75). 5. Remove the lower anchor bolt (see page 23-7). 6. Turn up the carpet (A), then remove the 2 mounting bolts (B) and the plate (C).

3. Reconnect the negative battery cable. 4. After installing the side impact sensor, confirm proper system operation: Turn the ignition switch ON (II): the SRS indicator light should come on for about 6 seconds and then go off.

B

7. Disconnect the SRS floor harness 2P connector from the side impact sensor. 8. Remove the two Torx bolts (A) using a Torx T30 bit, then remove the side impact sensor (B).

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23-297

SRS Side Impact Sensor Replacement - '00 Coupe Installation

Removal

INOTICE I

INOTICEI • Be sure to install the harness wires so that they are not pinched or interfering with other parts. • Do not turn the ignition switch ON (II) and do not connect the battery cable while exchanging the side impact sensor.


1. Install the new side impact sensor with new Torx bolts (A) then connect the side wire harness 2P connector (B) to the side impact sensor (C).

1. Disconnect the negative battery cable, and wait at least 3 minutes before beginning work.

2. Reinstall the plate. A

9.8 N·m (1.0 kgf·m. 7.2Ibf·ftl

2. Remove the seat assembly (see page 20-98). 3. Remove the front door sill trim (see page 20-74). 4. Remove the rear side trim panel (see page 20-74). 5. Remove the lower anchor bolt (see page 23-5). 6. Turn up the carpet (A), then remove the two clips (B) and the plate (C). B

3. Reconnect the negative battery cable. 4. After installing the side impact sensor, confirm proper system operation: Turn the ignition switch ON (II): the SRS indicator light should come on for about 6 seconds and then go off.

7. Disconnect the side wire harness 2P connector from the side impact sensor. 8. Remove the two Torx bolts (A) using a Torx T30 bit, than remove the side impact sensor (B).

23-298

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Side Impact Sensor Replacement - '01-02 Models Installation

Removal

INOTice I

INOTiCe I


• Be sure to install the harness wires so that they are not pinched or interfering with other parts. • Do not turn the ignition switch ON (II) and do not connect the battery cable while exchanging the side impact sensor. 1. Install the new side impact sensor with a new Torx bolt (A), then connect the side wire harness 2P connector (B) to the side impact sensor (C).

1. Disconnect the negative battery cable, and wait at least 3 minutes before beginning work. 2. Remove the seat assembly (see page 20-83).

~~/~~

3. Remove the front door sill trim (see page 20-75). 4. Remove the center pillar trim (see page 20-75).

B/

5. Remove the lower anchor bolt (see page 23-7).

t>

6. Turn up the carpet (A), then remove the two mounting bolts (B) and the plate (C).

A/ 9.8N·m

--=-~

(1.0 kgf·m, 7.2Ibf.ftl

2. Reconnect the battery negative cable. 3. After installing the side impact sensor, confirm proper system operation: Turn the ignition switch ON (II): the SRS indicator light should come on for about 6 seconds and then go off. B

7. Disconnect the side wire harness 2P connector from the side impact sensor. 8. Remove the Torx bolt (A) using a Torx T30 bit, then remove the side impact sensor (B).

BACK

23-299

SRS OPOS Unit Replacement Installation

NOTE: Review the seat replacement procedure in the body section (see page 20-99) before performing repairs or service.

1. Place the new OPOS unit on the seat-back frame. Tighten the three screws (A), then connect the OPOS unit harness 8P and sensor connectors to the OPOS unit. Reinstall the cover.

Removal 1. Disconnect the negative battery cable, and wait at least 3 minutes before beginning work. 2. Disconnect the side airbag harness 2P connector (see page 23-282). 3. Remove the seat assembly (Sedan) (see page 2098), (Coupe) (see page 20-97), and seat-back cover (Sedan) (see page 20-98), (Coupe) (see page 20-97). 4. Remove the cover (A), then disconnect the OPDS unit harness 8P and sensor connectors from the OPOS unit. 5. Remove the three screws (B) and OPDS unit (C).

A

2. Install the new seat-back cover (Sedan) (see page 20-98), (Coupe) (see page 20-97). 3. Install the seat assembly (Sedan) (see page 20-98), (Coupe) (see page 20-97), then connect the side airbag harness 2P connector.

c

4. Reconnect the battery negative cable. 5. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 6. Initialize the OPOS unit (see page 23-46). B

23-300

7. After installing the OPOS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator light should come on for about 6 seconds and then go off.

BACK

Service Manual Index

NOTE: Refer to the following list to look up DTCs, symptoms, fuses, connectors, wire harnesses, specifications, maintenance schedules, and general service information: DTC Troubleshooting Indexes ABS{TCS Components ......•.....•........... 19-40 Automatic Transaxle ............................. 14-7 Fuel and Emissions ................................ 11-6 HeatingNentilation ................................ 21-5 SRS ............................•........................... 23-48 Symptom Troubleshooting Indexes

AlC .................................•...•................... 21-34 ABS{TCS Components ........................ 19-41 Automatic T ransaxle ..••..••...•................. 14-8 Cruise Control System .......................... 4-43 Fan Controls ......................................... 10-16 Fuel and Emissions ................................ 11-9 HeatingNentilation ................................ 21-6 Moonroof/Sunroof ...........................•... 20-61 SRS •......•...............•....................•........... 23-61 Steering ................................................... 17-4 FuselRelay Indexes AlC Compressor Clutch Relay .....•...... 22-43 AlC Condenser Fan Relay .•................. 22-43 Blower Motor Relay ............................. 22-43 ELD (Electrical Load Detector) ............ 22-43 Headlight Relay •................................... 22-43 Horn Relay ............................................ 22-43 Power Distribution ...............•............... 22-46 Radiator Fan Relay .•...............•.•..•........ 22-43 Under-dash Fuse/Relay Box, Driver's ........ 22-44 Under-dash Fuse/Relay Box, Passenger's .. 22-45 Under-hood Fuse/Relay Box ............... 22-43

AIC Compressor Relief Valve Replacement ......................................... 21-52 AIC Condenser Component Location Index ................. 21-31 Replacement ......................................... 21-53

ABS Control Unit Replacement ......................................... 19-70

AIC Condenser Fan Circuit Troubleshooting ................................... 21-37

ABS Indicator Replacement ABS{TCS Components .................... 22-59 Indicators .......................................... 22-59

AIC Condenser Fan Relay Component Location Index ..... 10-15,21-31 AIC Pressure Switch Component Location Index ................. 21-31 AIC Pressure Switch Circuit Troubleshooting ................................... 21-41

AIC Service Valve, High Pressure Component Location Index •................ 21-31 AIC Service Valve, Low Pressure Component Location Index ................. 21-31 AIC Signal Circuit Troubleshooting ................................ 11-102 AfT Assembly Removal .......................................•..•... 14-114 Installation .......................................... 14-119 AfT Clutch Pressure Control Solenoid Valves Test ...............................................•...... 14-108 Replacement ....................................... 14-109

Specifications section •••.••••••.•..•••• Section 2

AfT Countershaft Assembly Disassembly/lnspection/Reassembly ...... 14-171

AIC Component Location Index ................. 21-31 Description ........................................... 21-35 Circuit Diagram .................................... 21-36 Test ..................................................•..... 21-43 AlC Compressor Component Location Index ................. 21-31 Replacement ......................................... 21-48 AIC Compressor Clutch Inspection ............................................. 21-50 Overhaul ....•...............•.......................... 21-51 AIC Compressor Clutch Circuit Troubleshooting ................................... 21-39 AIC Compressor Clutch Relay Component Location Index ................. 21-31

ABS Indicator Circuit Troubleshooting ................................... 19-67 ABS Modulator Unit Removal/Installation ............................ 19-69 ABSfTCS Components Component Location Index ..............•.. 19-36 How-to Information ............................. 19-37 Description ........................................... 19-42 Circuit Diagram .................................... 19-50 Accessory Power Socket, Front Test/Replacement .............................. 22-133 Accessory Power Sockets Circuit Diagram .................................. 22-132 Accumulator Body Disassembly/lnspection/Reassembly ...... 14-165 Air Cleaner Element Replacement ....................................... 11-131 Air Mix Control Motor Replacement ......................................... 21-20 Test ........................................................ 21-20

AfT Differential Component Location Index .............. 14-200

Airbag, Driver's Component Location Index .......•... 23-24, 25 Replacement ....................................... 23-300 Repair .................................. 23-305, 306, 308

AfT Gear Position Indicator Replacement AfT Gear Position Indicator System ..... 14-142 Component Location Index AfT Gear Position Indicator System ....... 22-57

Airbag, Front Passenger's Component Location Index ........... 23-24, 25 Replacement ....................................... 23-302

Maintenance section .....•...•.•.•.••.•. Section 3

A

A-pillar Trim Component Location Index ..•.............. 20-72

AIC Condenser Fan Assembly Component Location Index. 10-2, 15,21-31 Test .......................................................... 10-8 Replacement ......................................... 10-14

Connector and Wire Harness Indexes Component Connectors (to hamess) ......... 22-12 Grounds (to components) ................... 22-49 In-line Connectors (to hamess) ........... 22-11

General Information section ........ Section 1

AfT Shift Lever Removal .............................................. 14-127 Installation .......................................... 14-128 Disassembly/Reassembly ................. 14-130

AfT Gear Position Indicator System Component Location Index .............. 14-136 Circuit Diagram .................................. 14-137 Test ...................................................... 14-141 AfT Hydraulic Controls Test ...................................................... 14-104 AfT Mainshaft Assembly Disassembly/lnspection/Reassembly ...... 14-168

Alternator Replacement ........................................... 4-32 Overhaul ...............•.............................•... 4-33 Alternator Belt Inspection/Adjustment .......•.................. 4-40 Alternator FR Signal Circuit Troubleshooting •..•••.........•.•.•............ 11-104 Alternator-compressor Belt Inspection/Adjustment .......................... 4-39

AfT Secondary Shaft Assembly Disassembly/lnspection/Reassembly ...... 14-175 Inspection ........................................... 14-176

Antenna Lead Component Location Index .•........••.• 22-122

AfT Shift Cable Replacement ....................................... 14-131 Adjustment ......................................... 14-134

(cont'd)

Service Manual Index (cont'd) ATF Inspection ........................................... 14-113 Replacement ....................................... 14-1 13

Brake Booster Test ........................................................ 19-17 Replacement ......................................... 19-18

c

ATFCooier Repair .................................................. 14-125

Brake Calipers Overhaul ......................................... 19-13,22

ATF Cooler Lines and Hoses Component Location Index ................... 10-2 Replacement ....................................... 14-1 26

Brake Discs Inspection ....................................... 19-12,21

Cable Reel Component Location Index . 22-130, 23-24, 25 Replacement .............................. 23-311, 314

ATFPump Inspection ........................................... 14-162 Audio Unit Component Location Index .............. 22-122 Removal/Installation .......................... 22-124 Replacement ....................................... 22-124 Audio/Entertainment Component Location Index .............. 22-122 Circuit Diagram .................................. 22-123 Automatic Transaxle Description ........................................... 14-18 Test ...................................................... 14-101

B

Brake Drums Inspection ............................................. 19-25 Brake Fluid Level Switch Test Brake System Indicator Components ...... 19-9 Conventional Brake Components ..... 19-9 Component Location Index Brake System Indicator Components .... 22-57 Brake Light Failure Sensor Test ........................................................ 22-78 Brake Lights Circuit Diagram .................................... 22-91 Brake Lines and Hoses Inspection ............................................. 19-30 Replacement ......................................... 19-31

Camshaft Component Location Index ..................... 6-3 Inspection ............................................... 6-41 Installation .............................................. 6-50 Camshaft Pulley Component Location Index ..................... 6-3 Camshaft Seal Component Location Index ..................... 6-3 Carpet Component Location Index ................. 20-72 Replacement ......................................... 20-B1 Catalytic Converter System How-to Information ............................. 11-42 Test ...................................................... 11-135 Ceiling Light Component Location Index .............. 22-115 Test ...................................................... 22-121

Back-up Light Switch Test .......................................................... 13-3

Brake Master Cylinder Replacement ......................................... 19-14 Adjustment ........................................... 19-15 Inspection ............................................. 19-15

Back-up Lights Circuit Diagram .................................... 22-90

Brake Pads Inspection/Replacement ................ 19-10, 19

Center Panel Removal/Installation ............................ 20-86

Balancer Belt Component Location Index ..................... 6-3 Inspection ............................................... 6-20

Brake Pedal Adjustment ............................................. 19-5

Charging System Component Location Index ................... 4-27 Circuit Diagram ...................................... 4-28 Troubleshooting ..................................... 4-29

Balancer Shaft Bearings Inspection ............................................... 7-15 Balancer Shaft Oil Seal Installation .............................................. 7-38 Balancer Shafts Inspection ............................................... 7-15 Ball Joint Boots Replacement ......................................... 18-15 Ball Joints Removal .................................................. 18-9

Brake Pedal Position Switch Test .......................................................... 4-50 Brake Pedal Position Switch Signal Circuit Troubleshooting ................................ 11-107 Brake Shoes Replacement ......................................... 19-27 Brake System Indicator Replacement Brake System Indicator Components .... 22-59 Conventional Brake Components .. 22-59

Battery Test ........................................................ 22-51

Brake System Indicator Circuit Circuit Diagram Brake System Indicator Components ...... 19-8 Conventional Brake Components ..... 19-8

Blower Motor Replacement ......................................... 21-27

Brake Wheel Cylinders Replacement ......................................... 19-29

Blower Motor Circuit Troubleshooting ................................... 21-15

Bulkhead Cover, Rear Component Location Index ................. 20-72

Blower Motor Relay Component Location Index ................. 21-31 Blower Unit Removal/Installation ............................ 21-26

Bumper, Front Removal/Installation .................. 20-140,142 Bumper, Rear Removal/Installation .................. 20-145,148

Center Console Removal/Installation ............................ 20-83

Charging System Indicator Replacement Charging System .............................. 22-59 Indicators .......................................... 22-59 Child Seat Tether Anchor Installation ............................................ 23-19 Removal/Installation ................ 23-20,21,22 CKP/TDC (Crankshaft Position/Top Dead Center) Sensors Component Location Index ..................... 6-3 Replacement ........................................... 6-55 Clock Circuit Diagram .................................. 22-128 Replacement ....................................... 22-129 Clutch Component Location Index ................... 12-3 Clutch Disc Component Location Index ................... 12-3 Replacement ........................................... 12-7 Clutch Interlock Switch Test ............................................................ 4-6

Clutch Master Cylinder Component Location Index ................... 12-3 Replacement ........................................... 12-5 Clutch Pedal Component Location Index .....•............. 12-3 Adjustment ............................................. 12-4

Countershaft Bearing, A/T Housing Replacement ....................................... 14-155 Countershaft Bearing, Torque Converter Housing Replacement ....................................... 14-167

Cruise Control Unit Input Test ................................................ 4-46 Cylinder Head Assembly Component Location Index ..................... 6-3 Removal ................................•................• 6-30 Installation ...........................................••. 6-52

Clutch Pedal Position Switch Test .......................................................... 4-50

Countershaft Bearings Removal ................................................ 13-34 Replacement ......................................... 13-43

Clutch Pressure Plate Component Location Index ................... 12-3

Countershaft Idler Gear Installation .......................................... 14-194

Clutch Release Bearing Component Location Index ................... 12-3

Countershaft Reverse Selector Hub Replacement ....................................... 14-172

Cylinder Head Cover Component Location Index ...............•..... 6-3 Installation .............................................. 6-54

Clutch Slave Cylinder Component Location Index ................... 12-3 Replacement ........................................... 12-6

Countershaft Speed Sensor Replacement ....................................... 14-109

Cylinder Head Cover Gasket Component Location Index ..................... 6-3

Crankshaft Inspection ........................................... 7-8, 21 Removal .................................................. 7-18 Installation .............................................. 7-33

Cylinder Head Gasket Component Location Index ..................... 6-3

Combination Light Switch Test/Replacement ................................ 22-95 Connecting Rod Bearings Replacement ........................................... 7-13 Connecting Rod Bolts Inspection ............................................... 7-28 Connecting Rods Inspection ................................•................ 7-8 Replacement ........................................... 7-25

Crankshaft Main Bearings Replacement ............................................. 7-9 Crankshaft Oil Seal, Pulley End Installation .............................................. 7-38 Crankshaft Oil Seal, Transmission End Installation .............................................. 7-39

Control Arms Component Location Index ................... 18-4 Replacement ......................................... 18-29

Crankshaft Pulley Component Location Index Crankshaft ............................................. 6-3 Timing Belt ............................................ 6-3 Removal/Installation Timing Belt .......................................... 6-18

Conventional Brake Components Component Location Index ......•.•.......... 19-3 Inspection ......•..................•..................... 19-4 Repair .................................................•.... 19-7

Crankshaft Pulley Bolt Component Location Index Crankshaft ............................................. 6-3 Timing Belt ............................................ 6-3

Coolant Replacement ......................................... 10-10

Cruise Control Actuator Test .......................................................... 4-52 Replacement ........................................... 4-53

Connectors (See first page ofthis Index)

Coolant Reservoir Component Location Index ................... 10-2 Coolant Temperature Gauge Troubleshooting Cooling System .................................. 10-5 Component Location Index Coolant Temperature Gauge Components ......................................... 22-57

Cruise Control Actuator Cable Adjustment .•........................................... 4-55 Cruise Control Actuator Solenoid Test ........................................•................. 4-51 Cruise Control Communication Circuit Troubleshooting ..................................... 4-45

Coolant Temperature Gauge Sending Unit Component Location Index Coolant Temperature Gauge Components ........................ 10-2,22-57 Cooling System .................................. 10-2 Test Cooling System .................................. 10-7

Cruise Control Main Switch Test/Replacement .................................. 4-49

Cooling System Component Location Index .....•...........•. 10-2

Cruise Control Set/Resume/Cancel Switch Test/Replacement .................................. 4-49

Countershaft Bearing Hub/Bearing Replacement ....................................... 14-174

Cruise Control System Component Location Index ................... 4-41 Circuit Diagram ...................................... 4-42

Cruise Control Indicator Replacement Cruise Control System ..................... 22-59 Indicators .......................................... 22-59

Cylinder Head Bolts Component Location Index ..................... 6-3 Inspection ............................................... 6-35

Cylinder Head, Bare Component Location Index ..................... 6-3 Inspection ............................................... 6-35

D Dampers, Front Component Location Index ................... 18-3 Replacement ......................................... 18-18 Dampers, Rear Component Location Index ................... 18-4 Replacement .....................................•..• 18-30 Dash Lights Brightness Control Circuit Diagram .................................. 22-112 Dash Lights Brightness Controller Test ................•.•................................... 22-114 Dash Vents Removal/Installation Dashboard .......•........................... 20-88, 89 Heating/Ventilation .......................... 20-89 Dashboard Removal/Installation ............................ 20-90 Dashboard Lower Cover Removal/Installation ...•..•...•........... 20-84, 85 Differential Carrier Bearing Outer Races, AIT Component Location Index .............. 14-200 Replacement ....................................... 14-204 Differential Carrier Bearing Outer Races, MIT Component Location Index ................. 13-53 Differential Carrier Bearings, A/T Component Location Index .............. 14-200 Replacement ....................................... 14-202 Inspection ........................................... 14-205

(cont'd)

Service Manual Index (cont'd) Differential Carrier Bearings. MIT Component Location Index ................. 13-53 Replacement ......................................... 13-55 Adjustment ........................................... 13-57 Differential Carrier. AfT Component Location Index .......•.•.... 14-200 Replacement ....................................... 14-201 Differential Carrier. MfT Component Location Index ...••••.......... 13-53 Replacement ......................................... 13-54 Differential Oil Seals. AfT Component Location Index ....•.•.•..•.. 14-200 Replacement ....................................... 14-203 Differential Oil Seals. MIT Component Location Index ................. 13-53 Replacement ......................................... 13-55 Differential Pinion Gears. A/T Inspection ..................................,........ 14-201 Differential Pinion Gears. MIT Inspection ..........•...•..•.............•......•..••.. 13-54 Distributor Replacement ........................................... 4-19 Overhaul ........................................... 4-21,22 DLC (Data Link Connector) Component Location Index .•••...••.. 23-24. 25 Door Courtesy Light Component Location Index .............. 22-108 Door Courtesy Lights Component Location Index ............•. 22-108 Door Glass Replacement ................................... 20-14,16 Adjustment ..................................... 20-26, 28

Door Lock Knob Switches Component Location Index Keyless Entry/Security Alarm System ........••...••••.........•.. 22-206 Test Keyless Entry/Security Alarm System ............................. 22-224 Power Door Locks .......................... 22-224 Door Lock Switches Component Location Index Keyless Entry/Security Alarm System ............................. 22-206 Power Door Locks .......................... 22-229 Test Power Door Locks .......................... 22-225 Door Moldings Replacement ....................................... 20-164 Door Opening Trim Component Location Index ...............•. 20-72 Door Outer Handles Replacement Front Doors ....................................... 20-11 Rear Doors ........................................ 20-19 Door Panels Removal/Installation Front Doors ..................................... 20-8, 9 Rear Doors ........................................ 20-17 Door Sill Trim Component Location Index .....•........•.. 20-72 Door Strikers Adjustment ........................................... 20-30 Door Switches Component Location Index Door Courtesy Lights ..................... 22-108 Entry Light Control System •.......... 22-115 Keyless Entry/Security Alarm System ............................. 22-206 Power Door Locks ................•.......•. 22-229

Door Key Cylinder Switches Component Location Index Keyless Entry/Security Alarm System ............................. 22-206 Power Door Locks ..•.............•..•.••••. 22-229 Test Keyless Entry/Security Alarm System ............................. 22-225 Power Door Locks .......................... 22-225

DRL (Daytime Running Lights) Control Unit Input Test .............................................. 22-96

Door Latches Replacement Front Doors ....................................... 20-14 Rear Doors ........................................ 20-21

DRL Indicator Replacement Headlights ......................................... 22-59 Indicators .......................................... 22-59

Door Lock Actuators Component Location Index Keyless Entry/Security Alarm System ............................. 22-206 Power Door Locks .......................... 22-229 Test Keyless Entry/Security Alarm System ...•••...••............•••••...•. 22-223 Power Door Locks .......................... 22-223

DTCs (See first page ofthis Index)

Drive Plate Removal/Installation ................................ 7-7

Dust and Pollen Filter Replacement ......................................... 21-25

E ECM Component Location Index .............. 22-200 ECTSensor Component Location Index ................... 10-2 EGRValve Replacement ............................................. 9-2 Emblems Replacement .............................. 20-159.160 End Cover. AIT Removal .............................................. 14-149 Engine Assembly Removal .................................................... 5-2 Installation .............................................. 5-10 Engine Block Assembly Component Location Index ..................... 7-3 Engine Block. Bare Inspection ............................................... 7-22 Repair ...................................................... 7-24 Engine Mount Control Solenoid Valve Component Location Index •.................. 4-56 Engine Mount Control System Component Location Index ....•.............. 4-56 Circuit Diagram ...................................... 4-57 Troubleshooting .....••.•.•.•.•.....••............... 4-58 Entry Light Control System Component Location Index ..•...•....... 22-115 Circuit Diagram •...•.•....•••.................... 22-116 EVAP Control System Component Location Index .............. 11-142 EVAP Two-Way Valve Test ...................................................... 11-158 Evaporator Component Location Index ..••.•...••..•••• 21-31 Removal/Installation •....••..........••...•..... 21-46 Evaporator Temperature Sensor Test ........................................................ 21-23 Replacement ......................................... 21-47 Exhaust Manifold Removal/Installation ..•........................• 9-3, 4 Exhaust Pipe Replacement ......................................... 9-5, 6

F

D41ndicator Circuit Troubleshooting ................................... 14-93 Fan Controls Component Location Index ................. 10-15 Circuit Diagram .............................. 10-17,18

Final Driven Gear, AIT Component Location Index .............. 14-200 Replacement •....•................................. 14-201 Final Driven Gear, MIT Component Location Index ................. 13-53 Replacement ......................................... 13-54 Aywheel Removal/Installation Crankshaft ............................................. 7-7 Component Location Index Clutch •.......•.•...........•....................•.....•. 12-3 Frame Repair Chart ........................................ 20-182 Front Doors Component Location Index ...........••.. 20-2, 4 Adjustment ........................................... 20-29 Front Driveshaft Assembly Inspection ............................................... 16-3 Removal .•...........................................•.... 16-3 Disassembly .........•....••.........••................ 16-5 Resassembly .......................................... 16-9 Installation ............................•.....•......... 16-20 Front Seats Component Location Index ••. 20-97, 98, 22190 Circuit Diagram .......................... 22-191,192 Front Speakers Component Location Index .••••......... 22-122 Replacement ....................................... 22-125

Fuel Injection Air Control Valve Troubleshooting ................................ 11-130

H

Fuel Injection System (PGM-AI Component Location Index ................. 11-45

Hazard Warning Switch Component Location Index .....•....•... 22-104 Test ..........•........................................... 22-107

Fuel Injectors Replacement ................•................•....... 11-95 Fuel Lines and Hoses Component Location Index ............•. 11-109 Inspection ........................................... 11-116 Removal .............................................. 11-118 Installation .......................................... 11-119 Fuel Pipe Protector Replacement ....................................... 20-167 Fuel Pressure Regulator Component Location Index .....•........ 11-109 Replacement ....................................... 11-121 Fuel Pump Component Location Index .............. 11-109 Test ...................................................... 11-115 Replacement ••.........................•..........• 11-1 22 Fuel Rail Component Location Index .............. 11-109 Fuel Supply System Component Location Index .............. 11-109 Adjustment ......................................... 11-113 Troubleshooting ........................•....... 11-113

Front Suspension Component Location Index .•.....•.........•. 18-3

Fuel Tank Component Location Index .............. 11-109 Replacement ....................................... 11-123

Fuel and Emissions Description ........................................... 11-10 Circuit Diagram •.•...•.....•..•.............•...... 11-33

Fuel Tank Vapor Control Valve Test ...................................................... 11-159 Replacement ....................................... 11-161

Fuel Fill Cap Component Location Index ..••.........• 11-109

Fuses (See first page of this Index)

Fuel Fill Door Latch Component Location Index ..••••........ 20-169 Replacement ....................................... 20-177 Fuel Fill Door Opener Component Location Index ••........•... 20-169 Fuel Fill Door Opener Cable Component Location Index ...........••. 20-169 Fuel Filter Component Location Index .........•.•.. 11-109 Replacement ....................................... 11-121 Fuel Gauge Test Fuel Supply System ...••...••......•.•.... 11-126 Component Location Index Fuel Gauge Components .•........••..... 22-57 Fuel Gauge Sending Unit Component Location Index Fuel Gauge Components •.........•••.... 22-57 Fuel Supply System ....................... 11-109 Test/Replacement Fuel Supply System ••..•.............•.... 11-127

Headlight Adjustment ........................................... 22-98 Replacement ......................................... 22-98 Component Location Index ...•.......... 22-206 Headlight Relay Component Location Index Headlights ....................................... 22-206 Keyless Entry/Security Alarm System ...................•......... 22-206 Headlights Circuit Diagram ..•......... 22-84, 85, 86, 88, 92 Headliner Component Location Index ................. 20-72 Removal/Installation ............................ 20-79 Heater Control Panel How-to Information ............................... 21-4 Disassembly/Reassembly ................... 21-24 Removal/Installation ............................ 21-24 Heater Control Power and Ground Circuits Troubleshooting ................................... 21-19 Heater Fan Switch Test ......................•......••......................... 21-23 Heater Hoses and Pipes Component Location Index ................... 10-2 Heater Unit Replacement ......................................... 21-28 Heater Valve Component Location Index ................... 10-2 Heater Valve Cable Adjustment ........................................... 21-30

G Gauge Assembly Component Location Index ................. 22-57 Replacement ......................................... 22-68 Gauges Component Location Index ................. 22-57 Circuit Diagram .............................. 22-60, 64 General Information (See section 1) Glove Box Removal/Installation ............................ 20-87

Heating/Ventilation Component Location Index ...•............... 21-3 Description .............................................. 21-7 Circuit Diagram ...................................... 21-8 High Beam Cut Relay Component Location Index .............. 22-206 High Beam Indicator Replacement Headlights ......................................... 22-59 Indicators .......................................... 22-59 High Mount Brake Light Replacement •..................•................... 22-102

Glove Box Light Component Location Index .............. 22-108

Hood Replacement ....................................... 20-150 Adjustment ......................................... 20-151

Grille Replacement ....................................... 20-160

Hood Insulator Replacement ....................................... 20-152 (cont'd)

Service Manual Index (cont'd) Hood Latch Component Location Index .............. 20-169 Replacement ....................................... 20-175 Hood Opener Cable Component Location Index .............. 20-169 Replacement ....................................... 20-170 Hood Release Handle Component Location Index .............. 20-169 Replacement ....................................... 20-175 Hood Seal Replacement ....................................... 20-153 Hood Switch Component Location Index .............. 22-206 Test ...................................................... 22-227 Horn Component Location Index Horns ............................................... 22-130 Keyless Entry/Security Alarm System ............................. 22-206 Test/Replacement Horns ............................................... 22-131 Horn Relay Component Location Index Horns ............................................... 22-130 Keyless Entry/Security Alarm System ....

Ignition Coil(s) Test .......................................................... 4-24

Intake Manifold Chamber Removal/Installation ................................ 9-2

Ignition Key Light Component Location Index .............. 22-115 Test ...................................................... 22-120

Intake Manifold Gasket Replacement ............................................. 9-2

Ignition Key Switch Component Location Index Entry Light Control System ........... 22-115 Keyless Entry/Security Alarm System ............................. 22-206 Test Entry Light Control System ........... 22-120 Keyless Entry/Security Alarm System ............................. 22-120 Power Door Locks .......................... 22-120 Ignition Key/Transponder Component Location Index .............. 22-200 Ignition Switch Test Starting System ................................ 22-55 Wiring System .................................. 22-55 Replacement Wiring System .................................. 22-56

22-206

Ignition System Component Location Index ................... 4-17 Circuit Diagram ...................................... 4-18 Inspection ............................................... 4-19

Horn Switch Component Location Index .............. 22-130

Ignition Wires Test/Inspection ....................................... 4-25

Horns Component Location Index .............. 22-130 Circuit Diagram .................................. 22-131

Immobilizer Indicator Replacement Immobilizer System ......................... 22-59 Indicators .......................................... 22-59 Component Location Index Immobilizer System ....................... 22-200

H02S. Primary Replacement ......................................... 11-97 H02S. Secondary Replacement ......................................... 11-97 Hubs Component Location Index Front Suspension ............................... 18-3 Rear Suspension ................................ 18-4 Replacement Rear Suspension ........................ 18-22.24

Immobilizer Receiver Unit Component Location Index .............. 22-200 Replacement ....................................... 22-205 Immobilizer System Component Location Index .............. 22-200 Circuit Diagram .................................. 22-201 Description ......................................... 22-202 Troubleshooting ................................ 22-204 Indicators Component Location Index ................. 22-57

Interlock System Component Location Index .............. 14-143 Circuit Diagram .................................. 14-144 Intermediate Shaft Assembly Removal ................................................ 16-21 Disassembly ......................................... 16-22 Resassembly ........................................ 16-24 Installation ............................................ 16-26 Intermittent Dwell Time Controller Component Location Index .............. 22-179 Intermittent Wiper Relay Component Location Index .............. 22-179

K Key Interlock Solenoid Test ...................................................... 14-147 Key Interlock System Circuit Troubleshooting ................................... 14-99 Keyless Entry Transmitter Component Location Index .............. 22-206 Repair .................................................. 22-228 Test ...................................................... 22-228 Keyless Entry/Security Alarm System Component Location Index .............. 22-206 Circuit Diagram .................................. 22-208 Description ......................................... 22-213 Keyless Receiver Unit Component Location Index .............. 22-206 Kick Panel Component Location Index ................. 20-72 Knuckles Component Location Index Front Suspension ............................... 18-3 Rear Suspension ................................ 18-4 Replacement Front Suspension ............................. 18-10 Rear Suspension .............................. 18-25

Inner Fender Replacement ....................................... 20-167 lAC (Idle Air Control) Valve Replacement ............................................. 9-2 Component Location Index ................. 11-98 IAT (Intake Air Temperature) Sensor Replacement ............................................. 9-2 ICM (Ignition Control Module) Input Test ....................................•........... 4-23 Idle Control System Component Location Index ................. 11-98 Adjustment ......................................... 11-108

Inside Rearview Mirror Component Location Index ........... 20-31.32 Replacement ......................................... 20-37 Instrument Panel Removal/Installation ............................ 20-84 Intake Air System Component Location Index .............. 11-129 Intake Manifold Removal/Installation ................................ 9-2

L Leading Arms Component Location Index ................... 18-4 Replacement ......................................... 18-28 License Plate Light Replacement Lights. Exterior ............................... 22-103 Component Location Index Keyless Entry/Security Alarm System ............................. 22-206

lights, Exterior Component Location Index ................. 22-82

M/T Shift Cables Replacement ......................................... 13-52

lights, Interior Component Location Index .............. 22-108 Circuit Diagram .................................. 22-109

M/T Shift Lever Replacement ......................................... 13-52

lights-on Reminder Circuit Diagram .................................... 22-79 lights-on Reminder Indicator Replacement Headlights ......................................... 22-59 Lights-on Reminder ......................... 22-59 Lock-up Control Solenoid Valve Test ...................................................... 14-103 Low Fuel Indicator Test Fuel Supply System ....................... 11-128 Replacement Fuel Supply System ......................... 22-59 Indicators .......................................... 22-59 Low Oil Pressure Indicator Replacement Low Engine Oil Indicator Components ................................. 22-59 Lubrication System .......................... 22-59 Lower Arms Component Location Index Front Suspension ............................... 18-3 Rear Suspension ................................ 18-4 Replacement Front Suspension ............................. 18-17 Rear Suspension .............................. 18-29 Lubrication System Component Location Index ..................... 8-3 Test ............................................................ 8-4

M MIT Assembly Component Location Index ................... 12-3 Removal .................................................. 13-4 Installation ............................................ 13-10 Disassembly ......................................... 13-21 Resassembly ........................................ 13-48

MIT Counters haft Assembly Inspection ....................................... 13-32, 35 Disassembly ......................................... 13-34 Resassembly ........................................ 13-36

MIT Differential Component Location Index ................. 13-53 Inspection ............................................. 13-54 MIT Mainshaft Assembly Inspection ....................................... 13-26,29 Disassembly ......................................... 13-28 Resassembly ........................................ 13-30 Adjustment ........................................... 13-45

MIT Reverse Shift Fork Inspection ............................................. 13-25

Main Valve Body Removal .............................................. 14-156 Repair .................................................. 14-158 Installation .................................. 14-159,189 Disassemblyllnspection/Reassembly ...... 14-160 Mainshaft Bearing, Torque Converter Housing Replacement ....................................... 14-166 Mainshaft Bearings Removal ................................................ 13-28 Installation ............................................ 13-30 Replacement ......................................... 13-44 Mainshaft Oil Seal Replacement ......................................... 13-44 Mainshaft Sealing Rings Replacement ....................................... 14-170 Maintenance (See section 3) Maintenance Required Indicator Replacement ......................................... 22-59 Map light/Spotlight Component Location Index .............. 22-108 Test ...................................................... 22-110 MES (Memory Erase Signal) Connector Component Location Index ........... 23-24, 25 MIL Replacement Fuel Injection System (PGM-FI) ...... 22-59 Indicators .......................................... 22-59 MIL Circuit Troubleshooting ................................... 11-91 Mirrors Component Location Index ........... 20-31, 32 Mode Control Motor Replacement ......................................... 21-21 Test ........................................................ 21-21

Moonroof Frame Component Location Index ................. 20-60 Replacement ......................................... 20-66 Moonroof Glass Component Location Index ................. 20-60 Adjustment ........................................... 20-62 Replacement ......................................... 20-62 Moonroof Motor Component Location Index ... 20-60,22-153 Replacement ......................................... 20-65 Test ...................................................... 22-155 Moonroof Open Relay Component Location Index .............. 22-153 Moonroof Position Switches Component Location Index ... 20-60,22-153 Adjustment ........................................... 20-70 Moonroof Sunshade Component Location Index ................. 20-60 Replacement ......................................... 20-64 Moonroof Switch Component Location Index .............. 22-153 Test ...................................................... 22-155 MoonroofISunroof Component Location Index ... 20-60,22-153 Test ........................................................ 20-71 Circuit Diagram .................................. 22-154 MTF Inspection/Replacement ........................ 13-3 Multiplex Control Inspection Connector Component Location Index .............. 22-134 Multiplex Control System Component Location Index .............. 22-134 Circuit Diagram .................................. 22-135 Description ......................................... 22-136 Troubleshooting ................................ 22-137 Input Test ............................................ 22-140 Multiplex Control Unit, Door Component Location Index Entry Light Control System ........... 22-134 Headlights ....................................... 22-134 Keyless Entry/Security Alarm System ............................. 22-134 Multiplex Control System ............. 22-134 Power Door Locks .......................... 22-134 Power Windows ............................. 22-134

Moonroof Cable Assembly Component Location Index ................. 20-60 Moonroof Close Relay Component Location Index .............. 22-153 Moonroof Drain Channel Component Location Index ................. 20-60 Replacement ......................................... 20-63 Moonroof Drain Channel Slider Component Location Index ................. 20-60 Replacement ......................................... 20-68 Moonroof Drain Tubes Component Location Index ................. 20-60 (cont'd)

Service Manual Index (cont'd) Multiplex Control Unit, Driver's Input Test Dash Lights Brightness Control .... 22-113 Entry Light Control System ........... 22-117 Headlights ......................................... 22-93 Interlock System ............................. 14-145 Keyless Entry/Security Alarm System ............................. 22-215 Lights-on Reminder ......................... 22-80 Power Windows ............................. 22-172 Wiper/Washer ................................. 22-182 Component Location Index Dash Lights Brightness Control .... 22-134 Entry Light Control System ........... 22-134 Headlights ....................................... 22-134 Interlock System ............................. 22-134 Key Light Timer .............................. 22-134 Key-in Reminder ......•.•............•....... 22-134 Keyless Entry/Security Alarm System . 22-134 Multiplex Control System ............. 22-134 Power Door Locks .......................... 22-134 Power Windows ............................. 22-134 Seat Belt Reminder .......•.........•...... 22-134 Wiper/Washer ................................. 22-134

Oil, Engine Replacement ............................................. 8-5

Multiplex Control Unit, Passenger's Component Location Index Entry Light Control System ........•.. 22-134 Keyless Entry/Security Alarm System. 22-134 Multiplex Control System ............. 22-134 Power Door Locks .......................... 22-134 Power Windows ............................. 22-134 Wiper/Washer .........•....................... 22-134

Outside Power Mirror Switch Component Location Index .............. 22-143 Test ...................................................... 22-147

OPDSSensor Component Location Index ........... 23-24, 25 OPDSUnit Component Location Index ........•.. 23-24, 25 Replacement ....................................... 23-322 Outside Manual Mirrors Component Location Index ................. 20-32 Replacement ......................................... 20-34 Outside Mirror Defogger Switch Test ...................................................... 22-147 Outside Mirror Holders Component Location Index ........... 20-31, 32 Replacement ..............................•...• 20-33, 36 Outside Power Mirror Actuators Test ...................................................... 22-148 Replacement ........•..................... 22-149,151

Outside Power Mirrors Component Location Index ... 20-31,32,22-

143 Replacement ......................................... 20-35 Circuit Diagram .......................... 22-144, 145 Test ...................................................... 22-146

o p

Oil Filter Component Location Index ..................... 8-3 Replacement .............................•.......... ~ .... 8-6 Oil Pan Component Location Index Engine Block Assembly ........•.............. 8-3 Lubrication System .............................. 8-3 Oil Pressure Switch Component Location Index Low Engine Oil Indicator Components .. 22-57 Lubrication System .............................. 8-3 Test Low Engine Oil Indicator Components ....... 8-4 Lubrication System .............................. 8-4 Oil Pump, Engine Component Location Index Engine Block Assembly ....................... 8-3 Lubrication System .............................. 8-3 Overhaul Lubrication System .............................. 8-7 Oil Screen Component Location Index ..................... 8-3

Piston Rings Replacement ........................................... 7-29 Pistons Replacement ........................................... 7-25 Installation .............................................. 7-31 Power Door Locks Component Location Index .............. 22-229 Circuit Diagram .................................. 22-230 Power Seat Unkage Disassembly/Reassembly ......•.. 20-121.122 Power Seat Motors Test .............................................. 22-195. 196 Power Seat Switch Test .............................................. 22-193.194 Power Steering Fluid Replacement ......................................... 17-14 Power Steering Fluid Reservoir Component Location Index ................... 17-3 Power Steering Unes and Hoses Replacement ......................................... 17-15 Power Steering Pump Component Location Index ................... 17-3 Test .................................................... 17-9. 10 Replacement ......................................... 17-16 Overhaul ............................................... 17-17 Power Steering Pump Belt Inspection/Adjustment ........................ 17-12

Oil Control Orifice Component Location Index •............•....... 6-3 Oil Drain Bolt Component Location Index ..................... 8-3

Piston Pins Replacement ........................................... 7-25

Park Lever Position Stop Inspection/Adjustment ...................... 14-152 Park Pin Switch Test ...................................................... 14-148 Parking Brake Inspection/Adjustment .......................... 19-6 Parking Brake Cable Replacement ......................................... 19-32 Parking Brake Switch Test Brake System Indicator Components ...•.. 19-9 Pa rki ng Brake ........... ... .... ... .... ...... ....... 19-9 Component Location Index Brake System Indicator Components .... 22-57 PCM Component Location Index Engine Mount Control System .•....... 4-56 Immobilizer System ....................... 22-200 PCVValve Test ...................................................... 11-141 PGM-A Main Relay Component Location Index .............. 11-109 PGM-FI Main Relay Circuit Troubleshooting ................................ 11-110

Power Window Motor, Driver's Component Location Index .............. 22-159 Test .................•.................................... 22-178 Power Window Motors, Passenger's Component Location Index .............. 22-159 Test ...................................................... 22-178 Power Window Relay Test ........................................................ 22-52 Component Location Index .............. 22-159 Power Window Switch, Master Component Location Index .......•...... 22-159 Replacement ....................................... 22-177 Power Window Switch, Passenger's Component Location Index ......•....... 22-159 Replacement ..............................•........ 22-177 Power Windows Component Location Index ............•. 22-159 Circuit Diagram .......... 22-160.164.168.170 PSP (Power Steering Pressure) Switch Component Location Index ................. 11-98 PSP (Power Steering Pressure) Switch Signal Circuit Troubleshooting ................................ 11-106

a Quarter Trim Panel Component Location Index ................. 20-72 Quarter Window Glass Replacement ................................... 20-22, 55 Quarter Window Glass Sticker Replacement ................................... 20-25, 59

R

Rear Suspension Component Location Index ................... 18-4

Seat Belts Component Location Index ............... 23-3,4

Rear Window Defogger Component Location Index .............. 22-156 Circuit Diagram .................................. 22-157

Seat Belts, Front Replacement ....................................... 23-5, 7 Inspection ............................................. 23-17

Rear Window Defogger Switch Component Location Index .............. 22-156

Seat Belts, Rear Replacement ................................... 23-12, 15

Rear Window Defogger Wires Component Location Index .............. 22-156 Repair .................................................. 22-158 Test ...................................................... 22-158

Seat Cover, Front Replacement ....................................... 20-123

Rear Window Glass Replacement ......................................... 20-49 Receiver IDryer Component Location Index ................. 21-31

Radiator Component Location Index ................... 10-2 Test .......................................................... 10-8 Replacement ......................................... 10-14 Radiator and Condenser Fans Common Circuit Troubleshooting ................................... 21-38 Radiator Cap Component Location Index ................... 10-2 Test .......................................................... 10-7 Radiator Fan Assembly Component Location Index. 10-2, 15,21-31 Test .......................................................... 10-8 Replacement ......................................... 10-14 Radiator Fan Circuit Troubleshooting ............................. 10-19,21 Radiator Fan Relay Component Location Index ................. 10-15 Radiator Fan Switch Component Location Index ............. 10-2,15 Test ........................................................ 10-24 Radiator Fan Switch Circuit Troubleshooting ................................... 10-23 Radiator Hoses and Pipes Component Location Index ................... 10-2 Rear Air Outlet Replacement ....................................... 20-168 Rear Door Hook Pin Replacement ......................................... 20-26 Rear Doors Component Location Index ................... 20-6

Recirculation Control Motor Replacement ......................................... 21-22 Test ........................................................ 21-22 Recirculation Control Motor Circuit Troubleshooting ................................... 21-14

Seat Cushion Cover, Rear Replacement .............................. 20-138,139 Seat Heater Elements Test ...................................................... 22-199 Seat Heater Switches Test ...................................................... 22-199 Seat Heaters Component Location Index .............. 22-197 Circuit Diagram .................................. 22-198 Seat Side Bolster Cover, Rear Replacement ....................................... 20-137

Refrigerant Replacement ............................. 21-54, 55, 56 Test ........................................................ 21-57

Seat Torsion Bar Replacement ....................................... 20-120

Refrigerant Oil Replacement ......................................... 21-32

Seat Wire Harness, Driver's Installation .................................. 20-115, 118

Regulator Valve Body Disassembly/Inspection/Reassembly ...... 14-163

Seat, Front Removal/Installation ............................ 20-99 Disassembly/Reassembly ....... 20-102,103, 104,105,106,107,108,109,110,111,112,1 13, 114

Rocker Arm Assembly Component Location Index ..................... 6-3 Removal .................................................. 6-36 Disassembly/Reassembly ............... 6-37, 38

Seat, Rear Removal/Installation .................. 20-128, 129

Rocker Arms Test .......................................................... 6-11 Inspection ............................................... 6-39

Seat-back Cover, Rear Replacement .............................. 20-134,135

Roof Drip Moldings Replacement .............................. 20-161,162

Seat-back Latch, Rear Replacement .............................. 20-132,133

Roof Moldings Replacement ....................................... 20-163

Seat-back Lock Cylinder, Rear Replacement ....................................... 20-133

s

Secondary Shaft Bearing, Torque Converter Housing Replacement ....................................... 14-167

Safety Indicator Component Location Index ................. 22-57

RearSheH Component Location Index ................. 20-72

Safety Indicator System Component Location Index ................. 22-73 Circuit Diagram .................................... 22-74 Input Test .............................................. 22-76

Rear Side Trim Panel Component Location Index ................. 20-72

Seat Armrest, Rear Replacement ....................................... 20-130

Rear Speakers Component Location Index .............. 22-122

Seat Belt Reminder Indicator Replacement Seat Belt Reminder .......................... 22-59

Secondary Shaft Idler Gear Bearing Replacement ....................................... 14-178 Security Indicator Component Location Index Indicators ........................................ 22-206 Keyless Entry/Security Alarm System ............................. 22-206 Test Indicators ........................................ 22-227 Keyless Entry/Security Alarm System ............................. 22-227 Select Lever Replacement ......................................... 13-18 (cont'd)

Service Manual Index (cont'd) Servo Body Disassembly/Inspection/Reassembly ...... 14-164 Shift Arm Replacement ......................................... 13-18 Shift Control Solenoid Valves Replacement ....................................... 14-107 Test ...................................................... 14-107 Shift Forks Inspection ............................................. 13-39 Disassembly/Reassembly ................... 13-40 Shift Lock Solenoid Test ...................................................... 14-147 Replacement ....................................... 14-148 Shift Lock System Circuit Troubleshooting ................................... 14-96 Side Airbag Indicator Replacement Indicators .......................................... 22-59 SRS .................................................... 22-59 Component Location Index SRS .............................................. 23-24, 25 Side Airbag, Driver's Component Location Index ........... 23-24, 25 Replacement ....................................... 23-304 Side Airbag, Front Passenger's Component Location Index ........... 23-24, 25

SRS Unit Component Location Index ........... 23-24, 25 Replacement .............................. 23-317, 318 Starter Test ............................................................ 4-8 Replacement ............................................. 4-9 Overhaul ................................................. 4-10 Starter Solenoid Test ............................................................ 4-7 Starter Switch Signal Circuit Troubleshooting ................................ 11-105

Throttle Body Test ...................................................... 11-130 Removal/Installation .......................... 11-133 Disassembly/Reassembly ................. 11-134

Steering Column Component Location Index ................... 17-3 Removal/Installation ............................ 17-25 Inspection/Adjustment ........................ 17-27

Throttle Cable Adjustment ......................................... 11-132

Steering Gearbox Component Location Index ................... 17-3 Inspection ............................................... 17-8 Removal ................................................ 17-30 Overhaul ............................................... 17-32 Installation ............................................ 17-47

Steering Linkage Inspection ............................................... 17-8

Side Sill Panels Replacement .............................. 20-165,166

Steering Lock Component Location Index ................... 17-3 Replacement ......................................... 17-28

SRS Component Location Index ... 23-23, 24, 25, 26,27 Description ............................... 23-62, 63, 65 Circuit Diagram .................. 23-67,68,70,72 SRS Indicator Replacement Indicators .......................................... 22-59 SRS .................................................... 22-59 Component Location Index SRS .............................................. 23-24, 25 SRS Indicator Circuit Troubleshooting ...... 23-264, 274, 279, 282, 287,297

Taillight Relay Component Location Index Keyless Entry/Security Alarm System . 22-206 Taillights .......................................... 22-206

Steering Component Location Index ................... 17-3 Troubleshooting ..................................... 17-6 Inspection ......................................... 17-7,11

Side Marker Light Replacement ....................................... 22-103

Speedometer Component Location Index ................. 22-57

Taillight Replacement .............................. 22-100,101 Component Location Index .............. 22-206

Thermostat Test .......................................................... 10-9 Replacement ......................................... 10-13

Steering Hanger Beam Replacement ......................................... 20-94

Specifications (See section 2)

Tachometer Component Location Index ................. 22-57

Starting System Component Location Index ..................... 4-3 Circuit Diagram ........................................ 4-4 Troubleshooting ....................................... 4-5

Side Impact Sensors Component Location Index ........... 23-24,25 Replacement ...................... 23-319, 320, 321

Spark Plugs Inspection ............................................... 4-26

T

Steering Rack Guide Adjustment ........................................... 17-29 Steering Wheel Component Location Index ................... 17-3 Inspection ............................................... 17-7 Removal ................................................ 17-22 Disassembly/Reassembly ................... 17-23 Installation ............................................ 17-24 Sub-frames Replacement ....................................... 20-180 Suspension Adjustment ............................................. 18-5 Synchro Ring, Dual-cone Inspection ............................................. 13-41 Synchro Sleeve Inspection/Reassembly ....................... 13-41

Tie-rod Ball Joint Boots Replacement ......................................... 17-50 Timing Belt Component Location Index ..................... 6-3 Inspection ............................................... 6-19 Adjustment ............................................. 6-22 Removal .................................................. 6-23 Installation .............................................. 6-26 Torque Converter Clutch Solenoid Valve Replacement ....................................... 14-106 Test ...................................................... 14-106 Trailing Arms Component Location Index ................... 18-4 Replacement ......................................... 18-28 Transmission Housing Removal .............................................. 14-153 Installation .......................................... 14-191 Transmission Range Switch Test ...................................................... 14-138 Replacement ....................................... 14-139 Trim Component Location Index ........... 20-72, 73 Removal/Installation .... 20-74, 75, 76, 77, 78 Troubleshooting (See first page of this Index) Trunk Floor Mat Component Location Index ................. 20-72 Trunk Key Cylinder Switch Component Location Index .............. 22-206 Test ...................................................... 22-226

Trunk Latch Switch Component Location Index Keyless Entry/Security Alarm System ............................. 22-206 Trunk Light ...................................... 22-108 Test Keyless Entry/Security Alarm System . 22-226 Trunk Light ...................................... 22-111 Trunk Lid Replacement ....................................... 20-154 Adjustment ......................................... 20-156 Trunk Lid Dynamic Damper Replacement ....................................... 20-158 Trunk Lid Latch Component Location Index .............. 20-169 Replacement ....................................... 20-178 Trunk Lid Lock Cylinder Component Location Index .............. 20-169 Replacement ....................................... 20-179 Trunk Lid Opener Component Location Index .............. 20-169 Replacement ....................................... 20-176 Trunk Lid Opener Cable Component Location Index .............. 20-169 Replacement .............................. 20-171,173 Trunk Lid Opener Solenoid Test ...................................................... 22-226 Trunk Lid Torsion Bar Replacement ....................................... 20-157 Trunk Lid Weatherstrip Replacement ....................................... 20-158 Trunk Light Assembly Component Location Index .............. 22-108 Test ...................................................... 22-111 Trunk Pass-through Cover Key Cylinder Replacement ....................................... 20-131 Trunk Rear Trim Panel Component Location Index ................. 20-72 Trunk Side Pocket Component Location Index ................. 20-72 Trunk Side Trim Panel Component Location Index ................. 20-72 Turn Signal Indicators Replacement Indicators .......................................... 22-59 Turn Signal/Hazard Warning Lights ....... 22-59 Component Location Index Turn Signal/Hazard Warning Lights ..... 22-104 Turn Signal Light Switch Component Location Index .............. 22-104 Turn Signal/Hazard Relay Component Location Index .............. 22-104 Test ...................................................... 22-106

Turn Signal/Hazard Warning Lights Component Location Index .............. 22-104 Circuit Diagram .................................. 22-105

VTEC Solenoid Valve Component Location Index ..................... 6-3 Test .......................................................... 6-10

Tweeters Component Location Index .............. 22-122

VTEC Solenoid Valve Filter Component Location Index ..................... 6-3

u

w

Under-dash Fuse/Relay Box, Driver's Removal/Installation ............................ 22-50

Washer Auid Level Indicator Replacement Indicators .......................................... 22-59 Wiper/Washer ................................... 22-59

Under-dash Fuse/Relay Box, Passenger's Removal/Installation ............................ 22-50 Upper Arms Component Location Index Front Suspension ............................... 18-3 Rear Suspension ................................ 18-4 Replacement Front Suspension ............................. 18-16 Rear Suspension .............................. 18-27

v Valve Guides Component Location Index ..................... 6-3 Inspection ............................................... 6-44 Replacement ........................................... 6-45 Valve Seals Component Location Index ..................... 6-3 Replacement ........................................... 6-16 Removal .................................................. 6-43 Valve Seats Repair ...................................................... 6-47 Valve Springs Component Location Index ..................... 6-3 Removal .................................................. 6-43 Valves Component Location Index ..................... 6-3 Adjustment ............................................. 6-14 Removal .................................................. 6-43 Inspection ............................................... 6-44 Installation .............................................. 6-49 Vanity Mirror Lights Component Location Index .............. 22-108 Vehicle Speed Signal Circuit Troubleshooting ............................. 22-69, 71 VSS Component Location Index Speedometer Components ............. 22-57 Replacement Cruise Control System ..................... 22-68 Fuel Injection System (PGM-Fil ...... 22-68 Speedometer Components ............. 22-68 VTEC Lost Motion Assemblies/Springs Component Location Index ..................... 6-3

Washer Fluid Level Switch Component Location Index .............. 22-179 Test ...................................................... 22-188 Washer Fluid Reservoir Component Location Index .............. 22-179 Replacement ....................................... 22-188 Washer Motor, Windshield Component Location Index .............. 22-179 Test ...................................................... 22-187 Washer Tube, Windshield Component Location Index .............. 22-179 Replacement ....................................... 22-189 Water Outlet Component Location Index ................... 10-2 Replacement ......................................... 10-12 Water Pump Component Location Index ................... 10-2 Inspection ............................................... 10-9 Replacement ......................................... 10-10 Wheel Bearings Component Location Index Front Suspension ............................... 18-3 Rear Suspension ................................ 18-4 Inspection Front Suspension ............................... 18-8 Wheel Speed Sensors Inspection ............................................. 19-70 Replacement ......................................... 19-71 Wheels and Tires Inspection ............................................... 18-8 Window Antenna Coil Component Location Index Antenna ........................................... 22-122 Rear Window Defogger ................. 22-156 Test Antenna ........................................... 22-127 Window Antenna Wires Component Location Index .............. 22-122 Repair .................................................. 22-126 Test ...................................................... 22-126 Windows Component Location Index ........... 20-38, 39 (cont'd)

Service Manual Index (cont'd) Windshield Glass Replacement ......................................... 20-40 Wiper Arms. Windshield Component Location Index .............. 22-179 Wiper Linkage. Windshield Component Location Index .............. 22-179 Wiper Motor. Windshield Component Location Index .............. 22-179 Replacement ....................................... 22-186 Test ...................................................... 22-186 Wiper/Washer Component Location Index .............. 22-179 Circuit Diagram .................................. 22-180 Wiper/Washer Switch Component Location Index .•............ 22-179 Test/Replacement ................•............. 22-185 Wire Harnesses (See first page of this Index) Wiring System How-to Information ............................... 22-3 Relay and Control Unit Locations .., 22-7.8. 10

1 1st/2nd Clutch Assemblv Disassembly ....................................... 14-179 Inspection ........................................... 14-182 Resassembly ...................................... 14-184

2 2nd Clutch Pressure Switch Replacement .............................. 14-110. 111

3 3rd Clutch Pressure Switch Replacement ....................................... 14-112 3rd/4th Clutch Assembly Inspection ........................................... 14-169

(HJ 1998 -2002 Service Manual V6 Supplement

General Information Chassis and Paint Codes - 1998 Model .................................................. 1-2 Chassis and Paint Codes - 1999 Model .................................................. 1-3 Chassis and Paint Codes - 2000 Model 11 .. 1..... II ... 11 ............ 1...... 1............. 1-4 Chassis and Paint Codes - 2001 Model ....... ........................................... 1-5 Chassis and Paint Codes - 2002 Model ............................

II •••••• •••• ••••••••••

1-6

Identification Number Locations .................... 1-7 Warning/Caution Label Locations ........... ....... 1-8 Under-hood Emission Control Label............... 1-9 Parts Marking .................................................... 1-14

General Information Chassis and Paint Codes -1998 Model Vehicle Identification Number

Engine Number

1HG CG1 64 * W A 000001

Ilrrriri

a

b

J30A1 - 1300001

I I a

cdefgh

b

a. Manufacturer, Make, and Type of Vehicle 1HG: HONDA OF AMERICA MFG., INC., U.S.A. HONDA, Passenger vehicle b. Line, Body, and Engine Type CG1: ACCORDV6/J30A1 CG2: ACCORD COUPE V6/J30A1 c. Body Type and Transmission Type 1: 2-door Coupe/5-speed Manual 2: 2-door Coupe/4-speed Automatic 6: 4-door Sedan/4-speed Automatic d. Vehicle Grade (Series) US model Canada model 4: LX, LXV6 4: LX, LXV6 5: EX, EXV6 5: EX, EXV6 6: EX-L e. Check Digit f. Model Year W: 1998 g. Factory Code A: Marysville, Ohio Factory in U.S.A. h. Serial Number 000001-: US model 800001-: Canada model

a. Engine Type J30A1: 3.0.e SOHC VTEC Sequential Multipart Fuel-injected engine b. Serial Number

Transmission Number B7XA - 5000001

IbI a

a. Transmission Type B7XA: 4-speed Automatic P2A8: 5-speed Manual b. Serial Number

Paint Code

Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification.

Code Color Mystic Blue Pearl 'Notet B-80P G-87P Dark Emerald Pearl NH-578 Taffeta White NH-592P Flamenco Black Pearl NH-612M Regent Silver Metallic RP-25P Black Currant Pearl RP-29P Raisin Pearl R-94 San Marino Red Heather Mist Metallic 'Note2 YR-508P * Note 1: US model only * Note 2: Canada model only

Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification. COLOR LABEL Example: INT. COLOR

TYPEE EXT. COLOR

B-80P KAS84AOA

1-2

BACK

Chassis and Paint Codes - 1999 Model Vehicle Identification Number

Engine Number J30A 1 - 2000001

I I a

1 HG CG1 64 * X A 000001

11IIII1I

a

b

b

cdefgh

a. Engine Type J30A 1: 3.0.e SOHC VTEC Sequential Multiport Fuel-injected engine b. Serial Number

a. Manufacturer, Make, and Type of Vehicle 1HG: HONDA OF AMERICA MFG., INC., U.S.A. HONDA. Passenger vehicle b. Line, Body, and Engine Type CG 1: ACCORD V6/J30A 1 CG2: ACCORD COUPE V6/J30A1 c. Body Type and Transmission Type 2: 2-door Coupe/4-speed Automatic 6: 4-door Sedan/4-speed Automatic d. Vehicle Grade (Series) US model Canada model 4: LX, LXV6 4: LX 5: EX, EXV6 5: EX e. Check Digit f. Model Year X: 1999 g. Factory Code A: Marysville, Ohio Factory in U.S.A. h. Serial Number 000001-: US model 800001 -: Canada model


I I a b

a. Transmission Type B7XA: 4-speed Automatic b. Serial Number

Paint Code Code Color G-87P Dark Emerald Pearl NH-578 Taffeta White NH-592P Flamenco Black Pearl Regent Silver Metallic -Not.2 NH-612M NH-623M Satin Silver Metallic Black Currant Pearl -Not.t RP-25P San Marino Red -Not.t R-94 YR-508M Heather Mist Metallic * Note 1: US model only * Note 2: Canada model only


COLOR LABEL

Example: INT. COLOR

TYPEE EXT. COLOR

8-80P KAS84AOA

Paint Code '----------/

BACK

1-3


Engine Number J30A1 - 3000001

1HG CG1 6 4 * Y A 000001

I I a

II111111 a b

b

cdef gh

a. Engine Type J30A 1: 3.0 ~ SOHC VTEC Sequential M ultiport Fuel-injected engine b. Serial Number

a. Manufacturer, Make, and Type of Vehicle 1HG: HONDA OF AMERICA MFG., INC., U.S.A. HONDA, Passenger vehicle b. Line, Body, and Engine Type CG1: ACCORD V6/J30A1 CG2: ACCORD COUPE V6/J30A1 c. Body Type and Transmission Type 2: 2-door Coupe/4-speed Automatic 6: 4-door Sedan/4-speed Automatic d. Vehicle Grade (Series) Canada model US model 4: LX, LXV6 4: LX 5: EX 5: EX, EXV6 e. Check Digit f. Model Year Y:2000 g. Factory Code A: Marysvi"e, Ohio Factory in U.S.A. h. Serial Number 000001-: US model 800001-: Canada model


I I a b


Paint Code Color Code Nighthawk Black Pearl B-92P G-87P Dark Emerald Pearl Taffeta White ·Not. NH-578 Satin Silver Metallic NH-623M RP-31M Signet Silver Meta"ic San Marino Red ·Not. R-94 YR-524M Naples Gold Meta"ic * Note: US model only



TYPEE EXT. COLOR

B-80P KAS84AOA

1-4

BACK

Chassis and Paint Codes - 2001 Model Engine Number

Vehicle Identification Number

1HG CG1 6 4

*

J30A1 - 4000001

1 A 000001

I I a

IIIIIII1

a

b

b

cdefgh

a. Manufacturer, Make and Type of Vehicle JHM: HONDA MOTOR CO., LTD. HONDA, Passenger vehicle 1HG: HONDA OF AMERICA MFG., INC., U.S.A. HONDA, Passenger vehicle b. Line, Body and Engine Type CG 1: ACCORD V6/J30A 1 CG2: ACCORD COUPE V6/J30A1 c. Body Type and Transmission Type 2: 2-door Coupe/4-speed Automatic 6: 4-door Sedan/4-speed Automatic d. Vehicle Grade (Series) US model Canada model 4: LX, LX V6 4: LX 5: EX, EXV6 5: EX e. Check Digit f. Model Year 1: 2001 g. Factory Code A: Marysville, Ohio Factory in U.S.A. C: Saitama in Japan (Sayama). h. Serial Number 000001-: US model 800001-: Canada model

a. Engine Type J30A 1: 3.0.e SOHC VTEC Sequential Multiport Fuel-injected engine b. Serial Number

Transmission Number

B7XA - 8000001

I I a b


Paint Code Code B-92P B-96P G-87P NH-578 NH-623M R-94 R-507P RP-31M YR-524M * Note 1: US model only

Color Nighthawk Black Pearl Eternal Blue Pearl ·Note2 Dark Emerald Pearl -No'.' Taffeta White -No'.' Satin Silver Metallic San Marino Red -No'e' Firepepper Pearl Signet Silver Metallic -No'e2 Naples Gold Metallic

* Note 2: Canada model only Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification. Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification.


TYPEE EXT. COLOR

8-80P KAS84AOA Paint Code ' - - - - - - - '

BACK

1-5


Engine Number J30A 1 - 5000001

1HG CG1 64* 2 A 000001

I I a

IIIII111 a b

b

cdef gh

a. Manufacturer, Make and Type of Vehicle JHM: HONDA MOTOR CO., LTD. HONDA, Passenger vehicle 1HG: HONDA OF AMERICA MFG., INC., U.S.A. HONDA, Passenger vehicle b. Line, Body and Engine Type CG 1: ACCORD V6/J30A 1 CG2: ACCORD COUPE V6/J30A1 c. Body Type and Transmission Type 2: 2-door Coupe/4-speed Automatic 6: 4-door Sedan/4-speed Automatic d. Vehicle Grade (Series) US model Canada model 1: SE 4: LX V6 4: LX 5: EX V6 5: EX e. Check Digit f. Model Year 2:2002 g. Factory Code A: Marysville, Ohio Factory in U.S.A. C: Saitama in Japan (Sayama) h. Serial Number 000001-: US model 800001 -: Canada model

a. Engine Type J30A1: 3.0 Q SOHC VTEC Sequential Multiport Fuel-injected engine b. Serial Number

Transmission Number

B7XA - 9000001

I I a b


Paint Code Code Color B-92P Nighthawk Black Pearl Eternal Blue Pearl 'Note2 B-96P Noble Green Pearl - Not., G-508P Taffeta White -Not., NH-578 NH-623M Satin Silver Metallic San Marino Red -Note' R-94 Firepepper Pearl R-507P Naples Gold Metallic YR-524M * Note 1: US model only * Note 2: Canada model only



TYPEE EXT. COLOR

B-SOP KAS84AOA Paint Code ' - - - - - - - '

1-6

BACK

Identification Number Locations

Engine Number


Transmission Number (Automatic)

BACK

1-7

General Information Warning/Caution Label Locations

ENGINE COOLANT INFORMATION

SERVICE INFORMATION (Under-hood Emission Control Labell

SRS WARNING LABEL

BATTERY CAUTION

1-8

BACK


Engine and Evaporative Families

Example:

Engine Family:

VEHICLE EMISSION CONTROL INFORMATION

W HNX V 03.0 FF1

THIS VEHICLE CONFORMS TO U. S. EPA REGULATIONS APPLICABLE TO 1991

III1I e

MODEL YEAR NEW MOTOR VEHICLES.

abc d (IN)O. 22±O. 02mm {EX} O. JO±O. 02mm

VALVE LASH

(COLDI SPARl PLUG GAP

a. Model Year W: 1998 b. Manufacturer Subcode HNX: HONDA c. Family Type V:LDV T:LDT d. Displacement e. Sequence Characters

1. 0-1. lmm

NO OTHER ADJUSTMENTS NEEDED. WHNXVDl. OFF1

rWC/H02S (2)

WHNXR0130AAA

EGR/SFI

(' 86.1 30-96 PROCEDURES) l.Ol

CATALYST

(HJ HONOA MOTOR CO. , LTO

30VHGXBG

@ PBC-ADD


Evaporative Family:

CALIFORNIA TLEV THIS VEHICLE CONFORMS TO U.S EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1998 NEW TLEV PASSENGER CARS PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED INTO COMMERCE FOR SALE IN THE STATE OF CALIFORNIA. TIER 1/LEV THIS VEHICLE CONFORMS TO U.S. EPA TIER 1 AND STATE OF CALIFORNIA LEV REGULATIONS APPLICABLE TO 1998 MODEL YEAR NEW MOTOR VEHICLES.

W HNX R 0130 AAA

1IIII abc d

e

a. Model Year W:1998 b. Manufacturer Subcode HNX: HONDA c. Family Type E: EVAP R: EVAP/ORVR d. Canister Work Capacity e. Sequence Characters

CALIFORNIA LEV THIS VEHICLE CONFORMS TO U.S EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1998 NEW LEV PASSENGER CARS PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED INTO COMMERCE FOR SALE IN THE STATE OF CALIFORNIA. CALIFORNIA ULEV THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1998 NEW ULEV PASSENGER CARS PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED INTO COMMERCE FOR SALE IN THE STATE OF CALIFORNIA.

BACK

1-9



Example:

Engine Family:

VEHICLE EMISSION CONTROL INFORMATION

X HNX V 03.0 FF1

rlr"

THIS VEHICLE CONFORMS TO U. S. EPA REGULATIONS APPLICABLE TO 1999

MODEL YEAR HEW MOTOR VEHICLES.

abc d VALVE LASH (COLD)

(IN) O. 22±O. 02mm (EX)O. lOtO. 02mm

SPARK PLUG GAP

1. 0-1. Imm

a. Model Year X: 1999 b. Manufacturer Subcode HNX: HONDA c. Family Type V:LDV T:LDT d. Displacement e. Sequence Characters

NO OTHER ADJUSTMENTS NEEDED. XHNXV03. OFF!

TWC/H02S (2)

XHNXR0130AAA

EGR/SFI

l.OL

CATALYST 30VHGXBG HONDA MOTOR CO •• LTO

(Soy) P8e-ADI


Evaporative Family:

CALIFORNIA TLEV THIS VEHICLE CONFORMS TO U.S EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1999 NEWTLEV PASSENGER CARS PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED INTO COMMERCE FOR SALE IN THE STATE OF CALIFORNIA. TIER 1/LEV THIS VEHICLE CONFORMS TO U.S. EPA TIER 1 AND STATE OF CALIFORNIA LEV REGULATIONS APPLICABLE TO 1999 MODEL YEAR NEW MOTOR VEHICLES.

X HNX R 0130 AAA

rlr"

abc d

e

a. Model Year X: 1999 b. Manufacturer Subcode HNX: HONDA c. Family Type E: EVAP R: EVAP/ORVR d. Canister Work Capacity e. Sequence Characters

CALIFORNIA LEV THIS VEHICLE CONFORMS TO U.S EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1999 NEW LEV PASSENGER CARS PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED INTO COMMERCE FOR SALE IN THE STATE OF CALIFORNIA. CALIFORNIA ULEV THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1999 NEW ULEV PASSENGER CARS PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED INTO COMMERCE FOR SALE IN THE STATE OF CALIFORNIA.

1-10

e

BACK



Example:

Engine Family:

VEHICLE EMISSION CONTROL INFORMATION THIS VEHICLE CONFORMS TO U. S. EPA

[]

MODEL YEAR NEW lEV PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2000 MODEL YEAR NEW LEV PASSENGER CARS. (COLD)

,.

"

1.0*1. lmm

NO OTHER ADJUSTMENTS NEEDEO.

'

YHNXV03. OFA3 YHNXR0130AAA

TWC!H02S (2) EGR/SF]

,

\

'.- ~

\

I I

\

Y HNX V 03.0 FF1

III11 c e

'- .. \

ab

•

., \ I

"

,:

Y:2000

'

• ______________ --"",.

d

a. Model Year

,-

'.t.J

RAe VALVE

CATALYST

(HJ

,I , , I', \

"\~'J

l.Ol

HONDA MOTOR CO .• LTD

EVIoP PURGE

:;::,. , ""'rg-::l :~OI

(I N) O. 22±O. 02mm (EX) O. lO±O. 02mm

VALVE LASH

SPARl PLUG GAP

TO CANISTER

;;. -+ :;FUEl·i'RESSURt ..=®. , !

NlEV REGULATIONS APPLICABLE TO 2000

b. Manufacturer Subcode

{ } FRONT

HNX: HONDA 30VHGFFG

I

@ I

c. Family Type V:LDV T: LDT

P8C-A02


FEDERAL THIS VEHICLE CONFORMS TO U.S. EPA NLEV REGULATIONS APPLICABLE TO 2000 MODEL YEAR NEW LEV PASSENGER CARS, AND CALIFORNIA REGULATIONS APPLICABLE TO 2000 MODEL YEAR NEW LEV PASSENGER CARS.

Evaporative Family:

Y HNX R 0130 AAA

r lc i le l

ab

d

a. Model Year Y:2000




BACK

1-11



Example:

Engine Family:

VEHICLE EMISSION CONTROL INFORMATION THIS VEHICLE CONFORMS TO U,S. EPA NLEV REGULATiONS APPLICABLE TO 2001 MODEL YEAR NEW lEV PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2001 MODEL YEAR NEW lEV PASSENGER CARS.

(IN) O. UfO. 02mm (EX) O. la±O. 02mm

VALVE LASH (COLO)

lAC VALVE

.,n

1.0-1.1mm

,

NO OTHER ADJUSTMENTS NEEDED.

IHNXV03.0MSU lHNXR0130AAF

loOt

TWC/HOZS (2) EGR/SF1

OBOII CERTIFIED

CATALYST

(HJ HONDA MOTOR CO. , LTD

fY!E.

t

~~~~~

'

I I I Ie I

ab

cd

I

I

I

I

\\..,~ '."

~

•

,

"

•

0

, .

' '

1 HNX V 03.0 M5U

CANIS!ER~

".;/",:- ;,::,.;,-" ,\ngt 0I FUEL-PR-ESSURE-~~~ I'

SPARK PLUG GAP

.fYAL

\ • .1

IA BYPASS CONTROL THERMAL VALVE ___

"

r

a. Model Year 1: 2001

{!r FRONT


30VAGFFG

@

c. Family Type V: LDV T:LDT

P8C-A03

FEDERAL THIS VEHICLE CONFORMS TO U.S. EPA NLEV REGULATIONS APPLICABLE TO 2001 MODEL YEAR NEW LEV PASSENGER CARS, AND CALIFORNIA REGULATIONS APPLICABLE TO 2001 MODEL YEAR NEW LEV PASSENGER CARS.

CANADIAN TIER 1 THIS VEHICLE CONFORMS TO U.S. EPA NLEV REGULATIONS AND CAN DIAN TIER 1 STANDARDS FOR 2001 MODEL YEAR NEW PASSENGER CARS.


Evaporative Family:

1 HNX R 0130 AAF

I IcI Ie I

ab

d

a. Model Year 1:2001




1-12

BACK



Example:

Engine Family:

o

VEHICLE EMISSION CONTROL INFORMATION THIS vEHICLE CONFORNS TO ll. S. EPA

roo

FUEL-'RESiii,t==®"

(1110. ZHO. 02mm (Exlo. 30:'0. Ohllil

VALVE LUN (COLD)

/

,I

~,I

f

I

SPARK PlUG GAP

1. 0·1. lmlD

/

NO OTHER ADJUSTMENTS NEEDED. 2HNXYOJ.OWlC

3.0l

\

CATALYST Honda Motor Co .• Ltd

\

EVA'PU"E

\

~.

I I

~?I

r lc i le l

ab

2:2002

\

~H~~~~~~E//

30VHGFFG

I

d

a. Model Year

.-

;

" ;;';;;.ssc"TROL/:'..o-

_______

2 HNX V 03.0 MYC

\

\

' I

':

\

¢

J;LVE

\

I I

\

- .-

y;r::): -:1

"/-,

I

\\~\

DaD I CERTIFIED

(HJ

:

, I

TWC/H02S(2) EGRISri

2HNlR0130UF

TOCANISTER

:"'i-:~O][ "'::'g

HLEV REGULATIONS APPLICABLE TO 200t NODEl YEAR NEW LEV PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2002 MODEL VEAR NEW LEV PASSENGER CARS.

I

~

b. Manufacturer Subcode

~ pac

c. Family Type

HNX: HONDA V: LDV T: LDT

.'&'04


FEDERAL and CANADIAN TIER 1 THIS VEHICLE CONFORMS TO U.S. EPA NLEV REGULATIONS APPLICABLE TO 2002 MODEL YEAR NEW LEV PASSENGER CARS, AND CALIFORNIA REGULATIONS APPLICABLE TO 2002 MODEL YEAR NEW LEV PASSENGER CARS.

Evaporative Family:

2 HNX R 0130 AAF

r lc i le l

ab

d

a. Model Year 2:2002




BACK

1-13

General Information Parts Marking To deter vehicle theft, certain major components are marked with the vehicle identification number (VIN). Original parts have self-adhesive labels. Replacement body parts will have self-adhesive labels, and a replacement engine and transmission will have the VIN plate attached with a break-off bolt. NOTE: Be careful not to damage the parts marking labels during body repair. Mask the labels before repairing the part.

1-14

BACK

specs Specifications Standards and Service Limits Engine Electrical .................................................... Engine Assembly .................................................. Cylinder Head ........................................................ Engine Block .......................................................... Engine Lubrication ................................................ Cooling ................................................................... Fuel and Emissions ............................................... Automatic Transmission and Differential ........... Steering .................................................................. Suspension ............................................................ Brakes ..................................................................... Air Conditioning ....................................................

2-2 2-2 2-3 2-4 2-5 2-5 2-5 2-6 2-12 2-13 2-13 2-13

Design Specifications Dimensions ............................................................ Weight (U.S.A.) ...................................................... Weight (CANADA) ................................................. Engine .................................................................... Starter .................................................................... Automatic Transmission ...................................... Steering .................................................................. Suspension ............................................................ Wheel Alignment .................................................. Brakes ..................................................................... Tires ........................................................................ Air Conditioning .................................................... Electrical Ratings ...................................................

2-14 2-14 2-14 2-14 2-14 2-14 2-15 2-15 2-15 2-15 2-15 2-15 2-16

Body Specifications Illustration .............................................................. 2-17

Standards and Service Limits Engme EI e ctrica . Measurement

Item

Ignition coil

Qualification

Rated voltage Primary winding resistance

at 68°F (20°C)

Secondary winding resistance

at 68°F (20°C)

Resistance

Spark plug

Type

Service Limit

0.34-0.42 Q 1.71-20.3kQ 1-4-2-5-3-6

Firing order Ignition wire

Standard or New

12 V

at 68°F (20°C)

25 kQ max. NGK: PZFR5F-ll DENSO: PKJ16CR-L 11

Gap

1.0-1.1 mm (0.039-0.043 in.) At idle (check

Ignition timing

1.3 mm (0.05 in.)

NT (in INJ or [fj): 10±2°BTDC at 680±50 rpm

the red mark) Alternator belt

Tension adjustment

Alternator

Output

Auto adjuster type At 13.5 V and

100A

normal engine temperature Starter

Output

1.6kW

Commutator mica depth

0.4-0.5 mm

0.15 mm (0.006 in.)

(0.016-0.020 in.) Commutator runout

0.02 mm (0.001 in.) max.

0.05 mm (0.002 in.)

Commutator 0.0.

28.0-28.1 mm (1.102-1.106 in.)

27.5 mm (1.083 in.)

Brush length

15.8-16.2 mm (0.62-0.64 in.)

11.0 mm (0.43 in.)

Brush spring tension (new)

15.7 -17.7 N (1.60 -1.80 kgf, 3.53 - 3.97 Ibs)

Engme Assem blIV Item

Compression

Measurement

Standard or New

Service Limit

Minimum

930 kPa (9.5 kgf/cm', 135 psi)

--

open throttle. (See Design Specs for

Maximum

200 kPa (2.0 kgf/cm', 28 psi)

--

ratio.)

2-2

Qualification

Pressure Check at 200 rpm with wide

variation

BACK

II Cylinder Head Measurement

Item Head

Warpage Height

Camshaft

End play Camshaft-to-holder oil clearance Total runout Cam lobe height

Valves

Clearance (cold) StemO.D. Stem-to-guide clearance

Valve seats

Width Stem installed height

Valve springs

Free length

Valve guides

1.0.

Installed height Rocker arms

Arm-to-shaft clearance

Standard or New

Qualification

-120.95-121.05 mm (4.762-4.766 in.) 0.05-0.20 mm (0.002-0.008 in.) 0.050-0.089 mm (0.0020-0.0035 in.) 0.03 mm (0.001 in.) max. Intake. primary 34.615 mm (1.3628 in.) Intake. mid 36.210 mm (1.4256 in.) Intake. 31.188 mm (1.2279 in.) secondary Exhaust 36.076 mm (1.4203 in.) Intake 0.20-0.24 mm (0.008-0.009 in.) Exhaust 0.28-0.32 mm (0.011-0.013 in.) Intake 5.485-5.495 mm (0.2159-0.2163 in.) Exhaust 5.450-5.460 mm (0.2146-0.2150 in.) Intake 0.020-0.045 mm (0.0008-0.018 in.) Exhaust 0.055-0.080 mm (0.0022-0.0031 in.) Intake 1.25-1.55 mm (0.049-0.061 in.) Exhaust 1.25-1.55 mm (0.049-0.061 in.) Intake 46.75-47.55 mm (1.841-1.872 in.) Exhaust 46.68-47.48 mm (1.838-1.869 in.) Intake 51.03 mm (2.009 in.) Exhaust 53.48 mm (2.106 in.) Intake 5.515-5.530 mm (0.2171-0.2177 in.) Exhaust 5.515-5.530 mm (0.2171-0.2177 in.) Intake 21.20-22.20 mm (0.835-0.874 in.) Exhaust 20.63-21.63 mm (0.812-0.852 in.) Intake 0.026-0.067 mm (0.0010-0.0026 in.) Exhaust 0.026-0.077 mm (0.0010-0.0030 in.)

BACK

Service Umit 0.05 mm (0.002 in.)

-0.20 mm (0.008 in.) 0.15 mm (0.006 in.) 0.04 mm (0.002 in.)

--

-----

-5.455 mm (0.2148 in.) 5.420 mm (0.2134 in.) 0.08 mm (0.003 in.) 0.12 mm (0.005 in.) 2.00 mm (0.079 in.) 2.00 mm (0.079 in.) 47.80 mm (1.882 in.) 47.73 mm (1.879 in.)

--5.55 mm (0.219 in.) 5.55 mm (0.219 in.)

--0.067 mm (0.0026 in.) 0.077 mm (0.0030 in.)

2-3

Standards and Service Limits Engme 81 ock Item Block

Piston

Measurement

Qualification

Standard or New

Service Limit

Warpage of deck

0.07 mm (0.003 in.) max.

0.10 mm (0.004 in.)

Bore diameter

86.000-86.015 mm (3.3858-3.3864 in.)

86.065mm (3.3884 in.)

Bore taper

--

0.05 mm (0.002 in.)

Reboring limit

--

0.5 mm (0.02 in.)

Skirt O.D.at 16.0 mm (0.63 in.) from

85.975-85.985 mm

bottom of skirt

(3.3848-3.3852 in.)

85.965mm (3.3844 in.)

Clearance in cylinder

0.015-0.040 mm

0.08 mm (0.003 in.)

(0.0006-0.0016 in.) Ring groove width

Piston rings

Ring-to-groove clearance

Top

1.220-1.230 mm (0.0480-0.0484 in.)

Second

1.220-1.230 mm (0.0480-0,0484 in.)

1.25 mm (0.049 in.)

Oil

2.805-2.825 mm (0.1104-0.1112 in.)

2.85 mm (0.112 in.)

Top

0.035-0.060 mm (0.0014-0.024 in.)

0.13 mm (0.005 in.)

0.030-0.055 mm (0.0012-0.0022 in.)

0.13 mm (0.005 in.)

0.20-0.35 mm (0.008-0.014 in.)

0.60 mm (0.024 in.)

0.040-0.55 mm (0.016-0.022 in.)

0.70 mm (0.028 in.)

0.20-0.70 mm (0.008-0.028 in.)

0.80 mm (0.031 in.)

21.962-21.965 mm (0.8646-0.8648 in.)

21.954mm (0.8643 in.)

-0.0050-+0.0010 mm

0.004 mm (0.0002 in.)

Second Ring end gap

Top Second Oil

Piston pin

0.0. Pin-to-piston clearance

1.25 mm (0.049 in.)

(-0.00020- +0.00004 in.) Connecting rod

0.005-0.014 mm

Pin-to-rod clearance

0.019 mm (0.0007 in.)

(0.0002-0.0006 in.) 21.970-21.976 mm

Small-end bore diameter

--

(0.8650-0.8652 in.) 56.0 mm (2.20 in.) 0.15-0.35 mm (0.006-0.014 in.)

--

End play installed on crankshaft Main journal diameter

71.976-72.000 mm

--

Rod journal diameter

52.976-53.000 mm

Large-end bore diameter Crankshaft

Nominal

0.45 mm (0,018 in.)

(2.8337 - 2.8346 in.)

--

(2.0857 - 2.0866 in.) Rod/main journal taper

0.005 mm (0.0002 in.) max.

0.010 mm (0.0004 in.)

Rod/main journal out-of-round

0.005 mm (0.0002 in.) max.

0.010 mm (0.0004 in.)

End play

0.10-0.35 mm (0.004-0.014 in.)

0.45 mm (0,018 in.)

0.020 mm (0.0008 in.) max.

0.03 mm (0.0012 in.)

Crankshaft

Runout Main bearing-to-journal oil

0.020-0.044 mm (0.0008-0.0017 in.)

0.050 mm (0.0020 in.)

bearings

clearance 0.020-0.044 mm (0.0008-0.0017 in.)

0.050 mm (0.002 in.)

Rod bearing clearance

2-4

BACK

Engme Lb· u rlcatlon Measurement

Item Engine oil

Standard or New

Qualification

Service Limit

5.0.e (5.3 US qt, 4.4 Imp qt) for engine overhaul

Capacity

4.4.e (4.6 US qt, 3.9 Imp qt) for oil change, including filter 4.0.e (4.2 US qt, 3.5 Imp qt) for oil change, without filter Oil pump

Inner-to-outer rotor clearance

0.04-0.16 mm (0.002-0.006 in.)

Pump housing-to-outer rotor clearance

0.14-0.19 mm (0.006-0.007 in.)

0.20 mm (0.008in.) 0.20 mm (0.008 in.)

Pump housing-to-outer rotor axial

0.02-0.07 mm (0.001-0.003 in.)

0.12 mm (0.005 in.)

clearance Oil pressure with oil temperature at 176°F (80°C)

at idle at 3,000 rpm

70 kPa (0.7 kgf/cm', 10 psi) 490 kPa (5.0 kgf/cm', 71 psi)

coomg r Item Radiator

Measurement

Qualification

Standard or New

Coolant capacity (includes engine,

Engine overhaul

7.5.e (7.9 US qt, 6.6 Imp qt)

heater, hoses and reservoir)

Coolant change

5.6.e (5.9 US qt, 4.9 Imp qt)

I

Reservoir

Coolant capacity

0.6.e (0.6 US qt, 0.5 Imp qt)

Radiator cap

Opening pressure

93-123 kPa (0.95-1.25 kgf/cm', 14-18 psi)

Thermostat

Opening temperature

'98-00 models

Begins to open Fully open

Opening temperature

'01-02 models

169-176°F (76-80°C) 194°F (90°C) 10.0 mm (0.39 in.) min.

Valve lift at fully open Thermostat

Service Limit

Begins to open Fully open

163-171°F (73-77°C) 190°F (88°C) 10.0 mm (0.39 in.) min.

Valve lift at fully open Radiator fan

Thermoswitch "ON" temperature

196-203°F (91-95°C)

switch

Thermoswitch "OFF" temperature

Subtract 5-15°F (3-8°C) from actual "ON" temperature

Fan timer "ON" temperature

217-232°F (103-111°C)

Fan timer "OFF" temperature

Subtract 5- 23°F (3-13°C) from actual "ON" temperature

Fuel and Emissions Item

Measurement

Fuel pressure

Pressure with regulator

regulator

vacuum hose disconnected

Fuel tank

Capacity

Engine idle

Idle speed with headlights

Qualification

Standard or New

I

Service Limit

280 - 330 kPa (2.9 - 3.4 kgf/cm', 41 - 48 psi) 64.8.e (17.1 US gal, 14.3 Imp gal) In [HI or [f]

680±50 rpm

and radiator fan off IdleCO%

0.1 max.

BACK

2-5

Standards and Service Limits Automatic Transmission and Differential Item

ATF (Automatic

Measurement

Capacity

Transmission

Qualification

Use Honda ATF-Z1

Standard or New

Service Umit

For fluid change: 2.9 4 (3.1 US qt, 2.6 Imp qt) For overhaul: 7.2 4 (7.6 US qt, 6.3 Imp qt)

Fluid) ATF pressure

Line pressure

At 1,500 rpm in

!HI or~

BOO-B60 kPa

760kPa

(B.2-B.B kgf/cm', 120-130 psi)

(7.7 kgf/cm', 110 psi)

790-B70 kPa

750kPa

position 4th clutch pressure

At 2,000 rpm in ~ position

3rd clutch pressure

At 2,000 rpm in

2nd clutch pressure

At 1,500 rpm in

1st cl utch pressu re

At 1,500 rpm in

~ position

00 position ill position Torque converter

(B.1-B.9 kgf/cm', 120-130 psi)

(7.6 kgf/cm', 110 psi)

790-B70kPa

750kPa

(B.1-B.9 kgf/cm', 120-130 psi)

(7.6 kgf/cm', 110 psi)

790-B70kPa

750kPa

(B.1-B.9 kgf/cm', 120-130 psi)

(7.6 kgf/cm', 110 psi)

790-B70 kPa

750kPa

(B.1-B.9 kgf/cm', 120-130 psi)

Stall speed: Check with vehicle on

(7.6 kgf/cm', 110 psi) 2,250-2,550 rpm

level ground Clutches

Clutch end plate-to-top disc

1st

1.2-1.4mm

clearance

(0.047-0.055 in.) 2nd

0.B5-1.05 mm

3rd

0.55-0.75 mm

4th

0.55-0.75 mm

1st 45.7 mm (1.BO in.)

43.7 mm (1.72 in.)

2nd

63.0 mm (2.48 in.)

61.0 mm (2.40 in.)

3rd,4th

33.5 mm (1.32 in.)

31.5 mm (1.24 in.)

(0.033-0.041 in.) (0.022-0.030 in.) (0.022-0.030 in.) Clutch return spring free length

1.94 mm (0.076 in.)

Clutch disc thickness Clutch plate thickness

1st and 2nd clutch end plate thickness

3rd and 4th clutch end plate thickness

1st 2.0 mm (0.079 in.)

When discolored

2nd

2.0 mm (0.079 in.)

When discolored

3rd

2.3 mm (0.091 in.)

When discolored

4th

2.0 mm (0.079 in.)

Mark 1 3.10 mm (0.122 in.) Mark2 3.20 mm (0.126 in.)

When discolored

Mark3 3.30 mm (0.130 in.)

When discolored

Mark4 3.40 mm (0.134 in.)

When discolored

Mark6 2.60 mm (0.102 in.)

When discolored

Mark7

2.70 mm (0.106 in.)

When discolored

MarkB 2.BO mm (0.110 in.)

When discolored

Mark9

2.90 mm (0.114 in.)

When discolored

MarkO

3.00 mm (0.11B in.)

When discolored

Mark 1 2.10 mm (0.OB3 in.)

When discolored

2.20 mm (0.OB7 in.)

When discolored

Mark2

Mark 3 2.30 mm (0.091 in.)

When discolored

Mark4 2.40 mm (0.094 in.) Mark 5 2.50 mm (0.09B in.)

When discolored

Mark6 2.60 mm (0.102 in.)

When discolored

When discolored

2.70 mm (0.106 in.)

When discolored

MarkB 2.BO mm (0.110 in.)

When discolored

Mark 9 2.90 mm (0.114 in.)

When discolored

Mark7

2-6

When discolored When discolored

BACK

Item

Valve body

Measurement

Stator shaft needle bearing contact 1.0.

ATF pump drive gear 1.0.

Reverse shift

Service Limit

When worn or

side

(1.0630-1.0638 in.)

damaged

ATF pump side

29.000-29.021 mm

When worn or

ATF pump gear thrust clearance ATF pump gear-to-body clearance

Standard or New

Qualification

Torque converter 27.000-27.021 mm

(1.1417-1.1426 in.)

damaged

0.03-0.05 mm (0.001-0.002 in.)

0.07 mm (0.003 in.)

Drive gear 0.210-0.265 mm (0.0083-0.0104 in.) Driven gear 0.070-0.125 mm (0.0028-0.0049 in.) 14.016-14.034 mm

--When worn or

(0.5518-0.5525 in.)

damaged

ATF pump driven gear shaft 0.0.

13.980-13.99 mm

When worn or

(0.5504-0.5508 in.) Fork finger thickness

5.60-6.00 mm (0.220-0.236 in.)

damaged 5.40 mm (0.213 in.)

fork Park gear and

When worn or

pawl Servo body

damaged Shift fork shaft bore 1.0.

14.000

Shift fork shaft valve bore 1.0.

37.000-37.039 mm

14.010 mm

(0.5512-0.5516 in.) 37.045 mm

(1.4567-1.4582 in.)

(1.4585 in.)

Regulator valve


32.000-32.025 mm

body Accumulator

(1.2598-1.2608 in.)

32.050mm (1.2618 in.)


35.000-35.025 mm

35.05mm

body Stator shaft


(1.3780-1.3789 in.)

(1.3799 in.)

29.000-29.013 mm

29.050mm (1.1437 in.)

(1.1417-1.1422 in.)

(cont'd)

BACK

2-7

Standards and Service Limits Automatic Transmission and Differential (cont'd) Measurement

Item

Mainshaft

Diameter of needle bearing contact area

Qualification

Standard or New

Service Limit

at stator shaft 22.984-23.000 mm (0.9049-0.9055 in.)

When worn or

52.975-52.991 mm

When worn or

at 3rd gear

(2.0856-2.0863 in.) at 4th gear collar 33.975-33.991 mm

damaged damaged When worn or

(1.3376-1.3382 in.)

damaged

1.0. of 3rd gear

59.000-59.019 mm

When worn or

(2.3228-2.3236 in.)

damaged

1.0. of 4th gear

40.000-40.016 mm (1.5748-1.5754 in.)

When worn or

End play of 3rd gear

0.03-0.31 mm (0.001-0.012 in.) 0.10-0.22 mm (0.004-0.009 in.)

--

7.85 mm (0.309 in.)

When worn or

No.2 7.90 mm (0.311 in.)

When worn or

No.3 7.95 mm (0.313 in.)

When worn or

No.4 8.00 mm (0.315 in.)

When worn or

No.5 8.05 mm (0.317 in.)

When worn or

No.6 8.10 mm (0.319 in.)

When worn or

5.00 mm (0.197 in.)

When worn or

Length of 4th gear collar

58.5-58.6 mm (2.303-2.307 in.)

damaged --

4th gear collar flange thickness

4.45-4.60 mm (0.175-0.181 in.)

When worn or

32 mmsealing ring

1.850-1.950 mm (0.073-0.077 in.)

damaged 1.800 mm (0.071 in.)

29 mm sealing

1.850-1.950 mm (0.073-0.077 in.)

1.800 mm (0.071 in.)

End play of 4th gear 41 x 73 mm thrust shim thickness

No.1

damaged

-damaged damaged damaged damaged damaged damaged


Sealing ring thickness

27x47x5mm

ring 2.025 - 2.060 mm (0.079 - 0.081 in.)

2.080 mm (0.082 in.)

3rd clutch

5.97 - 5.98 mm (0.2350 - 0.2354 in.)

5.95 mm (0.2343 in.)

4th clutch

11.47 - 11.48 mm (0.4516 - 0.4520 in.) 11.45 mm (0.4508 in.) 6.018 - 6.030 mm (0.2369 - 0.2374 in.) 6.045 mm (0.2380 in.)

Width of sealing ring groove Clutch feed pipe 0.0. Clutch feed pipe bushing 1.0.

3rd clutch 4th clutch

11.500 -11.518mm (0.4528 - 0.4535 in.)

2-8

BACK

11.530 mm (0.4539 in.)

Measurement

Item

Countershaft

Diameter of needle bearing contact area

Qualification

Standard or New

Service Limit

at 4th gear 34.975-34.991 mm (1.3770-1.3776 in.)

When worn or

at 2nd gear 39.979-40.000 mm (1.5740-1.5748 in.)

When worn or

at park gear

41.964-41.980 mm

When worn or

(1.6521-1.6528 in.) at right end

38.505-38.515 mm

damaged When worn or

damaged damaged

(1.5159-1.5163 in.)

damaged

1.0. of 4th gear

41.000-41.016 mm (1.6142-1.6148 in.)

When worn or

1.0. of idler gear

50.000-50.016 mm

When worn or

damaged

(1.9685-1.9691 in.)

damaged

1.0. of reverse gear

46.000-46.016 mm

When worn or

(1.8110-1.8116 in.) End play of 1st gear End play of 4th gear

0.00-0.33 mm (0.000-0.013 in.)

damaged --

End play of idler gear

0.015-0.045 mm (0.0006-0.0018 in.)

End play of reverse gear

0.10-0.25 mm (0.004-0.010 in.)

Length of distance collar

53.92-53.96 mm (2.123-2.124 in.)

Cotter thickness

1.99-2.02 mm (0.078-0.080 in.)

------

Reverse selector hub 0.0.

55.87 -55.90 mm (2.1996-2.2008 in.)

Whenwprnor

0.04-0.27 mm (0.002-0.011 in.)

damaged

(cont'd)

BACK

2-9

Standards and Service Limits Automatic Transmission and Differential (cont'd) Item

Secondary shaft

Measurement


Qualification

Standard or New

Service Limit

at 1st gear

37.978-37.993 mm (1.4952-1.4958 in.)

damaged

at 2nd gear

33.986-33.999 mm

When worn or

area

When worn or

(1.3380-1.3385 in.)

damaged

1.0. of 1st gear

44.000-44.016 mm

When worn or

(1.7323-1.7329 in.)

damaged

1.0. of 2nd gear

40.000-40.016 mm

When worn or

(1.5748-1.5754 in.)

damaged

End play of 1st gear

0.07-0.15 mm (0.003-0.006 in.)

--

0.04-0.12 mm (0.002-0.005 in.)

--

No.1

6.85 mm (0.270 in.)

When worn or

No.2

6.90 mm (0.272 in.)

When worn or

No.3

6.95 mm (0.274 in.)

When worn or

No.4 7.00 mm (0.276 in.)

When worn or

No.5 7.05 mm (0.278 in.)

When worn or

No.6 7.10 mm (0.280 in.)

When worn or

No.1

4.90 mm (0.193 in.)

When worn or

No.2

4.95 mm (0.195 in.)

When worn or

No.3

5.00 mm (0.197 in.)

When worn or

No.4

5.05 mm (0.199 in.)

When worn or

No.5

5.10 mm (0.201 in.)

When worn or

No.6 5.15 mm (0.203 in.)

When worn or

5.20 mm (0.205 in.)

When worn or

1.99-2.02 mm (0.078-0.080 in.)

--

End play of 2nd gear 38 x 56.5 mm splined washer thickness

damaged damaged damaged damaged damaged damaged 37 x 55 mm thrust shim thickness

damaged damaged damaged damaged damaged damaged No.7

damaged Cotter thickness

Reverse idler gear

Sealing ring thickness

1.890-1.950 mm (0.074-0.077 in.)

1.800 mm (0.071 in.)

Width of sealing ring groove

2.025-2.060 mm (0.080-0.081 in.)

2.080 mm (0.082 in.)


7.97-7.98 mm (0.3138-0.3142 in.)

7.95 mm (0.3130 in.)


8.000-8.015 mm (0.3150-0.3156 in.)

8.030 mm (0.3161 in.)

13.990-14.000 mm

When worn or


at reverse idler

(0.5508-0.5512 in.)

damaged

End play

0.03-0.36 mm (0.001-0.014 in.)

--

I.D.

18.007 -18.020 mm (0.7089-0.7094 in.)


0.97 -1.03 mm (0.038-0.041 in.)

--

0.97-1.03 mm (0.038-0.041 in.)

--

14.006-14.024 mm

When worn or

area


gear shaft

Transmission housing side Reverse idler gear shaft holder side

1.0. of reverse idler gear shaft holder

2-10

(0.5514-0.5521 in.)

damaged

1.0. oftransmission housing of reverse

14.006-14.024 mm

--

idler gear shaft contact area

(0.5514-0.5521 in.)

BACK

Item

Measurement

Standard or New

Qualification

Wire Diameter Main valve body

Modulator valve spring

1.6mm

Shift valve C spring

springs (see page 14-161)

Shift valve D spring Shift valve E spring

49.1 mm

(0.031 in.)

(0.260 in.)

(1.933 in.)

0.7mm

6.6mm

35.7 mm

(0.028 in.)

(0.260 in.)

(1.406 in.)

0.7mm

6.6mm

32.2mm

(0.028 in.)

(0.260 in.)

(1.268 in.) (1.185 in.)

0.9mm

7.6mm

63.0mm

(0.035 in.)

(0.299 in.)

(2.480 in.)

0.6mm

5.8mm

14.5 mm

(0.024 in.)

(0.228 in.)

(0.571 in.)

Torque converter check

1.2mm

8.6mm

35.1 mm

valve spring

(0.047 in.)

(0.339 in.)

(1.382 in.)

Servo control valve spring

0.7mm

6.6mm

35.7 mm

(0.028 in.)

(0.260 in.)

(1.406 in.)

0.7mm

6.1 mm

17.8mm

(0.028 in.)

(0.240 in.)

(0.701 in.)

5.5mm

37.4 mm

30.3mm

(0.217 in.)

(1.472 in.)

(1.193in.)

Stator reaction spring Regulator valve spring A

164) Regulator valve spring B Lock-up control valve spring Lock-up timing valve spring Shift valve B spring

springs (see Shift valve A spring CPC valve A spring CPC valve B spring 4th accumulator spring A 4th accumulator spring B 3rd accumulator spring A 3rd accumulator spring B 1st accumulator spring B

body springs (see page 14-

(1.319 in.)

30.1 mm

body springs

Accumulator

(0.409 in.) 6.6mm

(0.339 in.)

Reverse CPC valve spring

page 14-165)

(0.063 in.) 0.8mm

8.6mm

Cooler check valve spring

Servo body

33.5mm

1.1 mm

Lock-up shift valve spring

(see page 14-

Free Length

10.4 mm

(0.043 in.)

Relief valve spring

Regulator valve

D.D.

1st accumulator spring A

166) 2nd accumulator spring B 2nd accumulator spring A

1.8mm

14.7 mm

87.5mm

(0.071 in.)

(0.579 in.)

(3.445 in.)

1.7mm

9.4mm

44.0mm

(0.067 in.)

(0.370 in.)

(1.732 in.)

0.7mm

6.6mm

42.9mm

(0.028 in.)

(0.260 in.)

(1.689 in.)

0.65mm

6.6mm

34.8mm

(0.026 in.)

(0.260 in.)

(1.370 in.)

0.8mm

7.1 mm

40.4mm

(0.031 in.)

(0.280 in.)

(1.591 in.)

0.8mm

7.1 mm

40.4mm

(0.031 in.)

(0.280 in.)

(1.591 in.)

0.7mm

6.1 mm

17.8 mm

(0.028 in.)

(0.240 in.)

(0.701 in.)

0.7mm

6.1 mm

17.8mm

(0.028 in.)

(0.240 in.)

(0.701 in.)

2.6mm

19.6 mm

66.4mm

(0.102 in.)

(0.772 in.)

(2.614 in.)

2.4mm

12.8mm

51.5 mm

(0.094 in.)

(0.504 in.)

(2.028 in.)

2.6mm

19.6 mm

66.4 mm

(0.102 in.)

(0.772 in.)

(2.614 in.)

No. of Coils 9.8 21.7 17.2 13.4 10.7 22.4 6.8 14.3 17.2 7.9 2.12 16.5 13.4 14.2 15.6 16.9 16.9 7.9 7.9 9.7 11.5 9.7

2.4mm

12.8 mm

51.5 mm

(0.094 in.)

(0.504 in.)

(2.028 in.)

2.7mm (0.106 in.)

15.0 mm

52.5mm (2.067 in.)

10.3

(0.591 in.)

2.5mm

21.6 mm

87.5 mm

11.8

(0.098 in.)

(0.850 in.)

(3.445 in.)

2.4mm

12.6 mm

53.5mm

(0.094 in.)

(0.496 in.)

(2.106 in.)

2.7mm

19.6mm

66.3 mm

(0.106 in.)

(0.772 in.)

(2.610 in.)

11.5

12.9 9.9 (cont'd)

BACK

2-11

Standards and Service Limits Automatic Transmission and Differential (co nt' d) Item

AfT differential

Measurement

Qualification

Standard or New

Service Limit

--

Pinion shaft contact area J.D.

18.010-18.028 mm

Carrier-to-pinion shaft clearance

0.023-0.057 mm (0.001-0.002 in.)

0.1 mm (0.004 in.)

Driveshaft contact area J.D.

30.025-30.045 mm (1.182-1.183 in.)

--

Carrier-to-driveshaft clearance

0.045-0.086 mm (0.002-0.003 in.)

0.12 mm (0.005 in.)

Carrier-to-intermediate shaft clearance

0.080-0.116 mm (0.003-0.005 in.)

--

2.7-3.9 N·m

Adjust

carrier

(0.7091-· 0.7098 in.)

Tapered roller bearing starting torque

For new bearing

(preload)

(28-40 kgf·cm, 24-35Ibf·in.) For used bearing

2.5-3.6 N·m

Adjust

(25-37 kgf·cm, 22-32Ibf·in.)

AfT differential

Backlash

0.05-0.15 mm (0.002-0.006 in.)

pinion gear

J.D.

18.042-18.066 mm

Pinion gear-to-pinion shaft clearance

0.055-0.095 mm (0.0022-0.0037 in.)

---

(0.7103-0.7113 in.) 0.12 mm (0.005 in.)

steermg Item

Steering wheel

Measurement

Rotational play measured at outside edge Starting load measured at outside edge

Gearbox

Qualification

With engine

Standard or New

Service Limit

0-10 mm (0-0.39 in.)

--

30 N (3.1 kgf, 6.8 Ibs)

--

running With engine running

Angle of rack guide screw loosened

60 o ±5°

from locked position Pump

Output pressure with shut-off valve

7,600-8,300 kpa

closed

(78-85 kgf/cm', 1,110-1,210 psi)

Power steering

Capacity

fluid

Use Genuine

For fluid change: 0.4 e (0.42 US pt, 0.35 Imp qt)

Honda Power

For system overhaul: 1.1

e (1.16 US qt, 0.97 Imp qt)

Steering Fluid Used belt: 13.0-16.5 mm (0.51-0.65 in.)

Power steering


pump belt

applied mid-way between pulleys

New belt: 8.5-11.0 mm (0.34-0.43 in.)

NOTE: Adjust a

Tension (measured with belt tension

Use belt: 390-540 N (40-55 kgf, 88-120 Ibs))

new belt to the

gauge)

New belt: 740-880 N (75-90 kgf, 170-200 Ibs))

new belt spec, run the engine for 5 minutes, then readjust it to the used belt spec.

2-12

BACK

.~

suspenslon Measurement

Item

Wheel alignment

Qualification

Front 0000'± 1° Rear -0030'± 1°

Caster

Front 2°48'± 1°

Total toe

Front 0±2 mm (O± 1/16 in.) Rear

Front wheel turning angle

Inside wheel Outside wheel

Aluminum wheel

Standard or New

Camber

Runout

Steel wheel

Runout

Wheel bearings

End play

Service Limit

IN 2±2 (1/16± 1116 in.) 38°32'±2° 31°03' (Reference)

Axial

0-0.7 mm (0-0.03 in.)

Radial

0-0.7 mm (0-0.03 in.)

2.0 mm (0.08 in.) 1.5 mm (0.06 in.)

Axial

0-1.0 mm (0-0.04 in.)

2.0 mm (0.08 in.)

Radial

0-1.0 mm (0-0.04 in.)

1.5 mm (0.06 in.)

Front 0-0.05 mm (0-0.002 in.) Rear

0-0.05 mm (0-0.002 in.)

Brakes Item

Parking brake lever

Measurement

Qualification

Distance travelled when

Standard or New

Service Limit

6-9 clicks

pulled with 196 N (20 kgf, 441bs) of force

Brake pedal

Pedal height (carpet removed)

148 mm (513/16 in.)

Free play

1-5 mm (1/16-3/16 in.)

Master cylinder

Piston-to-pushrod clearance

Brake disc

Thickness

0-0.4 mm (0-0.015 in.) Front 22.9-23.1 mm (0.90-0.91 in.) Rear

Runout Parallelism Brake pads

21.0 mm (0.83 in.)

8.9-9.1 mm (0.35-0.36 in.)

8.0 mm (0.31 in.)

Front

0.10 mm (0.004 in.)

Rear

0.10 mm (0.004 in.) 0.015 mm (0.0006 in.)

Front and rear

Thickness

Front

10.5 -11.5 mm (0.41 - 0.45 in.)

1.6 mm (0.06 in.)

Rear

8.9-9.1 mm (0.355-0.358 in.)

1.6 mm (0.06 in.)

A"Ir Con d"" Itlonmg Item

Refrigerant

Measurement

Qualification

I

Standard or New

Service Limit

Type

HFC-134a (R-134a)

Capacities of systems

Calsonic condenser 450-500 g (15.9-17.6 oz) Showa condenser 600-650 g (21.2-22.9 oz)

Refrigerant oil

Type Capacity of components

DENSO: ND-OIL 8 (PIN 38897-PR7-A01AH or 38899-PR7-A01) Condenser

25 me (5/6 fl

Evaporator

40 me (1 1/3 fl

Each line and

OZ,

0.9 Imp OZ)

OZ,

1.4 Imp

OZ)

10 me (1/3 fl

OZ,

0.4 Imp OZ)

10 me (1/3 fl

OZ,

0.41mp oz)

hose Receiver Compressor Compressor (DENSO)

Starter coil resistance

at 68°F (20°C)

Pulley-to-pressure plate

160-175 ml! (5 1/3-6 fl

OZ,

5.6-6.2 Imp OZ)

3.4-3.8 Q 0.5±0.15 mm (O.02±0.006 in.)

clearance

BACK

2-13

Design Specifications Item

DIMENSIONS

Measurement

Qualification

Overall length

Specification

4-door

4,795 mm (188.8 in.)

2-door

4,745 mm (186.8 in.)

Overall width

1,785 mm (70.3 in.)

Overall height

4-door

Wheelbase Track

WEIGHT (U.S.A.)

1,455 mm (57.3 in.)

2-door

1,405 mm (55.3 in.)

4-door

2,715 mm (106.9 in.)

2-door

2,670 mm (105.1 in.)

Front

1,555 mm (61.2 in.)

Rear

1,535 mm (60.4 in.)

Ground clearance

158 mm (6.2 in.)

Seating capacity

Five

Gross Vehicle Weight Rating

4-door

4,2351bs

(GVWR)

2-door

4,1901bs 1,920 kg

WEIGHT

Gross Vehicle Weight Rating

4-door

(CANADA)

(GVWR)

2-door

ENGINE

Type

1.900 kg Water-cooled, 4-stroke SOHC VTEC V6 gasoline engine

Cylinder arrangement

60° V6-cylinder, transverse

Bore and stroke

86.0 x 86.0 mm (3.39 x 3.39 in.)

Displacement

2,997 cm' (m~) (183 cu in.)

Compression ratio

9.4

Valve train

Belt driven, SOHC VTEC 4 valves per cylinder

Lubrication system

Forced, wet sump, with trochoid pump

Oil pump displacement

at 6,000 engine rpm

Water pump displacement

at 6,000 engine rpm

58.4 Ii (61.7 US qt, 51.41mp qt)/minute 172 Ii (182 US qt, 151 Imp qt)/minute

Fuel required

UNLEADED gasoline with 86 pump octane number or

Type

Gear reduction

Normal output

1.6kW

higher STARTER

AUTOMATIC

Nominal voltage

12 V

Hour rating

30 seconds

Direction of rotation

Clockwise as viewed from gear end

Type

Electronically controlled automatic, 4-speed forward, 1

Primary reduction

Direct 1:1

TRANSMISSION

reverse Gear ratio

Final reduction

2-14

2.534

1st 2nd

1.502

3rd

0.947

4th

0.608

Reverse

1.846

Type

Single helical gear

Gear ratio

4.200

BACK

Item

STEERING

Qualification

Measurement

Overall ratio

15.77

Turns,lock-to-lock

3.05 380 mm (15.0 in.)

Steering wheel diameter SUSPENSION

WHEEL

Front

Independent double wishbone, coil spring with stabilizer

Rear

Five-link double wishbone

Shock absorber

Front and rear

Telescopic, hydraulic, nitrogen gas-filled

Camber

Front

0°

Type

Rear

-0°30'

Caster

Front

2°48'

Total toe

Front

o mm (Din.)

Rear

In 2 mm (1/16 in.)

ALIGNMENT

BRAKES

Type of service brake

Front

Power-assisted self-adjusting ventilated disc

Rear

Power-assisted self-adjusting solid disc

Front

59 cm' x 2 (9.0 sq in. x 2)

Rear

28 cm' x 2 (4.3 sq in. x 2)

Mechanical actuating, rear wheels

Type of parking brake Pad friction surface area TIRES

Specification

Power-assisted rack and pinion

Type

Size of front and rear tires

P205/65 R15 92V

Size of spare tires

T135/90D15100M

AIR

Cooling capacity

CONDITIONING

Compressor

5,240 Kcal/h (20,800 BTU/h) Type/Manufacturer

Swash plate/DENSO

Number of cylinders

10

Capacity

177.7 mll/rev. (10.84 cu in/rev.)

Maximum speed

7,600 rpm

Lubricant capacity

160 mll (5 1/3 fl oz)

Lubricant type

ND-OIL 8

Condenser

Type

Corrugated fin

Evaporator

Type

Corrugated fin

Blower

Type

Sirocco fan

Motor input

230W/12 V

Speed control

Manual AlC: 4-speed Auto AlC: Infinite variable

Maximum capacity Temperature control Compressor clutch

520 m'/h (18,300 cu ft/h) Air-mix type

Type

Dry, single plate, Poly-V belt drive

Electrical power

40 W maximum at 12 V

consumption at 68°F (20°C) Refrigerant

Type

HFC-134 a (R-134 a)

Quantity

Calsonic condenser 450-500 g (15.9-17.6 fI oz) Showa condenser 600 - 650 g (21.2 - 22.9 fl oz)

BACK

2-15

Design Specifications Measurement

Item

ELECTRICAL RATINGS

Qualification

Specification

12 V-55 AH/5 hours

Battery Starter

12 V-1.6 kW

Alternator

12 V-100A

Fuses

Under-hood fuse/relay box

100A, 50A, 40A, 30A, 20A, 15A

Under-dash driver's fuse/

30A, 15A, 10A, 7.5A

relay box Under-dash passenger's

30A, 20A, 10A, 7.5A

fuse/relay box Light bulbs

Headlight high beam

12V-60W

Headlight low beam

12 V-51 W

Front turn signal/Front side

12 V-24 W/2.2 CP (candlepower) (two filaments)

marker lights

2-16

Front parking lights

12V-3CP

Rear turn signal lights

12V-21 W

Brake/Taillights

12 V-21/5 W

Taillight

12V - 3CP

High mount brake light

12 V-21 W

Back-up lights

12 V-21 W

License plate light

12 V-3 CP

Ceiling light

12V-8W

Trunk lights

12V-5W

Door courtesy lights

12 V-2 CP

Vanity mirror lights

12V-1.1W

Glove box light

12V-3.4W

Spotlights

12 V-4 CP

Gauge lights

12V-1.26W,3.78W

Indicator lights

12V-LED,14V-0.56W,0.7W,1.4W

Panel and pilot lights

14 V-0.56 W, 0.84 W

Heater control panel lights

8V-1.2W, 14V-1.12W, 1.4W

BACK

Body Specifications

4-door sedan Unit: mm (in.)

Q) co
........

1,455 (57.3)

N

M

...: ..... 0

In In In

In

co

.....

.... ....

(cant'd)

BACK

2-17

Body Specifications (cont'd) 2-door coupe

Unit: mm (in.)

o

o

...

Lti c

00

..0

......

.. 1.405 (55.31

00

..

N

+H----+--I1I~1--t

...:

M

ci

....

III III III

III 00 ....

... ...

tt--+--'- ,

2-18

BACK

Maintenance Lubricants and Fluids ....................................... 3-2 Maintenance Schedule for Normal Conditions (1998-2000 Models) Listed by Distance/Time ............................................... 3-4

Maintenance Schedule for Severe Conditions (1998-2000 Models) Listed by Distance/Time ............................................... 3-6


Maintenance Schedule for Normal Conditions (2001-2002 Models) Listed by Distance/Time ............................................... 3-10

Maintenance Schedule for Severe Conditions (2001-2002 Models) Listed by Distance/Time ............................................... 3-12


Lubricants and Fluids

For details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work procedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.

LUBRICATION POINTS

NO. 1

Engine

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Transmission Brake line (includes ABS line) Power steering gearbox Throttle cable end (Dashboard lower panel hole) Throttle cable end (Throttle link) Brake master cylinder pushrod Pedal linkage Battery terminals Fuel fill lid Hood hinges and hood latch Trunk hinges and latch Door hinges, upper and lower Door opening detent Caliper piston boot, caliper pins, and boots. Brake line joints (Front and rear wheelhouse) Power steering system Air conditioning compressor

API CERTIFICATION SEAL

LUBRICANT Honda Motor Oil. API Service Grade: Use SJ "Energy Conserving" grade oil. The oil container may also display the API Certification seal shown below. Make sure it says "For Gasoline Engines." SAE Viscosity: See chart below. Honda ATF-Z1*' Honda DOT 3 Brake Fluid*2 Steering grease PIN 08733-B070E Silicone grease Multi-purpose grease

Honda White Lithium Grease

Silicone grease Rust preventives Honda Power Steering Fluid*3 Compressor oil: DENSO: NO-OIL 8 (P/N 38897-PR7A01AH or 38899-PR7-A01) For Refrigerant: HFC-134 a (R-134 a)

Recommended Engine Oil Engine oil viscosity for ambienttemperature ranges For '01-02 models

For '98-00 models

.1

1

-20

20

RWP=:4.j.@ 40

60

I:

1

100"F

80

I

I

I

I

I

I

-30

-20

-10

10

20

30

I

40'1:

+

II I I I I II -20

0

I ~O

I

I

-20

-10

20

40

60

100'F

80

I

I

I

I

0

10

20

30

I

4O'C

*1: Always use Honda ATF-Z1. Using a non-Honda ATF can affect shift quality. *2: Always use Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system. *3: Always use Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmission fluid can cause increased wear and poor steering in cold weather. NOTE: Lubricate all hinges, latches, and locks once a year. In corrosive areas, more frequent lubrication is necessary. We recommend Honda White Lithium Grease.

3-2

BACK

@

@

® @

@

i

® ®

I

./

BACK

3-3

Maintenance Schedule for Normal Conditions (1998~2000 Models) Listed by Distance/Time This two-page maintenance schedule outlines the minimum required maintenance. Service at the indicated time or distance, whichever comes first. Use the Maintenance Schedule for Severe Conditions if the vehicle meets any of the qualifiers listed in the severe conditions schedule or if the vehicle is normally driven in Canada. 7,500 mil 12,000 km/D Do items in A. 15,000 mil 24,000 km/ 1 year D Do items in A and B. 22,500 mil 36,000 km/D Do items in A. 30,000 mil 48,000 km/ 2 years D Do items in A, B, and C. 37 ,500 mil 60,000 km/ D Do items in A. 45,000 mil 72,000 km/3 years D Replace coolant (see page 10-10). Capacity: 5.6 fl (5.9 US qt, 4.9 Imp qt). Use Honda All Season Antifreeze/coolant Type 2. D Replace brake fluid. Use Honda DOT 3 Brake Fluid. Fill to between marks on reservoir. D Do items in A and B. 52,500 mil 84,000 km/D Do items in A. D Do items in A, B, and C. 60,000 mil 96,000 km/4 years 67,500 mi/108,000 km/D Do items in A. 75,000 mi/120,000 km/ 5 years D Replace coolant (see page 10-10). Capacity: 5.6 fl (5.9 US qt, 4.9 Imp qt). Use Use Honda All Season Antifreeze/coolant Type 2. D Do items in A and B. 82,500 mi/132,000 km/ D Do items in A. 90,000 mi/144,000 km/ 6 years D Replace transmission fluid. 2.9 fl (3.1 US qt, 2.6 Imp qt). Use Honda ATF-Z1 (see page 14-113). D Replace brake fluid. Use Honda DOT 3. Fill to between marks on reservoir. D Do items in A, B, and C. 97 ,500 mi/156,000 km/ D Do items in A. 105,000 mi/168,000 km/7 years D Inspect valve clearance (cold) (see page 6-13). Intake: 0.20-0.24 mm (0.008-0.009 in.), Exhaust: 0.28-0.32 mm (0.011-0.013 in.) D Replace spark plugs (see page 4-24). Use NGK (PZFR5F-11) or DENSO (PKJ 16CR-L11). GAP: 1.0-1.1 mm (0.039-0.043 in) D Replace timing belt (see page 6-19) and inspect water pump (see page 10-10). D Check idle speed. Should be 680±50 rpm in [HI or III position (see page 11-69). D Replace coolant (see page 10-10). Capacity: 5.6 fl (5.9 US qt, 4.9 Imp qt). Use Honda All Season Antifreeze/coolant Type 2. D Do items in A and B. 112,500 mi/181 ,000 km/D Do items in A. 120,000 mi/192,000 km/ 8 years D Do the items in A, B, and C. '

3-4

BACK

Do the items in parts A, B, and C as required for mileage/time interval listed. A

D D

Replace engine oil (see page 8-5). -Capacity with filter change: 4.4 A (4.6 US qt, 3.9 Imp qt) Rotate tires. Follow the pattern shown in the Owner's Manual -Check tire inflation and condition.

B

D D D D

D D D D D D D

Replace engine oil filter (see page 8-5). Inspect front and rear brakes (see page 19-2). o Check pads and discs for wear (thickness), damage, and cracks. o Check calipers for damage, leaks, and tightness of mount bolts. Check parking brake adjustment. Should be fully applied within 6 to 9 clicks. Inspect tie rod ends, steering gearbox, and boots (see page 17-12). o Check rack grease and steering linkage. o Check boots for damage and leaking grease. o Check fluid line for damage and leaks. Inspect suspension components. o Check bolts for tightness. o Check condition of ball joint boots for deterioration and damage. Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3)*'. Inspect brake hoses and lines (including ABS). -Check the master cylinder, proportioning control valve, and ABS modulator for damage and leakage. Check all fluid levels and condition offluids; check for leaks. If necessary, add ATF (see page 14-112), engine coolant, brake fluid, and windshield washer fluid. Inspect cooling system hoses and connections. o Check for damage, leaks, and deterioration. o Check for proper fan operation. Inspect exhaust system* . Check catalytic converter heat shield, exhaust pipe, and muffler for damage, leaks, and tightness (see page 9-4). Inspect fuel lines and connections*. Check for loose connections, cracks and deterioration; retighten loose connections and replace damaged parts (see page 11-74).

C

D Replace air cleaner element. D Inspect and adjust drive belt. Look for cracks and damage, then check belt deflection by pushing on it (about 22 Ibs) midway between the pulleys. - PIS pump belt: 13.0-16.5 mm (0.51-0.65 in) (see page 17-10). Replace the air conditioning filter (see page 21-26)*'. o Replace it twice as often (at 15,000 mile interval) if the vehicle is driven mostly in urban areas that have high concentrations of soot in the air from industry and diesel-powered vehicles. o Replace it whenever airflow from the climate control system is less than normal. o

D

According to state and federal regulations, failure to do the maintenance service items marked with asterisk (*) will not void customer's emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability. *': Refer to '98-02 ACCORD Service Manual (P/N 6158400)

BACK

3-5

Maintenance Schedule for Severe Conditions (1998-2000 Models) Listed by Distance/Time Service at the indicated distance or time, whichever comes first. Use this schedule ifthe vehicle is driven MAINLY in Canada or in any of the following conditions; if only OCCASIONALLY driven in these conditions, use the Normal Conditions schedule (see page 3-4). Severe Driving Conditions • Less than 5 miles (8 km) per trip or, in freezing temperatures, less than 10 miles (16 km) per trip • In extremely; hot weather (over 90°F/32°C) • Extensive idling or long periods of stop-and-go driving • Trailer towing • On muddy, dusty, or de-iced roads • Driving in mountainous conditions

o o o

3,750 mil 6,000 km/ Replace oil and filter. 7,500 mil 12,000 km/Do items in A. 11,250 mil 18,000 km/Replace oil and filter. 15,000 mil 24,000 km/ 1 year Clean air cleaner element with low pressure air. Do items in A and B. 18,750 mil 30,000 km/Replace oil and filter. 22,500 mil 36,000 km/ 1 1/2 years: Do items in A. 26,250 mil 42,000 km/ Replace oil and filter 30,000 mil 48,000 km/ 2 years: Do items in A, B, and C 33,750 mil 54,000 km/Replace oil and filter. Do items in A. 37,500 mil 60,000 km/2 1/2 years: 41,250 mil 66,000 km/Replace oil and filter. 45,000 mil 72,000 km/ 3 years: Clean air cleaner element with low pressure air. Replace coolant (see page 10-10). Capacity: 5.6!! (5.9 US qt, 4.9 Imp qt). Use Honda All Season Antifreeze/Coolant Type 2. Replace brake fluid (see page 19-7)*' . • Use Honda DOT 3; fill to between marks on reservoir. Do items in A and B. 48,750 mil 78,000 km/Replace oil and filter. Do items in A. 52,500mi/ 84,000 km 3 1/2 years: 56,250 mil 90,000 km/Replace oil and filter. 60,000 mil 96,000 km/ 4 years: Replace timing belt (see page 6-19) and inspectthe water pump (see page 10-9) if the vehicle is regularly driven in weather over 110°F (43°C) or under -20°F (-29°C); If not, replace the belts at 105,000 miles. Do items in A, Band C. 63,750 mi/l02,000 km/ Replace oil and filter. Do items in A. 67,500 mi/l08,000 km 41/2 years: 71,250 mi/114,000 kmReplace oil and filter. 75,000mi/120,000 km/5 years: Clean air cleaner element with low pressure air. Replace coolant (see page 10-10). Capacity: 5.6 II (5.9 US qt, 4.9 Imp qt). Use Honda All Season Antifreeze/CoolantType 2. Do items in A and B. 78,750 mi/126,000 km/Replace oil and filter. 82,500 mi/132,000 km/51/2 years Do items in A. Replace oil and filter. 86,250 mi/138,000 km/90,000 mi/144,000 km/ 6 years: Replace brake fluid (see page 19-7)*'. Use Honda DOT 3 brake fluid; fill to between marks on reservoir. Do items in A, Band C. Replace oil and filter. 93,750 mi/150,000 km/Do items in A. 97,500 mi/156,000 km/6 1/2 years: Replace oil and filter. 101,250 mi/162,000 km/105,000 mi/168,000 km/7 years: Clean air cleaner element with low pressure air. Inspect valve clearance (cold) (see page 6-13I1ntake: 0.20-0.24 mm (0.008-0.009 in.) Exhaust: 0.28-0.32 mm (0.011-0.013 in.) Replace spark plugs. Use NGK (PZFR5F-ll) or DENSO (PKJ16CR-L 11). Gap: 1.0-1.1 mm (0.039-0.043 in) (see page 4-24). Replace timing belt (see page 6-19), and inspect the water pump (see page 10-10) only if the belts was not replaced at 60,000 miles. Check idle speed. Should be 680±50 rpm in lID or [f] position (see page 11-69). Replace coolant (see page 10-10). Capacity: 5.6 II (5.9 US qt, 4.9 Imp qt). Use Honda All Season Antifreeze/Coolant Type 2. Do items in A and B. 108,750 mi/174,000 km/ 0 Replace oil and filter. 0 Do items in A. 112,500 mi/180,000 km/ 71/2 years: 116,250 mi/186,OOO km/ 0 Replace oil and filter. 0 Do items A, B, and C. 120,000 mi/192,000 km/ 8 years: *': Refer to '98-02 ACCORD Service Manual (P/N 61S8400)

o o

o o o o

o o o o o

o o

o o o o o o. o

o o o

o o o

o o o o o o

o o o o o o o

3-6

BACK

Do the items in parts A, B, and C as required for mileage/time interval. A

D D D

D D D

Replace engine oil and filter (see page 8-5). - Capacity with filter change: 4.411 (4.6 US qt, 3.9 Imp qt) Inspect front and rear brakes, every 6 months if vehicle is driven less than 7,500 miles per year (see page 19-2). • Check pads and discs for wear (thickness), damage, and cracks. • Check calipers for damage, leaks, and tightness of mount bolts. Rotate tires, if the vehicle has been driven the distance listed. Follow the pattern shown in the Owner's Manual. (Check tire inflation and condition.) Inspecttie rod ends, steering gearbox, and boots (see page 17-12). • Check rack grease and steering linkage. • Check boots for damage and leaking grease. • Check fluid lines for damage and leaks. Inspect suspension components. • Check bolts for tightness. • Check condition of ball joint boots for deterioration and damage. Inspect drives haft boots. Check boots for cracks and boot bands for tightness (see page 16-3)*'.

B

D D D

D D

D D D D

Check parking brake adjustment. - Should be fully applied within 6 to 9 clicks. Lubricate locks, latches, and hinges with Honda white lithium grease. Inspect brake hoses and lines (including ABS). Check the master cylinder, proportioning control valve, and ABS modulator for damage and leakage (see page 19-30)*'. Check fluid levels and condition of fluids; check for leaks. If necessary, add ATF (see page 14-112), engine coolant, brake fluid, and windshield washer fluid. Inspect cooling system hoses and connections. • Check for damage, leaks, and deterioration. • Check for proper fan operation. Inspect exhaust system. * Check catalytic converter heat shield, exhaust pipe, and muffler for damage, leaks, and tightness (see page 9-4). Inspect fuel lines and connections. * Check for loose connections, cracks and deterioration; retighten loose connections and replace damaged parts (see page 11-74). Check all lights. Check function of all interior and exterior lights, and the positions of the headlights (see page 22-98)*'. Inspect the vehicle underbody. Check the paint for damage, scratches, stone chipping, and dents.

C

D D D D

Replace air cleaner element. Inspect and adjust drive belt. Look for cracks and damage, then check tension by pushing on each belt (about 22 Ibs) midway between the pulleys: • PIS pump belt: 13.0- 16.5 mm (0.51-0.65 in) (see page 17-10) Replace transmission fluid. Use Honda ATF-Z1 (ATF). Replace air conditioning filter, every 15,000 miles if vehicle is driven mostly where air has high concentration of soot from industry and diesel-powered vehicles; also replace it anytime airflow is less than usual (see page 21-26)*'.

According to state and federal regulations, failure to do the maintenance items marked with asterisk (*) will not void customer's emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability. *': Refer to '98-02 ACCORD Service Manual (P/N 6158400)

BACK

3-7

Maintenance Schedule for Normal and Severe Conditions (1998-2000 Models) Listed by Maintenance Item Service at the indicated distance or time, whichever comes first. • If driven in normal conditions, do items with a dot (.) . • If driven in severe conditions (see page 3-6) or normally driven in Canada, do the circle (0) and dot (.1 items. Service at the indicated distance or time, whichever comes first.

miles x 1000 kmx 1000 years

3.75

7.5

11.25

15

18.75

22.5

26.25

30

33.75

37.5

6

12

18

24

30

36

42

48

54

60

-

1/2

-

1

-

11/2

-

2

-

21/2

Replace engine oil

Normal Conditions: Every 7,SOO miles (12,000 kml or 1 year Severe Conditions: Every 3,7S0 miles (6,000 km) or 6 months


Normal Condhions: Every other oil change Severe Conditions: Every oil change

0

Clean air cleaner element Replace air cleaner element Inspect valve clearance


•

Replace spark plugs Replace timing belt, NOTE 1 and inspect water pump

•


0


0

Inspect front and rear brakes Replace brake fluid Check parking brake adjustment Replace air conditioning filter NOTE'

• •

0

0

Lubricate locks, latches, and hinges Rotate tires (Check tire inflation and condition at least once a monthl

• 0

Inspect tie-rod ends, steering gearbox, and boots Inspect suspension components

0


0

Inspect brake hoses and lines (including ASSI Inspect all fluid levels and condition of fluids Inspect cooling system hoses and connections Inspect exhaust system* Inspect fuel lines and connections*

• • • • • • • • •


0

Inspect vehicle under body

0

• • • • • • • • • • • •

0

0

• 0

0 0

• 0

0 0

0

0

NOTE: 1. If the vehicle is regularly driven in very hot or cold weather, over 110°F (43°CI or under -20°F (-29°CI, replace this belt every 60,000 miles; If not, replace it at 10S,OOO miles. 2. Replace the air conditioning filter every 1S,OOO miles ifthe vehicle is driven mostly where air has a high concentration of soot from industry and diesel-powered vehicle; also replace it anytime airflow is less than usual. * According to state and federal regulations, failure to do the maintenance items marked with an asterisk (*) will not void the customer's emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term

3-8

BACK

."",

reliability.

41.25

45

48.75

52.5

56.25

60

63.75

67.5

71.25

75

78.75

82.5

86.25

90

93.75

97.5

101.25

105

108.75 112.5 116.25

120

66

72

78

84

90

96

102

108

114

120

126

132

138

144

150

156

162

168

175

181

187

193

-

3

-

31/2

-

4

-

41/2

-

5

-

51/2

-

6

-

61/2

-

7

-

71/2

-

8

Normal Conditions: Every 7,500 miles (12,000 km) or 1 year Severe Conditions: Every 3,750 miles (6,000 km) or 6 months Normal Conditions: Every other oil change Severe Conditions: Every oil change

0

0

•

0

•


0

• • • • •

0 0

0

• • • • • • • • • 0

0

•

• • • • • • • • • • •

0

0

•

0 0

0

• • •

•

•

0

0

0 0 0

0

0

0

• • • • • • • • •

0

0

• • • • • • • • • • • • • •

• 0 0 0

0

BACK

0

0

• • • • • • •

• 0

• 0 0

0

• 0 0 0

• • • • • • • • • 0

0

• • • • • • • • • • • • 0

• 0 0 0

0

0

3-9

Maintenance Schedule for Normal Conditions (2001-2002 Models) Listed by Distance/Time This two-page maintenance schedule outlines the minimum required maintenance. Service at the indicated time or distance, whichever comes first. Use the Maintenance Schedule for Severe Conditions if the vehicle meets any of the qualifiers listed in the severe conditions schedule or if the vehicle is normally driven in Canada.

o o o o o o o o o o o o o o o

7,500 mil 12,000 km/ Do items in A. 15,000 mil 24,000 km/ 1 year Do items in A and B. 22,500 mil 36,000 krn/Do items in A. 30,000 mil 48,000 km/ 2 years Do items in A, B, and C. 37 ,500 mil 60,000 km/ Do items in A. 45,000 mil 72,000 km/ 3 years Do items in Aand B. / /3 years Do item in D. 52,500 mil 84,000 krn/ Do items in A. 60,000 mil 96,000 km/4 years Do items in A, B, and C. 67,500 mi/108,000 krn/Do items in A. 75,000 mi/120,000 km/ 5 years Do items in A and B. 82,500 mi/132,000 km/Do items in A. 90,000 mi/144,000 km/ 6 years Do items in A, B, and C. / /6 years Do item in D. 97,500 mi/156,000 km/ Do items in A. 105,000 mi/168,000 km/7 years Inspect valve clearance (cold) (see page 6-13). Intake: 0.20-0.24 mm (0.008-0.009 in.), Exhaust: 0.28-0.32 mm (0.011-0.013 in.) Replace spark plugs (see page 4-24). Use NGK (PZFR5F-11) or DENSO (PKJ 16CR-L11). GAP: 1.0-1.1 mm (0.039-0.043 in) Replace timing belt (see page 6-19) and inspect water pump (see page 10-9). Check idle speed. Should be 680±50 rpm in IltI or ~ position (see page 11-69). Do items in A and B. . 112,500 mi/181,000 km/ Do items in A. Do the items in A, B, and C. 120,000 mi/192,000 krn/ 8 years 120,000 mi/192,000 km/6 years Replace transmission fluid. Use Honda ATF-Z1 (ATF) (see page 14-113), then every 90,000 miles (144,000 km) or 5 years -/-/9 years 0 Do item in D. 120,000 mi/192,000 km/1 0 years Replace Coolant (see page 10-10). Use Honda All Season Antifreeze/Coolant Type 2. Capacity: 5.64 (5.9 US qt, 4.9 Imp qt), then every 60,000 miles (96,000 km) or 5 years.

o o o o o

o o

o o

3-10

BACK

Do the items in parts A, B, C, and D as required for mileage/time interval listed. A

D Replace engine oil (see page 8-5). -Capacity with filter change: 4.4 ~ (4.6 US qt, 3.9 Imp qt) D Rotate tires. Follow the pattern shown in the Owner's Manual -Check tire inflation and condition. B

D Replace engine oil filter (see page 8-5). D Inspect front and rear brakes (see page 19-2). Check pads and discs for wear (thickness), damage, and cracks. Check calipers for damage, leaks, and tightness of mount bolts. Check parking brake adjustment. Should be fully applied within 6 to 9 clicks. Inspecttie rod ends, steering gearbox, and boots (see page 17-12). o Check rack grease and steering linkage. o Check boots for damage and leaking grease. o Check fluid line for damage and leaks. Inspect suspension components. o Check bolts for tightness. o Check condition of ball joint boots for deterioration and damage. Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3)*'. Inspect brake hoses and lines (including ABS). -Check the master cylinder, proportioning control valve, and ABS modulator for damage and leakage. Check all fluid levels and condition of fluids; check for leaks. If necessary, add ATF (see page 14-112), engine coolant, brake fluid, and windshield washer fluid. Inspect cooling system hoses and connections. o Check for damage, leaks, and deterioration. o Check for proper fan operation. Inspect exhaust system* . Check catalytic converter heat shield, exhaust pipe, and muffler for damage, leaks, and tightness (see page 9-4). Inspect fuel lines and connections*. Check for loose connections, cracks and deterioration; retighten loose connections and replace damaged parts (see page 11-74). o

o

D D

D D D D

D D D

c

D Replace air cleaner element. D Inspect and adjust drive belt. Look for cracks and damage, then check belt deflection by pushing on it (about 22 Ibs) midway between the pulleys. - PIS pump belt: 13.0-16.5 mm (0.51-0.65 in) (see page 17-10). Replace the dust and pollen filter (see page 21-26)*'. o Replace it twice as often (at 15,000 mile interval) if the vehicle is driven mostly in urban areas that have high concentrations of soot in the air from industry and diesel-powered vehicles. o Replace it whenever airflow from the climate control system is less than normal. o

D

o

D Replace brake fluid every 3 years (independent of Distance). Use Honda DOT 3 Brake Fluid. Fill to between marks on reservoir, (see page 19-7)*'.

According to state and federal regulations, failure to do the maintenance service items marked with asterisk (*) will not void customer's emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliabil ity. *': Refer to '98-02 ACCORD Service Manual (P/N 61S8400)

BACK

3-11

Maintenance Schedule for Severe Conditions (2001-2002 Models) listed by Distance/Time Service at the indicated distance or time, whichever comes first. Use this schedule ifthe vehicle is driven MAINLY in Canada or in any of the following conditions; if only OCCASIONALLY driven in these conditions, use the Normal Conditions schedule (see page 3-10). Severe Driving Conditions • Less than 5 miles (8 km) per trip or, in freezing temperatures, less than 10 miles (16 km) per trip • In extremely; hot weather (over 90°F/32°C) • Extensive idling or long periods of stop-and-go driving • Trailertowing • On muddy, dusty, or de-iced roads • Driving in mountainous conditions 3,750 mil 6,000 kml 7,500 mil 12,000 km/11 ,250 mil 18,000 km/15,000 mil 24,000 kml 1 year

D Replace engine oil and filter.

D D

Do items in A. Replace engine oil and filter.

D Clean air cleaner element with low pressure air. D Do items in A and S. D Replace engine oil and filter. 18,750 mil 30,000 km/D Do items in A. 22,500 mil 36,000 kml 1 112 years: D Replace engine oil and filter 26,250 mil 42,000 kml D Do items in A, S, and C 30,000 mil 48,000 kml 2 years: 33,750 mil 54,000 km/D Replace engine oil and filter. 37 ,500 mil 60,000 km/2 112 years: D Do items in A. 41,250 mil 66,000 km/45,000 mil 72,000 kml 3 years:

D

Replace engine oil and filter.

D Clean air cleaner element with low pressure air. D Do items in A, S, and D. -1-13 years D Do item in D. D Replace engine oil and filter. 48,750 mil 78,000 km/52,500mil 84,000 km 3 1/2 years: D Do items in A. 56,250 mil 90,000 km/D Replace engine oil and filter. 60,000 mi/96,000 km/3 years D Replace transmission fluid. Use Honda ATF-Z1 (ATF) (see page 14-113), then every 30,000 miles (48,000 km) or 2 years. 60,000 mil 96,000 kml 4 years: D Replace timing belt (see page 6-19) and inspect the water pump (see page 10-9) if the vehicle is regularly driven in weather over 110°F (43°C) or under -20°F (-29°C); If not, replace the belts at 105,000 miles. D Do items in A, Sand C. D Replace engine oil and filter. 63,750 mi/102,000 km/D Do items in A. 67,500 mi/108,000 km 41/2 years: 71 ,250 mi/114,000 km D Replace engine oil and filter. 75,000mi/120,000 km/5 years: D Clean air cleaner element with low pressure air. D Do items in A and S. D Replace engine oil and filter. 78,750 mi/126,000 km/D Do items in A. 82,500 mi/132,000 km/5 112 years D Replace engine oil and filter. 86,250 mi/138,000 km/90,000mi/144,000 km/5 years: D Replace transmission fluid. Use Honda ATF-Z1 (ATF) (see page 14-113), then every 30,000miles (48,000km) or 2 years. 90,000 mi/144,000 kml 6 years: D Do items in A, S, C. and D. -1-16 years D Do item in D. 93,750 mi/150,000 kml D Replace engine oil and filter. 97,500 mi/156,000 km/6 1/2 years: D Do items in A. 101,250 mi/162,000 km/ D Replace engine oil and filter. 105,000 mi/168,000 km/7 years: D Clean air cleaner element with low pressure air. D Inspect valve clearance (cold) (see page 6-13Hntake: 0.20-0.24 mm (0.008-0.009 in.) Exhaust: 0.28-0.32 mm (0.011-0.013 in.) D Replace spark plugs. Use NGK (PZFR5F-11) or DENSO (PKJ16CR-L11). Gap: 1.0-1.1 mm (0.039-0.043 in) (see page 4-24). D Replace timing belt (see page 6-19), and inspect the water pump (see page 10-9) only ifthe belts was not replaced at 60,000 miles. D Check idle speed. Should be 680 ± 50 rpm in [HI or [f) position (see page 11-69). D Do items in A and S. D Replace engine oil and filter. 108,750 mi/174,000 km/D Do items in A. 112,500 mi/180,000 km/ 71/2 years: D Replace engine oil and filter. 116,250 mi/186,000 km/120,000 mi/192,000 kml 7 years: D Replace transmission fluid. Use Honda ATF-Z1 (ATF) (see page 14-113), then every 30,000miles (48,000km) or 2 years. 120,000 mi/192,000 km/ 8 years: D Replace timing belt (see page 6-191. and inspect the water pump (see page 10-9) only ifthe belts was not replaced at 60,000 miles. D Do items A, S, and C. D Do item in D. -/-/9 years 120,000 mi/192,000 km/10 years D Replace engine coolant (see page 10-10). Use Honda All Season Antifreeze/Coolant Type 2. Capacity: 5.6 ~ (5.9 US gt, 4.9 Imp gtl. then every 60,000 miles (96,000 km) or 5 years.

3-12

BACK

r Do the items in parts A, S, C, and D as required for mileage/time interval. A

D D

D D

D D

Replace engine oil and filter (see page 8-5). - Capacity with filter change: 4.4l! (4.6 US qt, 3.91mp qt) Inspect front and rear brakes, every 6 months if vehicle is driven less than 7,500 mile per year (see page 19-2). • Check pads and discs for wear (thickness), damage, and cracks. • Check calipers for damage, leaks, and tightness of mount bolts. Rotate tires, ifthe vehicle has been driven the distance listed. Follow the pattern shown in the Owner's Manual. (Check tire inflation and condition.) Inspect tie rod ends, steering gearbox, and boots (see page 17-12). • Check rack grease and steering linkage. • Check boots for damage and leaking grease. • Check fluid lines for damage and leaks. Inspect suspension components. • Check bolts for tightness. • Check condition of ball joint boots for deterioration and damage. Inspect driveshaft boots. Check boots for cracks and boot bands for tightness (see page 16-3)*'.

B

D D D D

D D D

D D

Check parking brake adjustment. - Should be fully applied within 6 to 9 clicks. Lubricate locks, latches, and hinges with Honda white lithium grease. Inspect brake hoses and lines (including ASS). Check the master cylinder, proportioning control valve, and ASS modulator for damage and leakage (see page 19-30)*'. Check fluid levels and condition offluids; check for leaks. If necessary, add ATF (see page 14-112), engine coolant, brake fluid, and windshield washer fluid. Inspect cooling system hoses and connections. • Check for damage, leaks, and deterioration. • Check for proper fan operation. Inspect exhaust system.* Check catalytic converter heat shield, exhaust pipe, and muffler for damage, leaks, and tightness (see page 9-4). Inspect fuel lines and connections.* Check for loose connections, cracks and deterioration; retighten loose connections and replace damaged parts (see page 11-74). Check all lights. Check function of all interior and exterior lights, and the positions ofthe headlights (see page 22-98)*'. Inspect the vehicle underbody. Check the paint for damage, scratches, stone chipping, and dents.

c

D D

D

Replace air cleaner element. Inspect and adjust drive belt. Look for cracks and damage, then check tension by pushing on each belt (about 22 Ibs) midway between the pulleys: • PIS pump belt: 13.0-16.5 mm (0.51-0.65 in) (see page 17-10) Replace dust and pollen filter, every 15,000 miles if vehicle is driven mostly where air has high concentration of soot from industry and diesel-powered vehicles; also replace it anytime airflow is less than usual (see page 21-26)*'.

D

D

Replace brake fluid every 3 years (Independent of Distance). Use Honda DOT 3 Brake Fluid. Fill to between marks on reservoir, (see page 19-7)*'.

According to state and federal regulations, failure to do the maintenance items marked with asterisk (*) will not void customer's emissions warranties. However, Honda recommends that ali maintenance services be done at the recommended interval to ensure long-term reliability. *': Refer to '98-02 ACCORD Service Manual (P/N 61S8400)

BACK

3-13

Maintenance Schedule for Normal and Severe Conditions (2001-2002 Models) Listed by Maintenance Item Service at the indicated distance or time, whichever comes first. • If driven in normal conditions, do items with a dot (.) . • If driven in severe conditions (see page 3-12) or normally driven in Canada, do items with a circle (0) and items with a dot (.). Service at the indicated distance or time, whichever comes first.

I L I

miles x 1000 km x 1000 vears

Replace engine oil Replace engine oil filter

18.75 22.5 J 26.25 3.75 I 7.5 11.25 I 15 30 J 33.75 37.5 6 I 12 18 I 24 30 36 42 48 I 54 60 - I 1 - I 1/2 11/2 I 2 I 21/2 Normal Conditions: Every 7,500 miles (12,000 km) or 1 year Severe Conditions: Every 3 750 miles (6 000 km) or 6 months Normal Conditions: Every other oil change Severe Conditions: Every oil change

I

Clean air cleaner element Replace air cleaner element Inspect valve clearance Replace s~ark Qiugs Replace timina belt NOTE1 and inspect water pump Inspect and adlust drive belts Inspect idle speed* Replace engine coolant

10 J

I

I

I

.1

Ad·ust only if noisy.

• Normal Conditions: At 120,000 miles (192,000 km) or 10 years, then every 60,000 miles (96,000 km) or 5 years Severe Conditions: At 120,000 miles (192,000 km) or 10 years, then every 60 000 miles (96 000 km) or 5 years Normal Conditions: At 120,000 miles (192,000 km) or 6 years, then every 90,000 miles (144,000 km) or 5 years Severe Conditions: At 60,000 miles (96,000 km) or 3 years, then every 30000 miles (48 000 km) or 2 years


Inspect front and rear brakes Replace brake fluid Check parking brake adiustment Replace dust and pollen filter NOTE 2 Lubricate locks latches and hinges Rotate tires (Check tire inflation and condition at least once a month) Inspect tie-rod ends steerin~gearbox and boots Inspect su~pension comjJonents In~ect driveshaft boots Inspect brake hoses and lines (including ASS) Inspect all fluid levels and condition of fluids Inspect cooling system hoses and connections Inspect exhaust system* Inspect fuel lines and connections* Check lights and controls Inspect vehicle under body

0

I.

10

• •• ••• ••• •••

0

Every 3 years (inde endent of distance

•

• 0 0 0

0

•• ••• ••• • 0 0

• 0 0 0

0

•

0 0 0

0 0

NOTE: 1. Ifthe vehicle is regularly driven in very hot or cold weather, over 110°F (43°C) or under -20°F (-29°C), replace this belt every 60,000 miles; If not, replace it at 105,000 miles. 2. Replace the dust and pollen filter every 15,000 miles if the vehicle is driven mostly where air has a high concentration of soot from industry and diesel-powered vehicle; also replace it anytime airflow is less than usual. * According to state and federal regulations, failure to do the maintenance items marked with an asterisk (*) will not void customer's emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval to ensure long-term reliability.

3-14

BACK

41.25 66

45

48.7H 52.5 56.25 I 60 63.75167.5 71.25 75 178.75 82.5 114 78 I 84 90 I 96 102 I 108 120 I 126 I 132 I 31/2 4 I - I 41/2 5 I - I 51/2 3 Normal Conditions: Every 7,500 miles (12,000 km) or 1 year Severe Conditions: Every 3 750 miles (6 000 km) or 6 months Normal Conditions: Every other oil change Severe Conditions: Every oil chan~e

72

I. L

10 1

I

0

1 Adiust only if noisy.

I I

86.251 90 138 I 144 - I 6

I I.

0

•

93.75 I 97.5 I 101.25 150 I 156 I 162 - I 61/2 I -

I I

L 1

•

Normal Conditions: At 120,000 miles (192,000 km) or 10 years, then every 60,000 miles (96,000 km) or 5 years Severe Conditions: At 120 000 miles (192 000 km) or 10 years then every 60 000 miles (96 000 km) or 5 years Normal Conditions: At 120,000 miles (192,000 km) or 6 years, then every 90,000 miles (144,000 km) or 5 years Severe Conditions: At 60 000 miles (96 000 km) or 3 years then every 30 000 miles (48 000 kmtor 2years

I.

~.

10

• 0

•• •• ••• •• 0 0

• 0 0 0

I.

•• •• ••• ••• • 0

0 0

10

• • •• •• •• •••

10

I.

10

Every 3 years (inde endent of distance)

• 0 0 0

0

0 0

BACK

• 0 0 0

•• ••• •• ••• • 0

0 0

•

0 0 0

105 168 7

108.75 I 112.5 175 I 181 I 71/2

0

• • 0

0 0

-

120 193 8

•

•• • • •• ••• •• ••

116.25 187

0

• L0

•

0 0 0

• •• ••• •• ••• • 0

0 0

3-15

BACK

Engine Electrical Engine Electrical Special Tools ................................................................. 4-2

Starting System Component Location Index ......................................... Circuit Diagram ............................................................. Starter Circuit Troubleshooting .................................. Starter Solenoid Test ................................................... Starter Performance Test ............................................. Starter Replacement .................................................... Starter Overhaul ...........................................................

4-3 4-4 4-5 4-6 4-7 4-8 4-9

Ignition System Component Location Index ......................................... Circuit Diagram ............................................................. Ignition Timing Inspection ........................................... Distributor Replacement .............................................. Distributor Disassembly/Reassembly ........................ ICM (Ignition Control Module) Input Test ................... Ignition Coil Test ........................................................... Ignition Wire Inspection and Test ............................... Ignition Coil Troubleshooting ..................................... Spark Plug Inspection/Replacement ...........................

4-14 4-16 4-18 4-19 4-20 4-21 4-22 4-22 4-23 4-24

Charging System Component Location Index ......................................... Circuit Diagram ............................................................. Charging Circuit Troubleshooting .............................. Alternator-Compressor Belt Inspection and Replacement ..................................... Alternator Replacement ............................................... Auto-Tensioner Inspection .......................................... Alternator Overhaul .....................................................

4-25 4-26 4-27 4-31 4-31 4-33 4-35

Cruise Control Component Location Index ......................................... Circuit Diagram ............................................................. Symptom Troubleshooting Index ............................... Cruise Control Communication Circuit Troubleshooting ....................................................... Control Unit Input Test ................................................. Main Switch Test/Replacement .................................. Set/Resume/Cancel Switch Test/Replacement .......... Brake Pedal Position Switch Test ................................ Actuator Solenoid Test ................................................ Actuator Test ................................................................. Actuator/Solenoid/Cable Replacement ...................... Actuator Cable Adjustment .........................................

4-41 4-42 4-43 4-45 4-46 4-48 4-49 4-50 4-50 4-51 4-52 4-54

Engine Mount Control System Component Location Index ......................................... 4-55 Circuit Diagram ............................................................. 4-56 Troubleshooting ........................................................... 4-57

r--:'I

L:J

Engine Electrical Special Tools Ref. No.

CD

® ®

Tool Number A973X-041-XXXXX 07746-0010400 077 49-00 10000

Qty

DescriPtion Vacuum Pump/Gauge, 0-30 in.Hg Driver Attachment, 52 x 55 mm Driver

1 1 1

I ®

4-2

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r--:'I I.!:!..I

Starting System Component Location Index

OO[==:J OOQc::=:J

o

0 c=J

c:=Ju c::J DOD

STARTER CUT RELAY Test, page 22-55 in the '98-02 Accord Service Manual

TRANSMISSION RANGE SWITCH Test, page 14-140 Replacement, page 14-141

STARTER Starter Circuit Troubleshooting, page 4-5 Solenoid Test, page 4-6 Performance Test, page 4-7 Replacement, page 4-8 Overhaul, page 4-9

BATTERY

\

BACK

4-3

Starting System Circuit Diagram UNDER·HooD FUSE/RELAY BOX

IGNITION SWITCH

---f'::J

BATTERY

No.41 (l00A)

+1--....-

No.42 (50A)

1HOT.srART I'~

BLK - ......-o""""o---<:""o-o+-WKT

BlKIWHT

~L ___________ _

STARTER CUT RELAY

DRIVER'S UNDER.DASH . FUSE/RELAY

BOX

NO.13 (1.5A)

BlK/RED

BLU/oRN

BLUIWHT

~

'PCM • PGM-FI MAIN RELAY


(~ im position)

BLKlWHT

B

BLK

S

~~JOM

SOLENOID

M

STARTER

....... Gl0l

4-4

BACK

~

I.!:!J !""'" \

Starter Circuit Troubleshooting NOTE: • Air temperature must be between 59° and 1OO°F (15° and 38°C) during this procedure. • After this test, or any subsequent repair, reset the Powertrain Control Module (PCM) to clear any Diagnostic Trouble Code (DTC); refer to the '98-02 Accord Service Manual (see page 11-3). • The battery must be in good condition and fully charged.

Recommended Procedure: • Use a starter system tester. • Connect and operate the equipment in accordance with the manufacturer's instructions.

Alternate Procedure

4. Check the battery condition. Check electrical connections at the battery, the negative battery cable to body, engine ground cables, and the starter for looseness and corrosion. Then try starting the engine again.

Did the starter crank the engine? YES-The starting system is OK.•

NO - Go to step 5. 5. Make sure the transmission is in neutral, then disconnect the BLK/WHT wire (A) from the starter solenoid (B). Connect a jumper wire from the battery positive terminal to the solenoid terminal. B

1. Hook up the following equipment: • Ammeter, 0-400 A • Voltmeter, 0-20 V (accurate within 0.1 volt) • Tachometer, 0-1200 rpm

Did the starter crank the engine?

YES - Go to step 6. NO- Remove the starter and repair or replace as necessary .• 2. Remove the No. 46 (15 A) fuse from the under-dash fuse/relay box. 3. With the shift lever in [H] or [f], turn the ignition switch to start (III).

Did the starter crank the engine normally? YES-The starting system is OK.• NO-If the starter will not crank the engine at all, go to step 4. If it cranks the engine erratically or too slowly, go to step 7. If it won't disengage from the torque converter ring gear when you release the key, check for the following until you find the cause. • Solenoid plunger and switch malfunction • Dirty drive gear or damaged overrunning clutch.

BACK

6. Check the following items in the order listed until you find the open circuit. • Check the BLK/WHTwire and connectors between the driver's under-dash fuse/relay box and the ignition switch, and between the driver's under-dash fuse/relay box and the starter. • Check the ignition switch, refer to the '98-02 Accord Service Manual (see page 22-55). • Check the transmission range switch and connector (see page 14-141). • Substitute a known-good starter relay.

(cont'd)

4-5

Starting System Starter Circuit Troubleshooting (cont'd) 7. Check the engine speed while cranking the engine.

Is the engine speed above 100 rpm?

Starter Solenoid Test 1. Check the hold-in coil for continuity between the S terminal and the armature housing (ground). There should be continuity. • If there is continuity, go to step 2. • If there is no continuity, replace the solenoid.

YES-Go to step 8.

5

NO- Replace the starter, or remove and disassemble the starter, and check for the following until you find the cause .• • • • •

Excessively worn starter brushes Open circuit in commutator brushes Dirty or damaged helical spline or drive gear Faulty drive gear clutch

8. Check the cranking voltage and current draw.

Is cranking voltage no less than 8.5 volts, and current draw no more than 380 amps? YES-Go to step 9. NO- Replace the starter, or remove and disassemble the starter, and check for the following until you find the cause.•

2. Check the pull-in coil for continuity between the S and M terminals. There should be continuity. • Ifthere is continuity, the solenoid is OK. • If there is no continuity, replace the solenoid.

• Open circuit in starter armature commutator segments • Starter armature dragging • Shorted armature winding • Excessive drag in engine 9. Remove the starter and inspect its drive gear and the torque converter ring gear for damage. Replace any damaged parts.

4-6

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~

I.!:!..I Starter Performance Test 1. Disconnect the wires from the S terminal and the M terminal. 2. Make the connections as described below using as heavy a wire as possible (preferably equivalent to the wire used for the vehicle). To avoid damaging the starter, never leave the battery connected for more than 10 seconds.

5. Disconnect the battery from the starter body. If the pinion retracts immediately, it is working properly.

s

e

@ 12V

BATTERY 3. Connect the battery as shown. Be sure to disconnect the starter motor wire from the solenoid. If the starter pinion moves out, it is working properly.

s 6. Clamp the starter firmly in a vise. 12V

BATTERY

7. Connect the starter to the battery as described in the diagram below, and confirm that the motor starts and keeps rotating.

4. Disconnect the battery from the M terminal. If the pinion does not retract, the hold-in coil of the solenoid is working properly.

BATTERY 12V

12V

BATTERY 8. If the electric current and motor speed meet the specifications when the battery voltage is at 11.5 V, the starter is working properly.

BACK

4-7

Starting System Starter Replacement 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons.

6. Install in the reverse order of removal. Make sure the crimped side ofthe ring terminal (A) is facing out.

2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the Automatic Transmission Fluid (ATF) cooler hose from the clamp on the starter motor. 4. Disconnect the starter cable (A) from the B terminal on the solenoid, then disconnect the BLK/WHT wire (B) from the S terminal. A

B

A

7. Connect the battery positive cable and negative cable to the battery. 8. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 9. Retest starter performance.

\

8x 1.25mm 9N·m (0.9 kgf·m, 7Ibf·ft)

/

12x 1.25 mm 64N·m (6.5 kgf·m, 47 Ibf·ft)

5. Remove the two bolts holding the starter, then remove the starter.

4-8

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r--:'I

~ Starter Overhaul Disassembly/Reassembly

END COVER

BRUSH HOLDER

ARMATURE HOUSING

ARMATURE

NUT 9 N·m (0.9 kgf.m, 7 Ib'·ttl

\

MOLYBDENUM DISULFIDE

Q@)

/" STARTER SOlEND",

\= ....

~'

/

SOLENOID LEVER

GEAR HOUSING

GEAR HOUSING COVER

(cant'd)

BACK

4-9

Starting System Starter Overhaul (cont'd) 1. Remove the starter (see page 4-8). 2. Disassemble the starter as shown at the beginning of this procedure. Armature Inspection and Test

5. Check the commutator diameter. If the diameter is below the service limit, replace the armature. Commutator Diameter Standard (New): 28.0-28.1 mm (1.102-1.106 in.) Service Limit: 27.5 mm (1.083 in.)

3. Inspect the armature for wear or damage due to contact with the permanent magnet. If there is wear or damage, replace the armature.

6. Measure the commutator runout.

4. Check commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with # 500 or # 600 sandpaper (B).

• Ifthe commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments. • If the commutator runout is not within the service limit, replace the armature. Commutator Runout Standard (New): 0.02 mm (0.001 in.) max. Service Limit: 0.05 mm (0.002 in.)

4-10

BACK

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~

7. Check the mica depth (A). If the mica is too high (8), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or V-shaped (D). Commutator Mica Depth Standard (New): 0.4-0.5 mm (0.016-0.020 in.) Service Limit: 0.15 mm (0.006 in.)

9. Place the armature (A) on an armature tester (8).

Hold a hacksaw blade (C) on the armature core. If the blade is attracted to the core or vibrates while the core is turned, the armature is shorted. Replace the armature.

c

B

D

A

8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.

10. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (8), and between the commutator and armature shaft (C). If continuity exists, replace the armature.

(cont'd)

BACK

4-11

Starting System Starter Overhaul (cont'd) Starter Brush Inspection

Starter Brush Holder Test

11. Measure the brush length. If it is not within the service limit, replace the brush holder assembly.

12. Check that there is no continuity between the (+) brush holder (A) and (-) brush holder (B). If there is continuity, replace the brush holder assembly.

Brush Length Standard (New): 15.8-16.2 mm (0.62-0.64 in.) Service Limit: 11.0 mm (0.43 in.)

13. Insert the brush (A) into the brush holder, and bring the brush into contact with the commutator, then attach a spring scale (B) to the spring (C). Measure the spring tension atthe moment the spring lifts off the brush. If the spring tension is not within specification, replace the spring. Spring Tension: 15.7-17.7 N (1.6-1.8 kgf,3.53-3.97Ibf)

___- - 8

4-12

BACK

~

~ ~

14. Pry back each brush spring with a screwdriver, then position the brush about halfway out of its holder, and release the spring to hold it there. NOTE: To seat new brushes, slip a strip of # 500 or # 600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.

Overrunning Clutch Inspection

17. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly. 18. Rotate the overrunning clutch (A) both ways. If it does not lock in either direction or it locks in both directions, replace it.

15. Install the armature in the housing. Next, pry back each brush spring again, and push the brush down until it seats against the commutator, then release the spring against the end of the brush. B

I D

19. If the starter drive gear (8) is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the torque converter ring gear if the starter drive gear teeth are damaged.

16. Install the starter end cover (A) to retain the brush holder (8).

20. Reassemble the starter in reverse order of disassembly.

A

BACK

4-13

Ignition System Component Location Index '98-99 models:

~,

SPARK PLUG Inspection, page 4-24

IGNITION WIRES Inspection and Test, page 4-22

DISTRIBUTOR Replacement, page 4-19 Overhaul, page 4-20 Ignition Control Module (lCM) Input Test, page 4-21 Ignition Timing Inspection, page 4-18

4-14

BACK

~

I.!::J '00-02 models:

SPARK PLUG Inspection, page 4-24

IGNITION COIL Troubleshooting, page 4-23

BACK

4-15

Ignition System Circuit Diagram '98-99 models: IGNITION SWITCH

UNDER-HOOD FUSE/RELAY BOX BATIERY ~+

V - BlK -

No.41 (100A)

No,42 (50A) WHT

r---'

~--------------~

IG1 HOT in ON (II) and START (III) BlKlYEl

~

No,6 ~ (15A)


I

BlKlYEl

A

...-I--------.B

C IGNITION COil DISTRIBUTOR IGNITION CONTROL MODULE (ICM) ) ( Has built-in noise condenser

IGNITION WIRES

4-16

BACK

'00-02 models: IGNITION SWITCH


BAT ~

BATTERY

""""-_ _

(±)~-

-+---WHT---+o-..,..

BLKlYEL - - - ,

IGI

IGI HOT In ON (II) and START (III)

No.ll (15A)

yf-----J

f

~

~

~

BRN

BLK/RED

BOX

BLKlYEL

PCM

BRNIWHT


1

~

BLU/RED

WHT/BLU

YEUGRN

BLKlYEL

3

II

ICM

3

3

I

J

ICM

I

II

ICM

I

3

II

ICM

-

3

I

-

-

IGNITION COILS

JII~ 2

NO.6

2

NO.5

2

2

No.4

No.3

2

No.2

2

No.1

r r r r

BLK

~~ ~

........

......

......

... L.

... L.

.......

SPARK PLUGS

... L.

Gl0l ICM : ignition Control Module

BACK

4-17

Ignition System Ignition Timing Inspection 1. Check the idle speed, and adjust it if necessary (see page 11-87). 2. Connect the Honda PGM tester to the Data Link Connector (DLC), and follow the tester's prompts in the "SCS" menu (see the Honda PGM Tester Operator's Manual). 3. Start the engine. Hold the engine at 3,000 rpm with no load, shift lever in IN] or [fl, until the radiator fan comes on, then let it idle.

5. Point the light toward the pointer (A) on the timing belt cover. Check the ignition timing under a no load conditions: headlights, blower fan, rear window defogger, and air conditioner are not operating. If the ignition timing differs from the specification below, replace the PCM; refer to the '98-02 Accord Service Manual (see page 11-3). Ignition Timing: 10o ±2° BTDC (RED mark (B)) during idling in IN] or

[fl A

4. Connect the timing light to the No.1 ignition wire (ignition coil wire for '00-02 models).

B

6. Disconnect the Honda PGM tester and the timing light.

4-18

BACK

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Distributor Replacement - '98-99 models Removal

5. Connect the ignition wires to the distributor cap as shown.

1. Disconnect the connector(A) from the distributor.

No.5

D

-----A

6. Connect the 3P connector to the distributor.

B 22 N·m 12.2 kgf·m, 16 Ibf.ft)

2. Disconnect the ignition wires from the distributor cap. 3. Remove the distributor mounting bolts (B) then remove the distributor (C) from the cylinder head.

Installation 1. Bring the No.1 piston to compression stroke TDC. 2. Coat a new a-ring (D) with engine oil, then install it. 3. Slip the distributor into position. NOTE: The lug on the end of the distributor and its mating grooves in the camshaft end (E) are both offset to eliminate the possibility of installing the distributor 1800 out of time. 4. Tighten the mounting bolts (B).

BACK

4-19

Ignition System Distributor DisassemblyIReassembly - '98-99 models

/

_____0

/DISTRIBUTOR HOUSING Check for cracks and damage.

~

rr;::r;~~~=\7 CONTROL MODULE UCMI

O-RING Replace.


DISTRIBUTOR CAP Check for cracks, wear, damage, and fouling. Clean or replace.

4-20

BACK

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ICM (Ignition Control Module) Input Test - '98-99 models NOTE: • Ifthe malfunction indicator lamp (MIL) comes on, refer to the Diagnostic Trouble Code (DTC) troubleshooting Index; refer to the '98-02 Accord Service Manual. • Perform an input test for the ignition control module (lCM) after finishing the fundamental tests for the ignition system and the fuel and emissions systems.

2. Turn the ignition switch ON (II). Check for voltage between the No.2 terminal and body ground . There should be battery voltage. • If there is no battery voltage, check: - ignition coil. - BLK/YEL wire between the ICM and ignition coil. • If there is battery voltage, go to step 3.

1. Disconnect the 3P connector from the distributor. 3. Turn the ignition switch ON (II). Check for voltage between the No.3 terminal and body ground. There should be battery voltage. • If there is no battery voltage, check: - ignition coil. - BLU wire between the ICM and ignition coil. • If there is battery voltage, go to step 4. 4. Disconnect PCM connector B (25P) and check for continuity on the No.1 terminal between the ICM connector terminal No.1 (YEL/GRN) and PCM connector terminal B13. There should be continuity. 5. Check for continuity on the No.1 terminal to body ground. There should be no continuity. Ifthere is continuity (short to ground), the ICM is probably damaged. 6. Reconnect PCM connector B (25P) and the distributor 3P connector.


7. If all the tests are normal, replace the ICM.

BACK

4-21

Ignition System Ignition Coil Test - '98-99 models

Ignition Wire Inspection and Test - '98-99 models

1. Turn the ignition switch OFF. 2. Disconnect the 3P connector and the ignition coil wire.

1. Carefully remove the ignition wires by pulling on the rubber boots. Do not bend the wires; you might break them inside. 2. Check the condition of the ignition wire terminals. If any terminal is corroded, clean it, and if it is broken or distorted, replace the ignition wire.


3. Using an ohmmeter, measure resistance between the terminals. Replace the coil if the resistance is not within specifications. NOTE: Resistance will vary with the coil temperature; specifications are at 68°F (20°C). Primary Winding Resistance (Between the terminals 1 and 3): 0.34-0.42 Q

Check for broken, corroded, or bent terminals.

3. Connect ohmmeter probes, and measure resistance while flexing and moving the wire. Do not bend the wires; you might break them inside. Ignition Wire Resistance: 25 k Q max. at 68°F (20° e)

Secondary Winding Resistance (Between terminal 2 and secondary winding terminal): 17.1 - 20.3 k Q 2

3

4. If resistance exceeds 25 k Q, replace the ignition wire.

4-22

BACK

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Ignition Coil Troubleshooting - '00-02 models NOTE: Perform an ignition coil test after finishing the fundamental tests for the ignition system and the fuel and emissions system. 1. Remove the ignition coil cover.

8. With all the coils still disconnected, check for continuity between the body ground and PCM connector terminals C3, C4, C12, C13, C14, and/or C23 individually. PCM CONNECTOR C (31P) IGP lS3 (WHT /BLU)

2. Disconnect the 6 ignition coil 3P connectors. 3. Turn the ignition switch ON (II). 4. Measure the voltage at the No.3 terminal of each ignition coil 3P connector. IGNITION COIL 3P CONNECTOR

1

2 IG 3 (BLK/VEL)

Is there continuity? Wire side of female terminals


YES- Repair short to ground in the wire between ignition coil and PCM .•

YES - Go to step 5.

NO- Go to step 9.

NO- Repair open in the wire between ignition coil and No. 11 (15A) fuse in the driver's under-dash fuse/relay box .•

9. Connect PCM connector C (31P). 10. Connect the coil(s) and 3P connector(s).



6. Check for continuity between the No.2 terminal of each ignition coil 3P connector and body ground.

12. Measure the voltage at the No.1 terminal of each ignition coil 3P connector with the ignition switch to start (III).

IGNITION COIL 3P CONNECTOR

IGNITION COll3P CONNECTOR

1 GND 2 (BLK)

3

1

IGP lS1 (YEl/GRN) IGP lS2 (BLU/RED) IGP lS3 (WHT/BlU) IGP lS4 (BRN) IGP lS5 (BlK/RED) IGP lS6 (BRN/WHT)


3



YES-Go to step 7. Is there about 0.25 V to 0.5 V? NO - Repair open in the wire between ignition coil and body ground (G101) .• 7. Disconnect Powertrain Control Module (PCM) connector C (31 P).

BACK

YES- Replace the ignition coil.. NO-Repair open in the wire between ignition coil and PCM .•

4-23

Ignition System Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator. Burned or worn electrodes may be caused by: • Advanced ignition timing • Loose spark plug • Plug heat range too hot • Insufficient cooling

2. Do not adjust the gap of platinum tip plugs (A); replace the spark plug if the gap is out of specification. Electrode Gap: Standard (New): 1.0-1.1 mm (0.039-0.043 in.) Service Limit: 1.3 mm (0.05 in.)

Fouled plug may be caused by: • Retarded ignition timing • Oil in combustion chamber • Incorrect spark plug gap • Plug heat range too cold • Excessive idling/low speed running • Clogged air cleaner element • Deteriorated ignition coil Worn or deformed ~ electrodes

ir-

• Improper gap • Oil-fouling { • Carbon deposits • Cracked center

.'",",od.'n,"'.!o,

3. Replace the plug at the specified interval, or if the center electrode is rounded (A). Use only the spark plugs listed below. Spark Plugs: PZFR5F-11 NGK: DEN SO: PKJ16CR-L 11

4. Apply a small quantity of anti-seize compound to the plug threads, and screw the plugs into the cylinder head finger-tight. Torque them to 18 N·m (1.8 kgf·m, 13Ibf·ft).

4-24

BACK

r:-:'I l!!!.I

Charging System Component Location Index

UNDER-HOOD FUSE/RELAY BOX ] [ Has built-in ELECTRICAL LOAD DETECTOR (ELD) UNIT

ALTERNATOR Alternator/Regulator Test, step 1 on page 4-28 Replacement, page 4-31

CHARGING SYSTEM INDICATOR (In the gauge assembly) Test, page 22-29

BATIERY Test, page 22-30

BACK

4-25

Charging System Circuit Diagram UNDER-HOOD FUSE/RELAY BOX BATTERY No.41 (1 aOA)

+ ~--<,",,"C>-4~-++-~

~~~------------WHT--------------------~

IGNITION SWITCH IG1 HOT in ON (II) and START (III) BLKlYEL

I

~ No.S (15A) BLK/YEL


BLK/YEL BLKlYEL

CHARGING SYSTEM INDICATOR LIGHT BULB (1.4W) PCM

PCM

WHT/GRN BLK

--

--

~TERNATOR

ALTERNATOR

B

H

Y

WHT/BLU BLKlYEL

-C-

IG

--

RED :WHl

L

VOLTAGE REGULATOR

FR

~

,,

FIELD WINDING

FIELD WINDING RECTIFIER

RECTIFIER

,,

:<=),,

~

~

~~

-- ~

~

~

~

~

, I

-~ ~

,,

'00-02 models

--

'98-99 models

--

__ =-.1

--

-'

4-26

BACK

...

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Charging Circuit Troubleshooting Ifthe charging system indicator does not come on or does not go off, or the battery is dead or low, test the following items in the order listed below:

8. Disconnect the 4P connector from the alternator.

9. Ground the No.3 terminal of the 4P connector. Turn the ignition switch ON (II).

Battery (see page 22-30) Charging system indicator Alternator/regulator circuit Alternator control system


2

Charging System Indicator Test 3

1. Check the battery terminals, the battery ground, the main fuses, and that the 4P connector at the alternator and under-hood fuse/relay box terminals to be sure they are securely tightened.


4

l(WHT/BlU)

Are they securely tightened?

=

YES - Go to step 2.

Does the charging system indicator come on?

NO- Tighten or reconnect .•

YES- Go to step 10.

2. Turn the ignition switch ON (II). Does the charging system indicator come on? YES-Go to step 3. NO- Go to step 7.

NO- Turn the ignition switch OFF. Check for a blown No.6 (15 A) fuse and a blown charging system light bUlb. If the fuse and bulb are OK, repair the open in the WHT/BLU wire to the indicator bulb .• 10. Measure the voltage at the No.1 terminal of the alternator 4P connector with the ignition switch ON (II).



Does the charging system indicator go off? YES-Charging system indicator circuit is OK.• IG

NO-Go to step 4.

(BlK/VEl)


2

3

4


5. Disconnect the 4P connector from the alternator. 6. Turn the ignition switch ON (II).

=

Does the charging system indicator come on? Is there battery voltage? YES - Turn the ignition switch OFF, and repair the short in the WHT/BLU wire. Ifthe WHT/BLU wire is shorted to ground, the voltage regulator in the alternator may be damaged .• NO-Go to step 10.

YES- Repair or replace the alternator.• NO-Repair open in the BLK/YEL wire between the alternator and the under-dash driver's fuse relay box.•

7. Turn the ignition switch OFF. (cont'd)

BACK

4-27

Charging System Charging Circuit Troubleshooting (cont'd) Alternator and Regulator Circuit Test-'98-99 models


Is the voltage less than 12.0 V?

1. Be sure the battery is sufficiently charged and in good condition (see page 22-30).

YES- Repair or replace the alternator.• 2. Connect a VAT-40 (or equivalent tester), and turn the selector switch to position 1 (starting). LOAD ADJUSTER (CARBON PILE)

NO- Go to step 10.


r:::::::~~~~'

10. Apply a load with the VAT-40 until the battery voltage drops to between 12-13.5 V.

_VOLTMETER NEGATIVE LEAD (BLK)

II,

Is the amperage 75 A or more?

VOLTMETER POSITIVE LEAD (RED)

YES- The charging system is OK.•

/ FIELD SELECTOR

NO- Replace the alternator..

NEG~lWE

TESTER ; \ \ CABLE (BLK) POSITIVE TESTER CABLE (RED) INDUCTIVE PICK-UP (GRN)

3. Shift to park or neutral, and start the engine. Hold the engine at 3,000 rpm, with no load until the radiator fan comes on, then let it idle. 4. Raise the engine speed to 2,000 rpm, and hold it there.

Is the voltage over 16.0 V? YES - Repair or replace the alternator.. NO-Go to step 5. 5. Release the accelerator pedal, and let the engine idle. 6. Make sure all accessories are turned off. Turn the selector switch to position 2 (charging). 7. Remove the inductive pick-up, and zero the ammeter. 8. Place the inductive pick-up over the B terminal wire of the alternator so that the arrow points away from the alternator.

4-28

BACK

~ ~

Alternator and Regulator Circuit Test-'OO-02 models 1. Be sure the battery is sufficiently charged and in good condition (see page 22-30). 2. Connect a VAT-40 (or equivalent tester), and turn the selector switch to position 1 (starting).


Is the voltage less than 13.5 V? YES- Repair the alternator components (see page 4-35) .• NO-Go to step 10.

LOAD ADJUSTER (CARBON PILE)


==~== '

10. Apply a load with the VAT-40 until the battery voltage drops to between 12 -13.5 V.

...-VOLTMETER NEGATIVE LEAD (BLK)

VOLTMETER POSITIVE Ir~~~ ~AD (RED)

Is the amperage 75 A or more? YES-The charging system is OK.•

~;;===I'=

NO-Go to step 11.

~\ N~TIVE

TESTER CABLE (BLK) POSITIVE TESTER CABLE (RED) INDUCTIVE PICK-UP (GRN)

INDUCTIVE PICK-UP

11. With the engine speed still at 2,000 rpm, full-field the alternator Attach the probe to the VAT-40 fullfield test lead, and insert the probe into the full field access hold at the back of the alternator. Switch the field selector to the" A (Ground)" position momentarily, and check the amperage reading. Because voltage will rise quickly when the alternator is full-fielded, do not allow the voltage to exceed 18 V: it may damage the electrical system.

3. Shift to park or neutral, and start the engine. Hold the engine at 3,000 rpm, with no load until the radiator fan comes on, then let it idle.

REGULATOR (Located inside the end cover)


Is the voltage over 15.1 V? YES - Repair the voltage regulator .• NO-Go to step 5. 5. Release the accelerator pedal, and let the engine idle.

END COVER

FULL FIELD ACCESS HOLE

Is the alternator out put 75 A or more?

6. Make sure all accessories are turned off. Turn the selector switch to position 2 (charging).

YES - Replace the voltage regulator .•

7. Remove the inductive pick-up, and zero the ammeter.

NO- Repair or replace the alternator (see page 435) .•

8. Place the inductive pick-up over the B terminal wire of the alternator so that the a rrow poi nts away from the alternator.

(cont'd)

BACK

4-29

Charging System Charging Circuit Troubleshooting (cont'd) Alternator Control System Test

7. Check for continuity between the PCM connector terminal C2 and body ground.

1. Check for proper operation of the Electrical Load Detector (ELD) by confirming that the Malfunction Indicator Lamp (MIL) is OFF and there is no DTC for ELD failure.

PCM CONNECTOR C (31PI ALTC (WHT/GRNI

I

2. Disconnect the 4P connector from the alternator.

1 2 3 4

[7 12 13 14 [7 16

3. Start the engine and turn the headlights (high beam) ON.

23

Q 4. Measure voltage between the 4P connector terminal No.2 and the positive terminal of the battery. BATIERY

II

8 9 10

5 6 7

25

17 18 19 20 21

26 27 28

29 30

V II


= Is there continuity? YES - Repair short to ground in the wire between the alternator and PCM .•

C(WHT/GRN) ALTERNATOR 4P CONNECTOR

2

3

4


NO-Check thatthe terminals are firmly seated at the connectors. If OK, substitute a known-good PCM, and recheck; refer to the '98-'02 Accord Service Manual. If prescribed voltage is now available, replace the original PCM .• 8. Turn the headlight and ignition switch OFF. 9. Disconnect the PCM connector C (31 Pl.

Is there 1 V or less? YES-Go to step 8.

10. Check for continuity between the PCM connector terminal C2 and alternator 4P connector terminal No.2.

NO-Go to step 5. ALTC (WHT/GRNI

5. Turn the headlight and ignition switch OFF.

Q

C(WHT/GRNI

6. Disconnect the Powertrain Control Module (PCM) connector C (31P).

1 2 3 4

II

5 6 7

8 9 10

12 13 14 [7 16 17 18 19 20 21

23V 25

26 27 28

PCM CONNECTOR C (31 PI

29 30

17 II

1 2 3 4 ALTERNATOR 4P CONNECTOR


Is there continuity? YES- Test the alternator/regulator.• NO-Repair open in the wire between the alternator and PCM .•

4-30

BACK

r--+'I I.!:!..I Alternator-compressor Belt Inspection and Replacement

Alternator Replacement

1. Inspect the belt for cracks and damaged. If the belt is cracked or damaged, replace it. 2. Check that the pointer (A) on the auto-tensioner housing is not beyond the edge of the indicator rib (B) on the tensioner base.

1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable. 3. Move the auto-tensioner (A) to relieve tension from the alternator belt (B), and remove the alternator belt.

/ 3. Move the auto-tensioner (A) to relieve tensioner from the alternator belt (B), and remove the alternator belt.

4. Install the new belt in reverse order of removal.

(cont'd)

BACK

4-31

Charging System Alternator Replacement (cont'd) 4. Disconnect the condenser fan motor connector (A) from the condenser fan shroud. 6x1.0mm 9.a N·m (1.0 kgf·m. 7.2Ibf·ft)

7. Remove the mount bolt (A) and alternator bracket mounting bolt (8). then remove the harness clamp (C) from the alternator bracket.

B

6x 1.0 mm 9.a N·m (1.0 kgf·m. 7.2Ibf·ft)

5. Remove the condenser fan/shroud assembly (8). 6. Disconnect the 4P connector (A) and 8LK wire (8) from the alternator.

8x 1.25mm A 22 N·m 12.2 kgf·m.16Ibf·ft) 10x 1.25 mm 44 N·m 14.5 kgf·m. 33 Ibf·ft)

8. Install in the reverse order of removal. 9. Enter the anti-theft code for the radio, then enter the customer's radio station presets.

/"

"'.

'9a-99 models 6x 1.0 mm 7.a N·m 10.a kgf.m. 5.8Ibf·ft) '00-02 models ax 1.25 mm 12 N·m 11.2 kgf·m. 8.7 Ibf·ft)

4-32

BACK

r--:'I I.!:!..I Auto-Tensioner Inspection/Replacement 1. Check the position ofthe auto-tensioner indicator's pointer (A), start the engine, then check the position of the pointer again. If the position changes, go to step 5.

4. Check if the auto-tensioner (A) moves smoothly and check for abnormal noise when the pulley is turned counterclockwise with the designated tool. If the auto-tensioner does not move smoothly or if the there is abnormal noise. Replace the autotensioner. Do not move the auto-tensioner beyond its limit.

2. Check for abnormal noise from the tensioner pulley. If you hear abnormal noise, replace the tensioner pulley. 3. Stop the engine, then remove the alternator belt (see page 4-31).

A

5. Remove the auto-tensioner.

6x1.0mm 12 N·m 11.2 kgf·m. 8.7Ibf.ftl

(cont'd)

BACK

4-33

Charging System Auto-Tensioner Inspection/Replacement (co nt'd) 8. If necessary, remove the pulley bolt (A) (left-hand threads), and replace the tensioner pully (B). A

38 N·m

c 7. Attach a torque wrench (A) to the pulley bolt. Measure the torque when the tensioner is turned counterclockwise. If the torque is less than specified value, replace the auto tensioner. 23 N·m (2.3 kgf·m, 17 Ibf·ft) A

4-34

BACK

j ..

m. '" (bf·ft]

~ ~ Alternator Overhaul - '00-02 models Exploded View

SPACER RING \

STATOR DRIVE-END HOUSING

~

REAR BEARING \

\

~@~

ROTOR

\

PULLEY LOCKNUT

STATOR THROUGH BOLT

REAR HOUSING

\

(cont'd)

BACK

4-35

Charging System Alternator Overhaul - '00-02 models (cont'd) Special Tools Required • Driver 07749-0010000 • Driver Attachment, 52 x 55 mm 07746-0010400

5. Remove the washer nut (A) and insulator (8) from the "8" terminal, then remove the end cover (C) and dust seal (D).

A--~

NOTE: Refer to the Exploded View as needed during this procedure. B

1. Test the alternator and regulator before you remove them (see step 1 on page 4-27). 2. Remove the alternator (see page 4-31). 3. If the front bearing needs replacing, remove the pulley locknut with a 10 mm wrench (A) and a 22 mm wrench (8). If necessary, use an impact wrench.

6. Remove the brush holder.

4. Remove the 3 flange nuts (A) and the screw (8) from the alternator, then remove the plate terminal (C).

4-36

BACK

r:-:'I

~

9. Remove the 4 flange nuts.

7. Remove the voltage regulator.

8. Remove the 4 screws (A), then remove the rectifier (B) and rubber seal (C).

10. Remove the 4 insulators (A), rear housing (B) and washer (C).

(cont'd)

BACK

4-37

Charging System Alternator Overhaul- '00-02 models (cont'd) 11. (If you are not replacing the front bearing and/or rear bearing, go to step 18). Remove the rotor from the stator drive end housing.

14. With a hammer and commercially available tools shown, install a new rear bearing in the rotor shaft.

12. Inspect the rotor shaft for galling, and inspect the bearing journal surface in the stator housing for seizure marks .

15. Remove the front bearing retainer plate.

• If either the rotor or stator housing is damaged, replace the alternator. • If both the rotor and the stator housing are OK, go to step 13. 13. Remove the rear bearing using a puller as shown.

4-38

BACK

r-:'I

~

16. Support the stator housing in a vise, and drive out the front bearing with a brass drift (A) and hammer.

Rectifier Test 18. Check for continuity in each direction, between the B terminal (A) and P terminals (B), and between the E terminal (C) and P terminals (B) of each diode pair. All diodes should have continuity in only one direction. Because the rectifier diodes are designed to allow current to pass in one direction, and the rectifier is made up of 8 diodes (4 pairs), you must test each diode in both directions for continuity with an ohmmeter that has diode checking capability: a total of 16 checks .

A

• If any diode failed, replace the rectifier assembly. (Diodes are not available separately.) • If all the diodes are OK, go to step 19.

17. With a hammer and the special tools, install a new front bearing in the stator housing.

A

J~

~

..

~

..

B',

J~

B,

B. B. B. J~

~

.

~

.

J~

c

(cont'd)

BACK

4-39

Charging System Alternator Overhaul- '00-02 models (cont'd) Alternator Brush Inspection

Stator Test

19. Measure the length of both brushes (A) with a vernier caliper (B).

22. Check that there is continuity between each pair of leads (A).

• If either brush is shorter than the service limit, replace the brush assembly. • If brush length is OK, go to step 20.

• Ifthere is continuity, go to step 23. • Ifthere is no continuity, replace the alternator.

_----::::::::::::::::;:?A

Alternator Brush Length: Standard (New): 10.5 mm (0.41 in.) Service Limit: 1.5 mm (0.06 in.)

B

23. Check for no continuity between each lead and the coil core (B). • If there is no continuity, go to step 24. • Ifthere is continuity, replace the alternator. Rotor Slip Ring test 20. Check that there is continuity between the slip rings

24. Reassemble the alternator in reverse order of disassembly, and note these items:

(A).

• If there is continuity, goto step 21. • If there is no continuity, replace the alternator. C

• Be careful not to get any grease or oil on the slip rings. • If you removed the pulley, tighten its locknut to 111 N·m (11.3 kgf·m, 81.7 Ibf·ft) when you reinstall it.

J

A

21. Then check that there is no continuity between each slip ring (A) and the rotor (B) and the rotor shaft (C). • If there is no continuity, go to step 22. • If there is continuity, replace the alternator.

4-40

BACK

~

I!!!.I

Cruise Control Component Location Index

CRUISE CONTROL INDICATOR (Built into gauge assembly) Bulb Locations, page 22-32

SET/RESUME/CANCEL SWITCH Test, page 4-49 Replacement, page 4-49

MAIN SWITCH Test, page 4-48 Replacement, page • •-• • •

BRAKE PEDAL POSITION SWITCH Test, page 4-50 Pedal Height Adjustment, page 19-8 VACUUM TANK

ACTUATOR Test, page 4-51 Solenoid Test, page 4-50

ACTUATOR CABLE Adjustment, page 4-54 TRANSMISSION RANGE SWITCH Test, page 14-140

BACK

4-41

Cruise Control Circuit Diagram

UNDER-HOOD FUSE/RELAY BOX BATTERY

No.42 (SOA)

-§BAT

1-I~--""",""",r:ro...D-_r:ro...D-+-WHT

No.47 (20A)

[ ]: '01-02 models


IGNITION SWITCH BLKlYEl


-+-+-----.

~ No.9

IG1 IG1 HOT in ON (II) and STMT (III)

(7.SA)

HORN RELAY

?

~ NO.6

(1 SA)

RED/BlK

YEl

IT GRN/BlU BLU/RED

~

MAIN SWITCH

WHTIYEl 2[3] lTGRN

1 [7] BLK

S [2] RED

RED/BLK

HORN SWITCH

HORNS

II

II

SET

CAN-II CEl

SET/ RESUME/ RECANCEL SUME SWITCH

LTl~N

2

BlK CABLE REEL

It------~ l

, PCM • GAUGE ASSEMBLY

PCM

\( \(

3

I


2

3


RED/BLK 4[1]

G!:

lTGRN/RED

LTGRN/BLK

BLUIWHT

BlU/GRN

2

6

7 CRUISE CONTROL UNIT

12

8

GAUGE ASSEMBLY

lTGRN

WHT/BlK

~

BlU/BlK

5

14

11

BRAKE LIGHTS

BRN/BlK BRNIWHT

BRN CRUISE CONTROL ACTUATOR

lTBlU

13 10 3

BLK

BlK

TRANSMISSION RANGE SWITCH [ON: [g], IiW ,Ii@ ] 3 BlK

BlK

1 1 G202

4-42

G101

BACK

BLK

1 GS01

r--:'I I.!!:.I Symptom Troubleshooting Index NOTE: • The numbers in the table show the troubleshooting sequence . • Before troubleshooting, - check that the speedometer works properly. - check for proper engine vacuum at the actuator. - check the No.9 (7.5A) and No.6 (15A) fuses in the driver's under-dash fuse/relay box, and No. 47 (20A) fuse in the under-hood fuse/relay box. - check that the horn sounds. - check the tachometer to see if it works properly. Symptom

Cruise control cannot be set.

Cruise control can be set, but indicator light does not go on.

Cruise speed is noticeably higher or lower than what was set. Excessive overshooting or undershooting when trying to set speed. Speed fluctuates on a flat road with cruise control set. Vehicle does not decelerate or accelerate accordingly when SET/RESUME/CANCEL button is pushed. Set speed not cancelled (engine rpm stays high) when shift lever is moved to [NJ position. Set speed is not cancelled when brake pedal is pushed.


Also check for

Check main switch (see page 4-48) 2. Check SET/RESUME/CANCEL switch (see page 4-49) 3. Check brake pedal position switch and mounting (see page 4-50) 4. Check transmission range switch (see page 14-140) 5. Check control unit (see page 4-46) Check control unit (see page 4-46)

• Poor ground: G101 • Open circuit, loose or disconnected terminals: LT GRN, LT GRN/RED, GRV, LT BLU, BLU/WHT • Poor ground: G501 • Open circuit, loose or disconnected terminals: VEL, BLU/BLK

1.

1.

Check actuator and vent line for the actuator (see

2. page 4-51)

2.

Check control unit (see palle 4-46) Check actuator and vent line for the actuator (see page 4-51) Check control unit (see page 4-46) Check actuator (see page 4-51) Check control unit (see page 4-46) Check SET/RESUME/CANCEL switch (see page 4-49) Check control unit (see page 4-46)

1.

Check transmission range switch (see page 14-140)

1.

2. 1.

2. 1.

2. Check control unit (see page 4-46) 1.

2.

Check brake pedal position switch and mounting (see page 4-50) Check control unit (see palle 4-46)

Open circuit, loose or disconnected terminals: LT GRN/RED, LT GRN/BLK Open circuit, loose or disconnected terminals, short to ground: LT BLU Open circuit, loose or disconnected terminals: WHT/BLK

(cont'd)

BACK

4-43

Cruise Control Symptom Troubleshooting Index (cont'd) Symptom

Set speed, does not cancell when main switch is pushed OFF Set speed, does not cancelled when CANCEL button is pushed Set speed will not resume when RESUME button is pushed (with main switch on, set speed is temporarily cancelled by pressing brake pedal). The transmission shifts down slower than normal when going up a hill with the cruise control on.

4-44


1. Check main switch (see page 4-48)

2. Check control unit (see page 4-46) 1. Check SET/RESUME/CANCEL switch (see page 4-49)

2. Check control unit (see page 4-46) 1. Check SET/RESUME/CANCEL switch (see page 4-49)

2. Check control unit (see page 4-46)

1. Troubleshoot the cruise control communication circuit (see page 4-45)

BACK

Also check for

Shorted main switch, or short to power: LT GRN Open circuit, loose or disconnected terminals: LT GRN/ RED, LT GRN/BLK Open circuit, loose or disconnected terminals: LT GRN/ BLK

Open circuit, loose or disconnected terminals, short to ground: BLU/GRN

r:-:'I I.!:I Cruise Control Communication Circuit Troubleshooting 1. Start the engine. 2. Turn on the cruise control main switch, then drive the vehicle to speeds over 25 mph (40 km/h) with the cruise control.

8. Connect a voltmeter between cruise control unit 14P connector terminal No.8 and body ground. Test-drive the vehicle at speeds over 25 mph (40 km/h) with the cruise control set, and watch the voltmeter. CRUISE CONTROL UNIT 14P CONNECTOR

Does the cruise control operate? YES-Go to step 3.

8

NO-Check the cruise control unit (see page 4-46). or cruise control actuator.•

2

3

9

10

567 11

12 13 14

3. Turn the ignition switch OFF. 4. Disconnect Powertrain Control Module (PCM) connector A (32P) and cruise control unit 14P connector.


5. Check for continuity between the PCM connector terminal A5 and body ground.

YES - Go to step 9.

PCM CONNECTOR A (32P) IBLU/GRN

/

2

3

5

4

12 13 14 15

V

25 26 27

6

V

8

9

17 18 19 20 21

V

2B 29 30

V

Is there about 1 V?

10

V

23 24 32 '--

.Q

NO-Substitute a known-good control unit.lfthe system works properly, replace the cruise control unit.. 9. Connect a voltmeter between PCM connector terminal A 15 and body ground. Drive the vehicle at speeds over 25 mph (40 km/h) with the cruise control set, and watch the voltmeter. PCM CONNECTOR A (32PI


IBLU/GRN VI2


3

4

1 12 1 13 14 15

YES- Repair a short to ground in the wire between the PCM connector terminal A5 and the cruise control unit 14P connector terminal No.8 .•

'::L

NO-Goto step 8.

=

6. Reconnect PCM connector A (32P) and cruise control unit 14P connector.

5

/

25 26 27

6

/

8

9

17 18 19 20 21

V

28 29 30

/

10 / 1 23 241 32

-


Is there about 1 V?


YES-Check for loose connections of the BLU/GRN wire between the cruise control unit and the PCM. If necessary replace the PCM and recheck, refer to '98-02 Accord Service Manual (see page 11-3).• NO- Repair or open in the BLU/GRN wire between the A5 terminal and the cruise control unit.•

BACK

4-45

Cruise Control Control Unit Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS before performing repairs or service, refer to the '98-02 Accord Service Manual (see page 23-25). 1. Remove the driver's dashboard lower cover. 2. Disconnect the 14P connector from the control unit. 3. Inspect the connector and socket terminals to be sure they are all making good contact . • If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system . • If the terminals look OK, go to step 4.

lTGRN/BlK

CRUISE CONTROL UNIT

lTBLU

Wire side of female terminals BRN/BlK

4. With the 14P connector disconnected, make these input tests.

4-46

Cavity 9

Wire BRN/WHT

1

BRN


11

BRN/BLK


2

GRY


Ignition switch ON (II), main switch ON and brake pedal depressed, then released

Test: Desired result Check for resistance to ground: There should be 80-120 Q. Check for resistance to ground: There should be 40-60 Q. Check for resistance to ground: There should be 70-110 Q. Check for voltage to ground: There should be 0 V with the pedal depressed and battery voltage with the pedal released.

BACK

Possible cause if result is not obtained • Faulty actuator solenoid • Poor ground (G202) • An open in the wire • Short to ground

• Faulty brake pedal position switch • An open in the wire • Open in cruise control main switch. • Blown No.6 (15A) fuse in the driver's under-dash fuse/relay box

r--:'I

~

Cavity

Wire

3

BLK

5

WHT/BLK

6

7

LTGRN/ RED

Test condition Under all conditions Brake pedal depressed, then released

Set button pushed

LTGRN/ BLK

Resume button pushed

10

BLU/BLK


12

BLU/WHT

13

LTGRN

Ignition switch ON (II) and main switch ON; raise the front of the vehicle, and rotate 1 wheel slowly while holding the other wheel Ignition switch ON (II) and main switch ON

14

LTBLU

Shift lever in ~

8

BLU/GRN

00, ~ or

Test: Desired result Check for continuity to ground: There should be continuity. Check for voltage to ground: There should be battery voltage with the pedal depressed, and 0 V with the pedal released.

Check for voltage to ground: There should be battery voltage. When testing terminal No.6, there should be no voltage on terminal No.7. Check for voltage to ground: There should be battery voltage. When testing terminal No.7, there should be no voltage on terminal No.6. Attach to ground: Cruise indicator light in the gauge assembly should comes on.

Check for voltage between the BLU/WHT (+) and BLK (-) terminals: There should be 0-8 V -O-S V (2.S V average). Check for voltage to ground: There should be battery voltage.


Reconnect the cruise Check for voltage to ground: control unit 14P connector, There should be approx. 1 V start the engine, main switch ON and drive the vehicle to speeds over 25 mph (40 km/h) with the cruise control set.

• • •

• • •

• • • •

Possible cause if result is not obtained Poor ground (GS01) An open in the wire Blown No. 47 (20A) fuse in the under-hood fusel relay box Faulty brake pedal position switch An open in the wire Blown No. 47 (20A) fuse in the under-hood fuse/ relay box Faulty horn relay Faulty set/resume/cancel switch Faulty cable reel An open in the wire

• Blown bulb • Blown No.9 (7.SA) fuse in the under-dash driver's fuse/relay box • Faulty dimming circuit in the gauge assembly • An open in the wire • Faulty vehicle speed sensor • An open in the wire • Short to ground

• Blown No.6 (15A) fuse in the under-dash driver's fusel relay box • Faulty main switch • An open in the wire • Faulty transmission range switch • Poor ground (G401) • An open in the wire • Faulty cruise control unit • Short to ground • Faulty PCM

S. If any test indicates a problem, find and correct the cause, then recheck the system. If all the input tests prove OK, the control unit may be faulty. Substitute a known-good control unit and retest. If the system works properly, replace the control unit.

BACK

4-47

Cruise Control Main Switch Test/Replacement '01-02 model:

'98-00 models: 1. Carefully pry the switch (A) out of the instrument panel.

1. Carefully pry the switch (A) out of the instrument panel. Terminal side of male terminals



B

3. Check for continuity between the terminals in each switch position according to the table. Terminal


Position OFF


ON

Terminal


Position OFF

ON 4. If the continuity is not as specified, replace the switch.

4-48

BACK

r:-:'I I.!:!.I ,.IfI""'"

Set/Resume/Cancel Switch Test/Replacement 3. Check for continuity between the terminals in switch position according to the table.

1. Carefully remove the set/resume/cancel switch cover (A) by prying between the cover and the switch (B) in the sequence shown.

• If there is continuity and it matches the table, but switch failure is occurred on the cruise control unit input test, check and repair the wire harness on the switch circuit. • If there is no continuity in one or both positions, replace the switch.

\ A

Terminal Position SET (ON) RESUME (ON) CANCEL (ON)

\

2

1

,.....

0 0

3 ,.....

-0

I

,.....

-0

2. Remove the 2 screws (A), then remove the switch (B).


BACK

4-49

Cruise Control Brake Pedal Position Switch Test 1. Disconnect the 4P connector from the switch (A).

Actuator Solenoid Test 1. Disconnect the 4P connector (A) from the actuator. Terminal side of male terminals

2. Check for resistance between the terminals according to the table.

2. Remove the brake pedal position switch.

NOTE: Resistance will vary slightly with temperature; specified resistance is at 70°F (20°C).

3. Check for continuity between the terminals according to the table.

\

Terminal Brake Switch

\

1

DEPRESSED RELEASED

2

3

0

-0

4

0

4. If necessary, replace the switch or adjust the pedal height, refer to '98-02 Accord Service Manual (see page 19-5).

Terminal Resistance (Q )

\

1

2

3

4

VENT SOLENOID 40-60 Q VACUUM SOLENOID 30-50 Q SAFETY SOLENOID 40-60 Q

~

~

4 1

3

2

3. If the resistance is not as specified, replace the actuator.

4-50

BACK

r:-:'I

~

Actuator Test 5. With voltage and vacuum still applied, try to pull the actuator rod out by hand. You should not be able to pull it out. If you can, it is defective.


Vacuum Pump/Gauge, 0-30 in.Hg A973X-041-XXXXX 1. Disconnect the actuator cable from the actuator rod and disconnect the 4P connector (A). Terminal side of male terminals

6. Disconnect ground from the No.3 terminal. The actuator rod should return. If it does not return, but the vent hose and filter are not plugged, the solenoid valve assembly is defective.

A973X-041-XXXXX

2. Connect battery power to the No.4 terminal and ground the No.1, No.2 and No.3 terminals. 3. Connect a vacuum pump to the vacuum hose, then apply vacuum to the actuator. 4. The actuator rod (A) should pull in completely. If the rod pulls in only part-way or not at all, check for a leaking vacuum line or defective solenoid. A

/.. BACK

7. Repeat steps 2 through 5, and disconnect ground from the No.1 terminal. The actuator rod should return. If it does not return, butthe vent hose and filter are not plugged, the solenoid valve assembly is defective. 8. If you replace the solenoid valve assembly, be sure to use new O-rings on each solenoid. 9. Disconnect power and ground from the 4P connector. Disconnect the vent hose from the actuator. Connect a vacuum pump to the actuator vent hose port, and apply vacuum. The actuator rod should pull in completely. If not, the vacuum valve is stuck open. Replace the actuator.

4-51

Cruise Control Actuator /Solenoid/Cable Replacement Removal/Installation

6. Loosen the locknut (A), then disconnect the actuator cable (B) from the throttle linkage (C).

1. Disconnect the 4P connector (A) from the actuator.

A

B

c

B

A

7. Install in the reverse order of removal, and adjust the free play at the throttle linkage after connecting the actuator cable.

2. Loosen the mounting bolt (B), and remove the mounting bolt (C), then remove the actuator with the bracket. 3. Disconnect the vacuum hose (D). 4. Remove the 3 nuts (A). B

D

5. Disconnect the actuator cable (B) from the actuator rod (C) by releasing the clip (D) from the rod with a screwdriver.

4-52

BACK

~ ~

DisassemblyIReassembly ACTUATOR CABLE

ACTUATOR BRACKET VACUUM TANK VACUUM HOSE

FILTER COVER ACTUATOR SOLENOID VALVES

BACK

4-53

Cruise Control Actuator Cable Adjustment 1. Check that the actuator cable (A) moves smoothly with no binding or sticking.

5. Turn the adjusting nut (8) until it is 3.75±0.5 mm (0.15±0.02 in.) away from the bracket (C). 3.75±O.5 mm (O.15±O.02 in.)

B

~

c

A

2. Start the engine. Hold the engine at 3,000 rpm with no load ([H] or [f] position) until the radiator fan comes on, then let it idle.

B

6. Pull the cable so that the adjusting nut (8) touches

the bracket, and tighten the locknut (A).

3. Measure the amount of movement of the output linkage (8) until the engine speed starts to increase. At first, the output linkage should be located at the fully closed position (C). The free play (D) should be 3.75±0.5 mm (0.15±0.02 in.). 4. Ifthe free play is not within specs, move the cable to the point where the engine speed starts to increase, and tighten the locknut (A) and adjusting nut (8). B

/

4-54

/

BACK

~

I!:!J

Engine Mount Control System Component Location Index

ENGINE MOUNT CONTROL SOLENOID VALVE

Troubleshooting, page 4-57

POWERTRAIN CONTROL MODULE (PCM) Troubleshooting, page 4-57

BACK

4-55

Engine Mount Control System Circuit Diagram UNDER-HOOD FUSE/RELAY BOX BATTERY No.41 (100A)

No.42 (SOA)

+r---+-~~--~~~--~

WHT

IGNITION SWITCH IGI HOT in ON (II) and START (III) BlKNEl

NO.6 (1 SA)


BUKNEl

ENGINE MOUNT CONTROL SOLENOID VALVE

GRNIWHT

A2 PCM

BlK

1 Gl0l

4-56

BACK

r:-:'I I.!!:!!.I Troubleshooting Special Tools Required Vacuum Pump/Gauge, 0-30 in.Hg A973X-041-XXXXX

4. Shift to

IHl or ~ position.

5. Disconnect the 2P connector from the engine mount control solenoid valve.

NOTE: Check the vacuum hoses and lines for damage and proper connections before troubleshooting. Follow this procedure if the engine vibrates excessively when idling.

6. Measure voltage between the No.2 terminal and body ground. ENGINE MOUNT CONTROL SOLENOID VALVE CONNECTOR

1. Warm up the engine to normal operating temperature (the cooling fan comes on 2 times). Wire side of female terminals

Is the idle speed less than 800 rpm? YES - Go to step 2. NO-Adjustthe idle speed (see page 11-87) .•

=

2. Fully depress the brake pedal. 3. With the transmission in gear, have an assistant disconnect and reconnect the 2P connector from the engine mount control solenoid valve.

Is there a noticeable change in idle smoothness when the 2P connector is disconnected? YES- Reconnect the 2P connector to the solenoid valve. The engine mount control system is OK.• NO-Go to step 4.

Is there battery voltage? YES-Go to step 7. NO-Repair open in BLK/YEL wire between the 2P connector and No.6 (15A) fuse in the driver's under-dash fuse/relay box .• 7. Measure voltage between the No.1 and No.2 terminals. ENGINE MOUNT CONTROL SOLENOID VALVE CONNECTOR GRN/WHT


BLK/YEL

/s there battery voltage? YES-Go to step 8. NO- Repair open in GRN/WHT wire between Powertrain Control Module (PCM) (A2) and the 2P connector. If the wire is OK, substitute a knowngood PCM and recheck, refer to '98-02 Accord Service Manual (see page 11-3) .• (cont'd)

BACK

4-57

Engine Mount Control System Troubleshooting (cont'd) 8. Raise the engine speed above 1,000 rpm. 9. Measure voltage between the No.1 and No.2 terminals. ENGINE MOUNT CONTROL SOLENOID VALVE CONNECTOR

11. Release the vacuum, then apply vacuum again.

Is there a noticeable change in idle smoothness with and without vacuum applied? YES - Go to step 12. NO-Isolate and replace the leaking engine mount.•


12. Disconnect the lower vacuum hose (A) from the engine mount control solenoid valve (8) and connect a vacuum pump/gauge to the hose.

BlK/VEl

Is there battery voltage? A973X-041-XXXXX

A:2((~

YES-Repair short to body ground in GRN/WHT wire between PCM (A2) and the 2P connector. If the wire is OK, substitute a known-good PCM and recheck, refer to '98-02 Accord Service Manual (see page 11-3).• NO-Gotostep 10. 10. Disconnect the upper vacuum hose (A) from the engine mount control solenoid valve (8), and connect a vacuum pump/gauge to the hose. Apply vacuum for 20 seconds.

YES - Replace the engine mount control solenoid valve .• NO-A hose is restricted or pinched orthe intake manifold port is plugged, Repair as needed .•

A

\

Is there manifold vacuum at idle a decrease when you raise the engien speed above 1,000 rpm?

A973X-04'·XXJ(XX

~ Does the engine mount hold vacuum? YES-Go to step 11. NO-Either the vacuum hose or one ofthe engine mounts has a vacuum leak. Repair as needed .•

4-58

BACK

r \

Engine Mechanical Engine Assembly Engine Removal ........................................................... 5-2 Engine Installation ........................................................ 5-11

Cylinder Head .................................................... 6-1 Engine Block ..................................................... 7-1 Engine Lubrication ........................................... 8-1 Intake Manifold/Exhaust System ................... 9-1 Engine Cooling ..... ..... ........ ........ ..... ........ .... ....... 10-1

NOTE: Refer to the 1998-2002 Accord Service Manual, PIN 61S8008, for items not shown in this section.

Engine Assembly Engine Removal Special Tool Required Belt Tension Release Arm, VA 9317, commercially available

5. Remove the Evaporative Emission (EVAP) canister hose (A) from the throttle body.

NOTE: • Use fender covers to avoid damaging painted surfaces. • To avoid damage, unplug the wiring connectors carefully while holding the connector portion. • Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts. 1. Remove the support struts from the hood, then fix the hood in a vertical position. 2. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. C

3. Disconnect the battery negative terminal first, then the positive terminal. Remove the battery. 4. Remove the throttle body cover (A) and intake manifold cover (B).

B

6. Remove the vacuum hose (B) and breather pipe (C), then remove the intake air duct (D). 7. Remove the ground cable (A) and harness clamp (B).

D

8. Remove 6 mounting bolts (C), and loosen the mounting bolt (D), then remove the battery base (E) and battery base bracket (F).

5-2

BACK

9. Remove the throttle cable (A) and cruise control cable (8) by loosening the locknuts (e), then slip the cable ends out of the accelerator linkage. Take care not to bend the cables when removing them. Always replace any kinked cable with a new one.

11. Relieve fuel pressure (see page 11-89). 12. Remove the fuel feed hose (A) and fuel return hose (8).

'98-99 models:

c

'00-02 models: ~------

10. Disconnect the engine wire harness connectors on the left side of the engine compartment.

A

13. Remove the brake booster vacuum hose (A) and the cruise control vacuum hose (8).

(cont'd)

BACK

5-3

Engine Assembly Engine Removal (cont'd) 18. Remove the starter cable clamps.

14. Remove the engine wire harness clamps.

~

11111111 111111 ~1~~111~ --.....-' •• ~~111111111 11111 1

15. Remove the battery cables (A), and disconnect the connector (8) from the under-hood fuse/relay box (C).

19. Disconnect the connectors from the Powertrain Control Module (PCM).

16. Remove the flange bolt (D), then remove the underhood fuse/relay box. 17. Remove the harness clamps (E).

5-4

BACK

20. Remove the grommet (A), then pullout the peM connectors.

22. Loosen the adjusting nut (A), and remove the locknut (8) and mounting bolt (e), then remove the Power Steering (P/S) pump belt (D) and pump without disconnecting the PIS hoses.

21. Move the auto-tensioner (A) with the belt tension release arm (8) to remove tension from the alternator belt (e), then remove the alternator belt.

23. Remove the PIS hose clamp (E). 24. Remove the radiator cap. 25. Make sure the hoist brackets are positioned properly. Raise the hoist to full height. 26. Remove the front tires/wheels. 27. Remove the splash shield.

(cont'd)

BACK

5-5

Engine Assembly Engine Removal (cont'd) 28. Loosen the drain plug in the radiator to drain the engine coolant (see page 10-10).

35. Remove the bolts (A) securing the shift cable holder (8), then remove the shift cable cover (C). To prevent damage to the control lever joint, be sure to remove the bolts securing the shift cable holder before removing the bolts securing the shift cable cover.

29. Drain the Automatic Transmission Fluid (ATF). Reinstall the drain plug using a new washer (see page 14-113). 30. Drain the engine oil. Reinstall the drain bolt using a new washer (see page 8-5). 31. Disconnect the Primary Heated Oxygen Sensor connector (A), then remove the exhaust pipe A (8).

A

36. Remove the lock bolt (D) securing the control lever (E), then remove the shift cable (F) with the control lever. Take care not to bend the shift cable while removing it. 37. Unplug the PIS hose clamps (A), and disconnect the engine mount control vacuum hose (8). 32. Remove the damper fork, refer to the '98-02 Accord Service Manual (see page 18-19). 33. Disconnect the suspension lower arm ball joints; refer to the '98-02 Accord Service Manual (see page 18-17). 34. Remove the driveshafts; refer to the '98-02 Accord Service Manual (see page 16-3). Coat all precisionfinished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends.

A

5-6

BACK

B

38. Lower the hoist, then remove the upper radiator hose (A), and the lower radiator hose (8).

40. Remove the Automatic Transmission Fluid (ATF) cooler hoses, then plug the ATF cooler hoses and lines.

A

39. Remove the distributor cap, then remove the heater hoses.

(cont'd)

BACK

5-7

Engine Assembly Engine Removal (cont'd) 41. Attach the chain hoist to the engine as shown.

42. Remove the side engine mount bracket.

43. Remove the rear mount bracket support nut (A) and mounting bolt (8).

5-8

BACK

47. Make a mark (A) on the front beam (8) and rear beam (e), then remove the front beam.

44. Remove the front mount bracket support nut.

B

48. Remove the Ale compressor without disconnecting the Ale hoses. 45. Make sure the hoist brackets are positioned properly. Raise the hoist to full height. 46. Remove the flange bolts securing the radius rods.

(cont'd)

BACK

5-9

Engine Assembly Engine Removal (cont'd) 49. Remove the rear mount.

51. Check that the engine/transmission is completely free of vacuum hoses, fuel and coolant hoses and electrical wiring. 52. Slowly lower the engine about 150 mm (6 in.). Check once again that all hoses and wires are disconnected from the engine/transmission. 53. Lower the engine all the way, and disconnect the chain hoist from the engine. 54. Remove the engine from under the vehicle.

50. Remove the transmission lower rear mount.

5-10

BACK

r

Engine Installation 1. Install the accessory brackets and tighten their bolts and nuts to the specified torques. P/SPUMP

8x 1.25 mm 22 N·m 12.2 kgf.m, 16lbf·ftl

BRACKET

10x 1.25mm 44 N·m 14.5 kgf·m, 33lbf·ftl

-..,f--.....:::::~

8x 1.25 mm 22 N·m 12.2 kgf.m, 16lbf·ftl

10 x 1.25 mm 44 N·m 14.5 kgf·m, 33lbf.ftl

(cont'd)

BACK

5-11

Engine Assembly Engine Installation (cont'd) 2. Position the engine under the vehicle. Attach the chain hoist to the engine, then lift the engine into position in the vehicle.

5. Install the AlC compressor.

INOTICE I Reinstall the mounting bolts/nuts in the sequence given. Failure to follow this sequence may cause excessive noise and vibration, and reduce bushing life. 3. Install the transmission lower rear mount.

!

8x 1.25 mm 22 N·m (2.2 kgf·m, 16lbf·ftl

6. Install the front beam. Align mark (A) on the rear beam (8) and front beam (C), then tighten the bolts (D). B

A


c

4. Install the rear mount bracket.

1

'

10x1.25mm 38 N·m (3.9 kgf.m, '\. 28 Ibf·ftl

\

D

D F


I

14x 1.5mm 103 N·m (10.5 kgf·m, 76lbf·ftl Replace.

7. Tighten the transmission lower rear mount mounting nuts (E) and transmission lower front mount mounting nuts (F).


5-12


BACK

8. Tighten the flange bolts on the radius rods. 14x 1.5 mm 162 N·m (16.5 kgf.m, 119 Ibf·ft)

11. Tighten the rear mount bracket support nut and mounting bolt. 12x 1.25 mm 54 N·m (5.5 kgf·m, 40Ibf·ft)

~a

I

/

9. Lower the hoist.

10 x 1.25 mm 38 N·m (3.9 kgf·m, 28 Ibf·ft)

10. Tighten the front mount bracket support nut. 12x 1.25mm 54 N·m (5.5 kgf·m, 40 Ibf.ft)

~e

12. Install the side engine mount bracket, then tighten the mounting bolts in the numbered sequence shown.

CD 10 x 1.25 mm

44 N·m (4.5 kgf.m, 40Ibf·ft)

\

®

12x 1.25 mm 54 N·m (5.5 kgf·m, 40Ibf·ft)

\ 13. Remove the chain hoist from the engine.

(cont'd)

BACK

5-13

Engine Assembly Engine Installation (cont'd) 14. Raise the hoist to full height. 15. Install a new spring clip on the end of each driveshaft, then install the driveshafts. Make sure each clip "clicks" into place in the differential and intermediate shaft. 16. Connect the suspension lower arm ball joints use new cotter pins; refer to the '98-02 Accord Service Manual (see page 18-17).

17. Install the damper fork; refer to the '98-02 Accord Service Manual (see page 18-21).

19. Install the control lever (A) with the shift cable on the control shaft. 00 not bend the shift cable any more than is necessary to install the control lever.

6x 1.0mm 12 N·m (1.2 kgf·m, 8.7 rbf·tt)

~~

18. Install exhaust pipe A (A); use new gaskets (8) and new self locking nuts (C). Then connect the Primary Heated Oxygen Sensor connector (0). 8x 1.25 mm 22 N·m (2.2 kgf·m, 16rbf·tt)

20. Install the lock bolt (8) with a new lock washer (C), then bend the lock tab of the lock washer. 21. Install the shift cable cover (0), then install the shift cable holder (E) on the shift cable cover. 22. Install the PIS hose into the clamps (A), and connect the engine mount control vacuum hose (8).

C 10x 1.25 mm

10x 1.25 mm 38 N·m (3.9 kgf·m, 28 rbf·tt)

C 10x 1.25 mm 54 N·m (5.5 kgf·m, 40 rbf·tt) Replace.

5-14

BACK

23. Connect the upper radiator hose (A), and the lower radiator hose (B).

25. Connectthe Automatic Transmission Fluid (ATF) cooler hoses.

A

24. Install the heater hoses, then install the distributor cap.


(cont'd)

BACK

5-15

Engine Assembly Engine Installation (cont'd) 27. Install the front tires/wheels.

34. Install the starter cable clamps.

28. Lower the hoist. 29. Install the alternator belt. 30. Loosely install the Power Steering (P/S) pump belt and pump. 31. Adjust the Power Steering (P/S) pump belt (see page 17-13). 32. Push in the Powertrain Control Module (PCM) connectors, through the bulkhead then install the grommet (A). A

35. Install the under-hood fuse/relay box (A) and harness clamps (B).

c

6x1.0mm 12 N·m (1.2 kgf·m, 8.7Ibf.ft) 6x1.0mm 12N·m (1.2kgf·m, 8.7Ibf·ft)

33. Connect the PCM connectors.

36. Install the battery cables (C), and connect the connector (D) from the under-hood fuse/relay box (A).

5-16

BACK

39. Install the fuel hose (A) and fuel return hose (8), using new washers (C).

37. Install the engine wire harness clamps.

'98-99 models: A

38. Install the brake booster vacuum hose (A) and the cruise control vacuum hose (8).

c

B

22 N·m (2.2 kgf·m, 16Ibf·ft)

'00-02 models:

"'--------

22N·m (2.2 kgf·m, 16Ibf·ft)

40. Connect the engine wire harness connectors on the left side of the engine compartment.

(cont'd)

BACK

5-17

Engine Assembly Engine Installation (cont'd) 41. Install the cruise control cable, then adjust the cable (see page 4-53).

45. Install the intake air duct (A), then install the vacuum hose (B) and breather pipe (C).

42. Install the throttle cable, then adjust the cable (see page 11-100). 43. Install the battery base bracket (A), battery base (B), then install the ground cable (C) and harness clamp (D).

8x 1.2Smm 22 N·m 12.2 kgf·m, 16Ibf·ft) / 6x1.0mm 12 N·m 11.2 kgf.m,

~~ftl c

B

46. Install the Evaporative Emission (EVAP) canister hose (D) to the throttle body. 47. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.

c

8x1.2Smm 22 N·m 12.2 kgf'm, 16 Ibf·ft)

44. Install the throttle body cover (A) and intake manifold cover (B).

48. Refill the engine with engine oil (see page 8-5). 49. Refill the transmission with Automatic Transmission Fluid (ATF) (see page 14-113). 50. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open (see page 10-10). 51. Move the shift lever to each gear, and verify that the AfT gear position indicator follows the transmission range switch. 52. Inspect for fuel leaks. Turn on (II) the ignition switch (do not operate the starter) so that the fuel pump runs for approximately 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line. 53. Enter the anti-theft code for the radio, then enter the customer's radio station presets.

5-18

BACK

~

Engine Mechanical Cylinder Head Special Tools .................................................................... Component Location Index ............................................. DTC Troubleshooting ...................................................... VTEC Solenoid Valve Test ............................................... VTEC Rocker Arms Test ................................................... Valve Clearance Adjustment ........................................... Crankshaft Pulley Removal and Installation ..................................................................... Timing Belt Inspection ..................................................... Timing Belt Removal ....................................................... Timing Belt Installatioin ................................................... Cylinder Head Removal ................................................... Cylinder Head Inspection for Warpage ...................................................................... Rocker Arm Assembly Removal ..................................... Rocker Arms and Shafts Disassembly/Reassembly ..... Rocker Arms and Shafts Inspection ............................... VTEC Lost Motion Assemblies Inspection .................................................................... Camshaft Inspection ........................................................ Valves, Springs, and Valve Seals Removal ...................................................................... Valve Inspection ............................................................... Valve Stem-to-Guide Clearance Inspection .................................................................... Valve Guide Replacement ............................................... Valve Seat Reconditioning .............................................. Valves, Springs, and Valve Seals Installation ................................................................... Camshaft/Rocker Arms, Camshaft Seal, and Pulley Installation ...................................... Cylinder Head Installation ............................................... TDC Sensor Replacement ............................................... CKP Sensor Replacement ................................................

BACK

6-2 6-3 6-6 6-9 6-10 6-13 6-17 6-18 6-19 6-22 6-31 6-36 6-36 6-37 6-38 6-39 6-40 6-43 6-44 6-44 6-45 6-47 6-49 6-50 6-51 6-55 6-56

Cylinder Head Special T 0015 Ref. No.

CD CD ® CD ® ® (j) ®-1 ®-2 ®-3

® @l

Tool Number 07HAH-PJ7010B 07 JAA-OO 1020A 07 JAB-OO 1020A 07MAB-PY30100 07 NAJ-P070 1OA 07VAJ-P8A010A 07VAJ-P8A020A 07406-0070300 07MAJ-PY4011A 07MAJ-PY40120 07742-0010100 07757-PJ1010A

Description Valve Guide Reamer, 5.5 mm Socket, 19 mm Holder Handle Pulley Holder Attachment, 50 mm Offset Pressure Gauge Adapter VTEC Air Adapter VTEC Air Stopper AfT Low Pressure Gauge W/Panel AfT Pressure Hose, 2,210 mm AfT Pressure Hose Adapter Valve Guide Driver, 5.5 mm Valve Spring Compressor Attachment

CD

Qtv 1 1 1 1 1 1 1 1 1 1 1 1

®

.~~

~ ®

®

®-1, ®-2, ®-3

5J I I

®

6-2

BACK

Component Location Index REAR UPPER COVER

RUBBER SEAL

TIMING BELT Inspection, page 6-18 Removal. page 6-19 Installation, page 6-22

~

PULLEY BOLT Replacement, page 6-17

CRANKSHAFT PULLEY Replacement, page 6-17 RUBBER SEAL

TIMING BELT DRIVE PULLEY

AUTO-TENS lONER

IDLER PULLEY

(cant'd)

BACK

6-3

Cylinder Head Component Location Index (cont'd) HEAD COVER GASKET CYLINDER HEAD BOLT

WASHER

RUBBER SEAL

OIL CONTROL ORIFICE

CYLINDER HEAD COVER

Installation, page 6-51

CYLINDER HEAD GASKET

OIL CONTROL ORIFICE

6-4

BACK

ROCKER ARM ASSEMBLIES

Removal, page 6-36 Inspection, page 6-37

CAMSHAFT

Inspection, page 6-40 VALVE KEEPERS

~---VALVE KEEPERS

-~

-----@) SPRING RETAINER

____ INTAKE VALVE SPRING

______ INTAKE VALVE SEAL Installation, page 6-49

~RETAINER I~USTVALVE

O-RING

~

~

SPRING

VALVE SPRING SEAT /Installation, page 6-49

@

/

~--EXHAUST VALVE SEAL

LOST MOTION

~~lIation, page 6-49 VALVE SPRING SEAT

ASSEMBLY

~ation, page 6-49

EXHAUST VALVE GUIDE INTAKE VALVE GUIDE

Inspection, page 6-44 Replacement, page 6-45

Inspection, page 6-44 Replacement, page 6-45

~~~~~~~@(b ....,-CYLINDER HEAD Removal, page 6-31 ~

Warpage, page 6-36 Valve seat reconditioning, page 6-47 6-51

@n..."s,;oo, pags INJECTOR BASE

~

~

\

EXHAUST VALVE

BACK

OILSEAL

INTAKE VALVE

Removal, page 6-43 Inspection, page 6-44 Installation, page 6-49

6-5

PGM-FI System DTC Troubleshooting Ole P1259: A problem in the VTEC Oil Pressure Switch circuit or VTEC Solenoid

7. Check for continuity on the VTEC oil pressure switch between the pressure switch connector terminals No.1 and No.2.

Valve circuit

VTEC OIL PRESSURE SWITCH CONNECTOR

Special Tools Required • Pressure Gauge Adaptor 07NAJ-P0701 OA • AfT Low Pressure Gauge W/Panel 07406-0070300 • AfT Pressure Hose, 2,210 mm 07MAJ-PY4011A • AfT Pressure Adaptor 07MAJ-PY40120 1. Do the Powertrain Control Module (PCM) reset procedure; refer to the '98-02 Accord Service Manual (see page 11-3). 2. Start the engine.


3. Warm up the engine to normal operating temperature (cooling fan comes on).

Is there continuity? 4. Road test the vehicle: Accelerate in [!] position to an engine speed over 4,000 rpm. Hold that engine speed for at least 2 seconds. If DTC P1259 is not repeated during the 1st road test, repeat this test two more times.

YES-Go to step 8. NO - Replace the VTEC oil pressure switch .• 8. Turn the ignition switch ON (II).

Is DTC P1259 indicated? 9. Measure the voltage between the VTEC oil pressure switch harness connector No.1 terminal and body ground.

YES - Go to step 5. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the VTEC solenoid valve and PCM .•

VTEC OIL PRESSURE SWITCH HARNESS CONNECTOR

5. Turn the ignition switch OFF. 6. Disconnect the VTEC oil pressure switch connector.


Is there battery voltage? YES - Go to step 10. NO-Inspect for an open or short to ground in the wire between the VTEC oil pressure switch and the PCM (C10). If the wire is OK, substitute a knowngood PCM and recheck .•

'""', 6-6

BACK

10. Measure voltage across the VTEC oil pressure switch harness 2P connector.

14. Remove the VTEC oil pressure switch (A) and install the special tools as shown, then reinstall the VTEC oil pressure switch.

VTEC OIL PRESSURE SWITCH HARNESS 2P CONNECTOR

A

07NAJ-P07010A

L-----{'Y,}------'


Is there battery voltage? 15. Reconnect the VTEC solenoid valve 1P connector and VTEC oil pressure switch 2P connector.

YES-Go to step 11. NO- Repair open in the wire between the VTEC oil pressure switch and G101.lfthe wire is OK, substitute a known-good PCM and recheck .•

16. Connect a tachometer. 17. Warm up the engine to normal operating temperature (cooling fan comes on).

11. Turn the ignition switch OFF. 12. Disconnect the VTEC solenoid valve 1P connector. 13. Check for continuity on the VTEC solenoid valve between the solenoid valve 1P connector terminal and body ground.

18. Check oil pressure at engine speeds of 1,000, 2,000 and 3,000 rpm. Keep measuring time as short as possible because the engine is running with no load (less than 1 minute). Is pressure below 49 kPa (0.5 kgflcrrf , 7 psi)?

VTEC SOLENOID VALVE 1P CONNECTOR

YES-Go to step 19. NO-Inspect the VTEC solenoid valve (see page 69) .•

.Q

19. Turn the ignition switch OFF. 20. Disconnect the VTEC solenoid valve 1P connector.


Is there 14- 30 Q ?

21. Attach the battery positive terminal to the VTEC solenoid valve terminal. 22. Start the engine and check oil pressure at an engine speed of 3,000 rpm.


Is pressure above 390 kPa (4.0 kgflcrrf ,57 psi)?

NO - Replace the VTEC solenoid valve .•

YES-Go to step 23. NO -I nspect the VTEC solenoid valve (see page 69) .•

(cont'd)

BACK

6-7

PGM-FI System DTC Troubleshooting (co nt'd) 23. With the battery positive terminal still connected to the VTEC solenoid valve, measure voltage between C10 and body ground.

27. Check for continuity between the VTEC solenoid valve 1P connector terminal and body ground. VTEC SOLENOID VALVE HARNESS 1P CONNECTOR

PCM CONNECTOR C (31PI VTM (BLU/BLKI

= Wire side offemale terminal


Is there continuity? Is there battery voltage above 4,000 rpm? YES- Repair short in the wire between the PCM (812) and VTEC solenoid valve connector.•

YES - Go to step 24. NO- Replace the VTEC oil pressure switch .• 24. Turn the ignition switch OFF.

NO-Substitute a known-good PCM and recheck. If symptom/indication goes away, replace the original PCM .•

25. Disconnect the battery positive terminal from the VTEC solenoid valve terminal. 26. Check for continuity between the VTEC solenoid valve harness 1P connector terminal and the PCM connector terminal 812. VTEC SOLENOID VALVE HARNESS 1P CONNECTOR

VTS (GRN/YELI

PCM CONNECTOR B (25PI Wire side of female terminals

Is there continuity? YES-Go to step 27. NO-Repair open in the wire between the PCM (812) and VTEC solenoid valve connector.•

6-8

BACK

Cylinder Head VTEC Solenoid Valve Test 1. Disconnect the 1P connector from the VTEC solenoid valve. 2. Measure resistance between the terminal and body ground.

4. If the filter is not clogged, push the VTEC solenoid valve with your finger and check its movement. If the VTEC solenoid valve is normal, check the engine oil pressure. 6x 1.0mm 12 N·m 11.2 kgf.m, 8.7 Ibf·ft)

Resistance: 14-30 Q

j

22 N·m 12.2 'gl·m.

o

&>

= 3. If the resistance is within specifications, remove the VTEC solenoid valve/oil filter assembly (A) from the oil pump, and check the VTEC solenoid valve filter (8) for clogging. If there is clogging, clean the filter and replace the engine oil filter and the engine oil. 8x 1.2Smm

""""'~//

22 N\12.2 '''.m. 1. Ibl.-:-ft.... )

BACK

6-9

Cylinder Head VTEC Rocker Arm Test Special Tools Required • VTEC Air Adapter 07VAJ-P8A010A • VTEC Air Stopper 07VAJ-P8A020A

2. Remove the Evaporative Emission (EVAP) canister hose (A) from the throttle body .

1. '98-99 models: Remove the throttle body cover (A), ignition wire cover (B) and intake manifold covers (C).

'00-02 models: Remove the throttle body cover (A), intake manifold covers (B) and intake manifold cover stay (C). '98-99 models:

C

B

3. Remove the vacuum hose (B) and breather pipe (C), then remove the intake air duct (D).

c

4. Remove the throttle cable (A) and cruise control cable (B) by loosening the locknuts (C), then slip the cable ends out of the accelerator linkage. Take care not to bend the cables when removing them. Always replace any kinked cable with a new one.

'00-02 models:

6-10

BACK

r 5. Remove the brake booster vacuum hose (A), vacuum hoses (8) and Positive Crankcase Ventilation (PCV) hose (C).


8. Remove the cylinder head covers. 9. Remove the front upper cover (see step 2 on page 6-18).

A

6. Remove the vacuum hose (A) ('98-99 models), breather hose (8) and water bypass hoses (C).

10. Set the No.1 piston at TOC (see step 10 on page 614). 11. Push on the intake mid rocker arm (A) for the No.1 cylinder. The mid rocker arm should move independently of the primary rocker arm (8) and secondary rocker arm (C) . • Ifthe intake mid rocker arm does not move, remove the mid, primary, and secondary intake rocker arms as an assembly, and check that the pistons in the mid and primary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary, mid and secondary rocker arms as an assembly, and retest . • Ifthe mid rocker arm moves freely, go to step 12.

A

B

B

c

c

A

(cont'd)

BACK

6-11

Cylinder Head VTEC Rocker Arm Test (cont'd) 12. Repeat step 11 on the remaining intake mid rocker

18. Make sure that the intake primary rocker arm (A) and intake secondary rocker arm (8) are mechanically connected by the piston and that the mid rocker arm (C) does not move when pushed manually. If any intake mid rocker arm moves independently of the primary and secondary rocker arms, replace the rocker arms as a set.

arms with each piston at TDC. When all the mid rocker arms pass the test, go to step 13.

13. Check that the air pressure on the shop air compressor gauge indicates over 690 kPa (7.0 kgf/cm2, 100 psi).

A

14. Inspect the valve clearance (see page 6-13). 15. Cover the timing belt with a shop towel to protect the belt.

16. Remove the 2 intake rocker shaft mounting bolts, then connect the special tools and Valve Inspection an air pressure regulator with a 0-100 psi gauge (A) as shown below.

B

c

19. Remove the tools. 20. Check for smooth operation of each lost motion assembly (see page 6-37). Replace the lost motion assembly if it does not move smoothly.

07VAJ-P8A020A

07VAJ-P8A010A

17. Loosen the valve on the regulator and apply the specified air pressure. Specified Air Pressure: 390 kPa (4.0 kgf/cm2, 57 psi) NOTE: Ifthe synchronizing pistons A and 8 do not move after applying air pressure; move the primary or secondary rocker arm up and down manually by rotating the crankshaft clockwise.

6-12

BACK

~

r

Valve Clearance Adjustment NOTE: Adjust the valves only when the cylinder head temperature is less than 100°F (38°C).


1. '98-99 models: Remove the throttle body cover (A), ignition wire cover (B) and intake manifold covers (C).

'00-02 models: Remove the throttle body cover (A), intake manifold covers (B) and intake manifold cover stay (C). '98-99 models:

3. Remove the vacuum hose (B) and breather pipe (C), then remove the intake air duct (0). 4. Remove the throttle cable (A) and cruise control cable (B) by loosening the locknuts (C), then slip the cable ends out of the accelerator linkage. Take care not to bend the cables when removing them. Always replace any kinked cable with a new one.

".,' \,

c '00-02 models:

(cant'd)

BACK

6-13

Cylinder Head Valve Clearance Adjustment (cont'd) 5. Remove the brake booster vacuum hose (A), vacuum hoses (8) and Positive Crankcase· Ventilation (PCV) hose (C).


6. Remove the vacuum hose (A) ('98-99 models), breather hose (8) and water bypass hoses (C).

8. Remove the cylinder head covers. 9. Remove the front upper cover (see step 2 on page

A

6-18).

10. Set the No.1 piston at TDC. Align the pointer (A) on the back cover with the No.1 piston TDC mark (8) on the front camshaft pulley. A

B

6-14

c

BACK

B

~

11. Select the correct thickness feeler gauge for the valves you're going to check. Intake: 0.20-0.24 mm (0.008-0.009 in.) Exhaust: 0.28-0.32 mm (0.011-0.013 in.)

13. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until the drag on the feeler gauge is correct. A 7xO.75mm 20 N·m (2.0 kgf.m, 14lbf·ftl

Adjusting screw locations: EXHAUST

No.1

No.2

No.3

REAR:

B

No.1

No.2

14. Tighten the locknut and recheck the clearance. Repeat the adjustment if necessary.

No.3

INTAKE

No.4

No.5

15. Rotate the crankshaft clockwise. Align the pointer (A) on the back cover with the No.4 piston TOC mark (B) on the front camshaft pulley.

No.6

A

B

FRONT:

No.4

No.5

No.6

EXHAUST

12. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem and slide it back and forth; you should feel a slight amount of drag. 16. Check and, if necessary, adjust the valve clearance on No.4 cylinder.

B

(cont'd)

BACK

6-15

Cylinder Head Valve Clearance Adjustment (cont'd) 17. Rotate the crankshaft clockwise. Align the pointer (A) on the back cover with the No.2 piston TDC mark (8) on the front camshaft pulley.

21. Rotate the crankshaft clockwise. Align the pointer (A) on the back cover with the No.3 piston TDC mark (8) on the front camshaft pulley.

B

A

A

B

18. Check and, if necessary, adjust the valve clearance on No.2 cylinder.




A

B


6-16

A

B


BACK

Crankshaft Pulley Removal and Installation Special Tools Required

• Holder Handle 07JAB-001020A • Holder Attachment, 50 mm, Offset 07 MAB-PY301 OA • Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket

Removal 1. Hold the pulley with holder handle (A) and holder attachment (B).

2. Install the crankshaft pulley, and tighten the bolt to 245 N·m (25.0 kgf·m, 181 Ibf·ft). Do not use an impact wrench. -1 Hold the pulley with holder handle (A) and holder attachment (B). -2 Tighten the bolt with a torque wrench and 19 mm socket (C).

A

07JAB-001020A

B

07MAB-PV3010A

B 07MAB-PV3010A

\

~c 07 JAA-001 020A (or Commercially available)

~c 07JAA-001020A (or Commercially available)


Installation 1. Clean the pulleys (A), crankshaft (B), bolt (C) and washer (D). Lubricate the points shown below.

0: Clean • : Lubricate

BACK

6-17

Cylinder Head Timing Belt Inspection 1. '98-99 models: Remove the throttle body cover (A), ignition wire cover (8) and intake manifold cover

2. Remove the front upper cover.

(e).

'00-02 models: Remove the throttle body cover (A) and intake manifold cover (8). '98-99 models:

\ 3. Inspect the timing belt for cracks and oil or coolant soaking. Replace the. belt if it is oil or coolant soaked. Remove any oil or solvent that gets on the belt.

c

'00·02 models:

6-18

BACK

Timing Belt Removal 3. Remove the front tires/wheels.


• Holder Handle 07JAB-001020A • Holder Attachment, 50 mm, Offset 07MAB-PY301 OA • Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket • Belt Tension Release Arm, YA931 7, commercially available


~~~ ........... =

~

1. Turn the crankshaft so its white mark (A) lines up with the pointer (B). B

/1 5. Move the auto-tensioner (A) with the belt tension release arm (B) to remove tension from the alternator belt (C), then remove the alternator belt.

A

2. Check that the rear camshaft pulley mark (A) and rear upper cover mark (B) are aligned. A

B

(cont'd)

BACK

6-19

Cylinder Head Timing Belt Removal (cont'd) 6. Loosen the adjusting nut (A), locknut (8) and mounting bolt (C), then remove the power steering (PIS) pump belt (D).

9. Remove the dipstick and tube (A); discard the 0ring (8).

e A

10. Hold the pulley with holder handle (A) and holder attachment (8). B

7. Support the engine with a jack and wood block under the oil pan.

07MAB-PY3010A

8. Remove the side engine mount bracket.

---e

07 JAA-001 020A lor Commercially available)


6-20

BACK

12. Remove the front upper cover (A), rear upper cover (8) and lower cover (C). B

14. To hold the timing belt adjuster its current position, screw the battery clamp bolt in as shown. Tighten it by hand, do not use a wrench.

\ 15. Remove the engine mount bracket. A

c 13. Remove one ofthe battery clamp bolts from the battery tray, and grind the end of it as shown.

(cont'd)

BACK

6-21

Cylinder Head Timing Belt Removal (cont'd)

Timing Belt Installation

16. Loosen the idler pulley bolt (A) about five or six turns, then remove the timing belt.

NOTE: The following procedure is for installing a new timing belt. If you are installing a used timing belt, refer to the next procedure.

New Belt 1. Clean the timing belt pulleys, and upper and lower covers. 2. Set the timing belt drive pulley to TDC by aligning the TDC mark (A) on the tooth of the timing belt drive pulley with the pointer (8) on the oil pump.

A

6-22

BACK

3. Clean the camshaft pulleys. Set the camshaft pulleys to TOC by aligning the TOC marks (A) on the camshaft pulleys with the pointers (8) on the back covers.

NOTE: Handle the auto-tensioner carefully so the oil inside does not spill or leak. If any of the oil has spilled or leaked out of the auto-tensioner, refill it with 5 W-30 motor oil. The total capacity is 6.5 mll (0.22 fl oz).

FRONT: B

6. Hold the auto-tensioner (A) with the maintenance bolt pointing up. Loosen and remove the maintenance bolt (8).

A

7. Clamp the boss of the auto-tensioner in a softjawed vise. 00 not grip the housing of the autotensioner.

REAR:

S. Insert a flat blade screwdriver (C) into the maintenance hole. Place the holder (0) (PIN 14540PSA-A01) on the auto-tensioner while turning the screwdriver clockwise to compress the bottom. NOTE: Take care not to damage the threads or the gasket contact surface with the screwdriver. 9. Reinstall the maintenance bolt (A). Always use a new gasket (8). A 8 N·m (0.8 kgf.m, 6 Ibf·ft)

~

4. Remove the battery clamp bolt from the back cover. 5. Remove the auto-tensioner.

(cont'd)

BACK

6-23

Cylinder Head Timing Belt Installation (cont'd) 10. Make sure no oil is leaking around the maintenance bolt, then install the auto-tensioner (A).

12. Tighten the idler pulley bolt.

NOTE: Make sure the holder (8) stays in place.

10x 1.25 mm

44 N·m /4.5 kgf·m, 33 Ibf·tt)

13. Remove the holder. 6x1.0mm 12 N·m (1.2 kgf.m,

8.7Ibf·ft)

11. Install the timing belt in a counter clockwise sequence starting with the drive pulley.

E

c

6-24

BACK

14. Install the engine mount bracket.

16. Clean the crankshaft pulley bolt and washer. 17. Clean all oil off the inside face (A) of the crankshaft pulley, and apply lubricant to the pulley bolt (S) and washer (C).

6x 1.0mm 12 N·m (1.2 kgf·m, 8.7Ibf·ft)

0: Clean • : Lubricate

c

! .

~/G ~10X1.25mm &'-44 N·m (4.5 kgf·m, 33 Ibf·ft)

[ff~

18. Install the crankshaft pulley, and tighten the bolt to 245 N·m (25.0 kgf·m, 181 Ibf·ft). Do not use an impact wrench.

15. Install the lower cover (A), front upper cover (S) and rear upper cover (C).

\

-1 Hold the pulley with holder handle (A) and holder attachment (S). -2 Tighten the bolt with a torque wrench and 19 mm socket (C). A B 07JAB-001020A

07MAB-PY3010A

\

"-c

B

07 JAA-001 020A (or Commercially available)

A 6x 1.0 mm 12 N·m (1.2 kgf·m, 8.7 Ibf·ft)

19. Rotate the crankshaft pulley about five or six turns clockwise so the timing belt positions on the pulleys.

(cont'd)

BACK

6-25

Cylinder Head Timing Belt Installation (cont'd) 20. Turn the crankshaft pulley so its white mark (A) lines up with the pointer (8).

22. Install the dipstick and tube (A) with a new O-ring (8).

B

6x 1.0 mm 12 N·m (1.2 kgf·m, 8.7 Ibf·tt)

A 21. Check the camshaft pulley marks. • If the camshaft pulley marks are at TDC, go to step 22 . • If the camshaft pulley marks are not at TDC, remove the timing belt and repeat steps 2 through 20.

23. Install and adjust the PIS pump belt (see page 1710).

24. Install the alternator belt. 25. Install the side engine mount bracket, then tighten the mounting bolts in the numbered sequence shown.

FRONT CAMSHAFT PULLEY:

Q) 10 x 1.25 mm 44 N·m (4.5 kgf·m, 33 Ibf·tt)

~ ®12x 1.25 mm

\ ' . ' '".m. 40 Ibf·ftl A

REAR CAMSHAFT PULLEY:

A

6-26

BACK

Used Belt Follow this procedure when installing a used timing belt. 1. Clean the timing belt pulleys, and upper and lower covers.

3. Clean the camshaft pulleys. Set the camshaft pulleys to TOC by aligning the TOC marks (A) on the camshaft pulleys with the pointers (B) on the back covers.

FRONT: B

A

2. Set the timing belt drive pulley to TOC by aligning the TOC mark (A) on the tooth of the timing belt drive pulley with the pointer (B) on the oil pump. B

\

A

REAR: B

(cont'd)

BACK

6-27

Cylinder Head Timing Belt Installation (cont'd) 4. If the auto-tensioner has extended and the timing belt cannot be installed, remove and compress the auto-tensioner (refer to steps 6-23 of the New Belt Installation Procedure).

7. Remove the battery clamp bolt from the back cover.

5. Install the timing belt in a counter clockwise sequence starting with the drive pulley. Take care not to damage the timing belt when installing it. -1 Drive pulley (A). -2 Idler pulley (B). -3 Front camshaft pulley (C). -4 Water pump pulley (D). -5 Rear camshaft pulley (E). -6 Adjusting pulley (F).

E

\

8. Install the engine mount bracket. 6x1.0mm 12 N·m 11.2 kgf·m, 8.7Ibf·ft)

~

0

c

6. Tighten the idler pulley bolt.

~--

-D10X1.25mm 44 N·m 14.5 kgf·m, 33Ibf·ft)

10x 1.2Smm 44 N·m (4.5 kgf·m, 33 Ibf·ft)

6-28

BACK

9. Install the lower cover (A), front upper cover (B) and rear upper cover (C). C

12. Install the crankshaft pulley, and tighten the bolt to 245 N·m (25.0 kgf·m, 181 Ibf·ft). Do not use an impact wrench.

\

-1 Hold the pulley with holder handle (A) and holder attachment (B). -2 Tighten the bolt with a torque wrench and 19 mm socket (C). B A 07

Jj'' "1'020A

07MAB-PY3010A

B A

~C

6x1.0mm 12 N·m 11.2 kgf·m, 8.7 Ibf·ft)

07JAA-001020A (or Commercially available)

10. Clean the crankshaft pulley bolt and washer. 11. Clean any oil off the inside face (A) of the crankshaft pulley, and apply lubricant to the pulley bolt (B) and washer (C). O:Clean • : Lubricate

13. Rotate the crankshaft pulley about five or six turns clockwise so the timing belt positions on the pulleys. 14. Turn the crankshaft pulley so its white mark (A) lines up with the pointer (B). B

C

I .. [J~ A

(cont'd)

BACK

6-29

Cylinder Head Timing Belt Installation (cont'd) 15. Check the camshaft pulley marks (A).

16. Install the dipstick and tube (A) with a new O-ring (8) .

• If the camshaft pulley marks are at TDC, go to step 16. • If the camshaft pulley marks are not at TDC, remove the timing belt and repeat steps 2 through 14.

A

FRONT CAMSHAFT PULLEY:

A

17. Install and adjust the PIS pump belt (see page 1710). 18. Install the alternator belt.

REAR CAMSHAFT PULLEY:

19. Install the side engine mount bracket, then tighten the mounting bolts in the numbered sequence shown. Ci)10 x 1.25 mm 44 N·m(4.5 kgf·m, 33 Ibf·ft)

~ ®12x 1.25 mm

' \ . ' k"·m. 40 Ibf·1tl A

~i

6-30

BACK

Cylinder Head Removal Special Tool Required Belt Tension Release Arm,YA9317, commercially available

'00-02 models:

Engine removal is not required this procedure. NOTE: • Use fender covers to avoid damaging painted surfaces. • To avoid damage, unplug the wiring connectors carefully while holding the connector portion. • To avoid damaging the cylinder head, wait until the engine coolant temperature drops below 100°F (38°C) before loosening the retaining bolts. • Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.


1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative terminal. 3. Drain the engine coolant (see page 10-10). 4. '98-99 models: Remove the throttle body cover (A) , ignition wire cover (B) and intake manifold covers (C).

'00-02 models: Remove the throttle body cover (A) , intake manifold covers (B) and intake manifold cover stay (C). '98-99 models:

C

B

6. Remove the vacuum hose (B) and breather pipe (C) , then remove the intake air duct (D).

c

(cont'd)

BACK

6-31

Cylinder Head Cylinder Head Removal (cont'd) 7. Remove the throttle cable (A) and cruise control cable (8) by loosening the locknuts (C), then slip the cable ends out ofthe accelerator linkage.Take care not to bend the cables when removing them. Always replace any kinked cable with a new one.

10. Remove the brake booster vacuum hose (A), vacuum hoses (8) and Positive Crankcase Ventilation (PCV) hose (C).

A

8. Relieve fuel pressure (see page 11-89).

11. Remove the vacuum hose (A), ('98-99 models) breather hose (8) and water bypass hoses (C). A

9. Remove the fuel feed hose (A) and fuel return hose (8).

'98-99 models:

B

'00-02 models

,-----

A

6-32

BACK

12. Remove the ground cable (A).

16. Loosen the adjusting nut (A), then remove the locknut (8) and mounting bolt (C). Remove the Power Steering (PIS) pump belt (D) and pump without disconnecting the PIS hoses.

~~\

o 13. Move the auto-tensioner (8) with the belt tension release arm (C) to remove tension from the alternator belt (D), then remove the alternator belt.

14. Support the engine with a jack and wood block under the oil pan.

o

B

17. Remove the PIS hose clamp (E). 18. Remove the alternator (see page 4-31).

15. Remove the side engine mount bracket. 19. Remove the engine wire harness connectors and wire harness clamps from the cylinder heads and the intake manifold.

• • • • • • • • • • • • • • •

Intake Air Temperature (lAT) sensor connector Idle Air Control (lAC) valve connector Throttle Position (TP) sensor connector Manifold Absolute Pressure (MAP) sensor connector Engine Coolant Temperature (ECT) sensor connector Radiator fan switch A connector Radiator fan switch 8 connector Coolant temperature gauge sending unit connector ('98-99 models) CKP sensor connector TDC sensor connector Exhaust Gas Recirculation (EGR) valve connector Distributor connector ('98-99 models) VTEC solenoid valve connector VTEC oil pressure switch connector Oil pressure switch connector

20. Remove the spark plug caps and distributor from the cylinder heads.

(cont'd)

BACK

6-33

Cylinder Head Cylinder Head Removal (cont'd) 21. Remove the intake manifold.

24. Remove the vacuum hoses (A) from the intake air bypass control thermal valve (8). A

/

B

22. Disconnect the six injector connectors. 23. Remove the fuel rails. '98-99 models:

A

25. Remove the timing belt (see page 6-19). 26. Remove the upper radiator hose (A) and lower radiator hose (8). A

\

'00-02 models:

6-34

BACK

B

27. Remove the heater hoses.

30. Remove the camshaft pulleys (A) and back covers (B).

28. Remove the front and rear exhaust manifolds (see page 9-3). 31. Remove the cylinder head covers. 29. Remove the water passage. 32. Remove the cylinder head bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.

CYLINDER HEAD BOLT LOOSENING SEQUENCE:

33. Remove the cylinder heads.

BACK

6-35

Cylinder Head Rocker Arm Assembly Removal

Cylinder Head Inspection for Warpage

1. Loosen the adjusting screws (A). NOTE: If camshaft-to-holder oil clearances (see page 640) are not within specifications, the cylinder head cannot be resurfaced.

A

If camshaft-to-holder oil clearances are within specifications, check the cylinder head for warpage. Measure along the edges, and three ways across the center. • If warpage is less than 0.05 mm (0.002 in.), cylinder head resurfacing is not required. • If warpage is between 0.05 mm (0.002 in.) and 0.2 mm (0.008 in.), resurface the cylinder head. • Maximum resurface limit is 0.2 mm (0.008 in.) based on a height of 121 mm (4.76 in.).

A

2. Remove the bolts and the rocker arm assembly. Cylinder Head Height: Standard (New): 120.95-121.05 mm (4.762-4.766 in.'

-1 Unscrew the rocker shaft mounting bolts two turns at a time, in a crisscross pattern, to prevent damaging the valves or rocker arm assembly. -2 When removing the rocker arm assembly, do not remove the rocker shaft mounting bolts. The bolts will keep the springs and the rocker arms on the shafts.


CAMSHAFT HOLDER BOLT LOOSENING SEQUENCE:

6-36

BACK

Rocker Arms and Shafts DisassemblyIReassembly NOTE: o Identify parts as they are removed so they can be reinstalled in their original locations. o Inspect the rocker shafts and rocker arms (see page 6-38). o Rocker arms must be installed in the same positions if reused. o When removing or installing the rocker arm assembly, do not remove the rocker shaft mounting bolts. The bolts will keep the springs and rocker arms on the shaft. o Bundle the rocker arms with rubber bands to keep them together as a set. o Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact points. INTAKE ROCKER SHAFT

INTAKE ROCKER

7~E_Y [QJ

e

0

0

[QJ [QJ

0

e

e

[QJ [QJ

0

0

0

e

[QJ

e

e

WM B

1

A

SPRING

[Q]o

o [Q]

0

o [Q]

0

o[Q]

~

EXHAUST ROCKER SHAFT

Letter B is stamped on rocker arm.

BACK

Letter A is stamped on rocker arm.

6-37

Cylinder Head Rocker Arms and Shafts Inspection Measure the intake rocker shaft and exhaust rocker shaft.

3. Measure the inside diameter of the rocker arm, and check it for an out-of-round condition.

1. Measure the diameter of the shaft at the first rocker location.

Rocker Arm-to-Shaft Clearance: Standard (New): Intake: 0.026-0.067 mm (0.0010-0.0026 in.) Service Limit: 0.067 mm (0.0026 in.) 0.026-0.077 mm Exhaust: (0.0010-0.0030 in.) Service Limit: 0.077 mm (0.0030 in.)

2. Zero the gauge (A) to the shaft diameter.

Inspect rocker arm face for wear.

4. Repeat for all rockers and both shafts. If the clearance is over the limit, replace the rocker shaft and all overtolerance rocker arms. If any intake rocker arm needs replacement, replace all three rocker arms in that set (primary, mid, and secondary).

6-38

BACK

VTEC Lost Motion Assemblies Inspection VTEC Rocker Arms 5. Inspect the rocker arm pistons (A). Push them manually. Ifthey do not move smoothly, replace the rocker arm set.

Push on the lost motion assembly (A) with your finger. If it does not move smoothly, replace it. A

NOTE:

• Apply oil to the pistons when reassembling . • When reassembling the primary rocker arm (8), carefully apply air pressure to the oil passage of the rocker arm.

B

r BACK

6-39

Cylinder Head Camshaft Inspection 1. Remove the rocker arms.

3. Seat the camshaft by pushing it toward the rear of the cylinder head.

2. Put the rocker shafts on the cylinder head, then tighten the bolts to the specified torque.

Specified torque: 8X1.25mm 24 N·m (2.4 kgf·m, 17 Ibf·ft) Apply engine oil to the bolt threads and flange

®

®

@

®

0

4. Zero the dial indicator against the end of the camshaft. Push the camshaft back and forth and read the end play.

Camshaft End Play: Standard (New): 0.05-0.20 mm (0.002-0.008 in.) 0.20 mm (0.008 in.) Service Limit:

®

5. Remove the camshaft thrust cover (A), then pull out the camshaft (B).

6-40

BACK

6. Wipe the camshaft clean, then inspect the lift ramps. Replace the camshaft if any lobes are pitted, scored or excessively worn. 7. Measure the diameter of each camshaft journal.

9. Clean the camshaft bearing surfaces in the cylinder head. Measure the inside diameter of each camshaft bearing surface, and check for an out-ofround condition. • If the camshaft-to-holder clearance is within limits, go to step 11. • If the camshaft-to-holder clearance is beyond the service limit and the camshaft has been replaced, replace the cylinder head. • If the camshaft-to-holder clearance is beyond the service limit and the camshaft has not been replaced, go to step 10. Camshaft-to-Holder Oil Clearance: Standard (New): 0.050-0.089 mm (0.0020-0.0035 in.) 0.15 mm (0.006 in.) Service Limit:

8. Zero the gauge to the journal diameter.

(cont'd)

BACK

6-41

Cylinder Head Camshaft Inspection (cont'd) 11. Measure cam lobe height.

10. Check total runout with the camshaft supported on V-blocks.

Cam Lobe Height Standard (New): • If the total runout of the camshaft is within the service limit, replace the cylinder head. • If the total runout is beyond the service limit, replace the camshaft and recheck the oil clearance. If tl1e clearance is still out of tolerance, replace the cylinder head. Camshaft Total Runout: Standard (New): 0.03 mm (0.001 in.) max. Service Limit: 0.04 mm (0.002 in.)

INTAKE PRI

34.615 mm (1.3628 in.)

MID

36.210mm (1.4256 in.)

SEC

31.188mm (1.2279 in.)

EXHAUST 36.076mm (1.4203 in.)

SEC MID PRI FRONT BANK

Rotate camshaft while measuring.

EX

IN

EX

-T/B

PRI MID SEC

REAR BANK

EX

IN

EX

-T/B

Inspect this area for wear.

6-42

BACK

Valves, Springs and Valve Seals Removal 3. Install the valve guide seal remover (A).


• Valve Spring Compressor Attachment 07757-PJ1010A • Commercially available Valve Spring Compressor KD383 with No.32 jaws • Commercially available Valve Guide Seal Remover KD3350

A

Identify the valves and valve springs as they are removed so that each item can be reinstalled in its original position. 1. Using an appropriate-sized socket (A) and plastic mallet (B), lightly tap the valve retainer to loosen the valve keepers. B

\

4. Remove the valve seal.

2. Install the valve spring compressor. Compress the spring and remove the valve keepers. 07157-PJ1010A

BACK

6-43

Cylinder Head Valve Inspection

Valve Stem-to-Guide Clearance Inspection

Measure the valve in these areas. Intake Valve Dimensions A Standard (New): 33.90-34.10 mm (1.335-1.343 in.) B Standard (New): 114.85-115.15 mm (4.522-4.533 in.) C Standard (New): 5.485-5.495 mm (0.2159-0.2163 in.) C Service Limit: 5.455 mm (0.2148 in.) D Standard (New): 0.85 -1.15 mm (0.033-0.045 in.) D Service Limit: 0.65 mm (0.026 in.) Exhaust Valve Dimensions A Standard (New): 28.90-29.10 mm (1.138-1.146 in.) B Standard (New): 112.85-113.15 mm (4.443-4.455 in.) C Standard (New): 5.450 - 5.460 mm (0.2146-0.2150 in.) C Service Limit: 5.420 mm (0.2134 in) D Standard (New): 1.05-1.35 mm (0.041-0.053 in.) D Service Limit: 0.95 mm (0.037 in.)

1. Slide the valve out of its guide about 10 mm, then measure the guide-to-stem clearance with a dial indicator while rocking the stem in the direction of normal thrust (wobble method). o If the measurement exceeds the service limit, recheck it using a new valve. o If the measurement is now within the service limit, reassemble using a new valve. o If the measurement with a new valve still exceeds the service limit, go to step 2. Intake Valve Stem-to-Guide Clearance: Standard (New): 0.04-0.09 mm (0.002-0.004 in.) Service Limit: 0.16 mm (0.006 in.) Exhaust Valve Stem-to-Guide Clearance: Standard (New): 0.11 - 0.16 mm (0.004-0.006 in.) Service Limit: 0.24 mm (0.009 in.)

/

1. .1 . - - - - - - - B - - - - - - - - - i....1 --11-- 0

[p~

( o

_____;_:---.J-L...jJO]

~ 2. Subtract the 0.0. of the valve stem, measured with a micrometer, from the 1.0. ofthe valve guide, measured with an inside micrometer or ball gauge. Take the measurements in three places along the valve stem and three places inside the valve guide. The difference between the largest guide measurement and the smallest stem measurement should not exceed the service limit. Intake Valve Stem-to-Guide Clearance: Standard (New): 0.020-0.045 mm (0.0008-0.0018 in.) 0.08 mm (0.003 in.) Service Limit: Exhaust Valve Stem-to-Guide Clearance: Standard (New): 0.055-0.080 mm (0.0022-0.0031 in.) Service Limit: 0.12 mm (0.005 in.)

6-44

BACK

Valve Guide Replacement Special Tools Required • Valve Guide Driver, 5.5 mm 07742-0010100 • Valve Guide Reamer, 5.5 mm 07HAH-PJ7010B

1. As illustrated below, use a commercially available air-impact valve guide driver (A) modified to fit the diameter of the valve guides. In most cases, the same procedure can be done using the special tool and a conventional hammer.

;

A

-D 0 . _1 __

5.3mm (0.21 in.'

5. Turn the head over and drive the guide out toward the camshaft side of head.

I +

I:'

["-..--1

mm 1 87 (3.43 in.'

4. Working from the camshaft side, use the driver and an air hammer to drive the guide about 2 mm (0.1 in.) towards the combustion chamber. This will knock off some of the carbon and make removal easier. Hold the air hammer directly in line with the valve guide to prevent damaging the driver. Wear safety goggles or a face shield.

57 mm (2.24 in.'

-I t 10.8mm (0.42 in.'

2. Select the proper replacement guides and chill them in the freezer section of a refrigerator for about an hour. 3. Use a hot plate or oven to evenly heat the cylinder head to 300°F (150°C). Monitor the temperature with a cooking thermometer. Do not get the head hotter than 300°F (150°C); Excessive heat may loosen the valve seats.

b

l

6. If a valve guide won't move, drill it out with a 8 mm (5/16 in.) bit, then try again. Drill guides only in extreme cases; you could damage the cylinder head if the guide breaks. 7. Remove the new guide(s) from the freezer, one at a time, as you need them.

(cont'd)

BACK

6-45

Cylinder Head Valve Guide Replacement (cont'd) 8. Apply a thin coat of clean engine oil to the outside of the new valve guide. Install the guide from the camshaft side of the head; use the special tool to drive the guide in to the specified installed height (A) of the guide (B). If you have all 12 guides to do, you may have to reheat the head. Valve Guide Installed Height: Intake: 21.20-22.20 mm (0.835-0.874 in.) Exhaust: 20.63-21.63 mm (0.812-0.852 in.)

9. Coat both the reamer and the valve guide with cutting oil. 10. Rotate the reamer clockwise the full length ofthe valve guide bore. 11. Continue to rotate the reamer clockwise while removing it from the bore. 12. Thoroughly wash the guide in detergent and water to remove any cutting residue. 13. Check the clearance with a valve (see page 6-44). Verify that the valve slides in the intake and exhaust valve guides without exerting pressure.

Turn reamer in clockwise direction only.

~

I

6-46

BACK

Valve Seat Reconditioning Ifthe valve guides are worn (see page 6-44), replace them (see page 6-45)before cutting the valve seats. 1. Renew the valve seats in the cylinder head using a valve seat cutter. -1 Carefully cut a 45° seat, removing only enough material to ensure a smooth and concentric seat. -2 Bevel the upper edge of the seat with the 30° cutter and the lower edge of the seat with the 60° cutter. Check the width of the seat and adjust accordingly. -3 Make one more very light pass with the 45° cutter to remove any possible burrs caused by the other cutters. Valve Seat Width: Standard (New): 1.25 -1.55 mm (0.049-0.061 in.) Service Limit: 2.00 mm (0.079 in.)

2. After resurfacing the seat, inspect it for even valve seating: Apply Prussian Blue compound (A) to the valve face. Insert the valve in its original location in the head, then lift it and snap it closed against the seat several times.

A

3. The actual valve seating surface (B), as shown by the blue compound, should be centered on the seat. • If it is too high (closer to 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 . • If 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 restore seat width. NOTE: The final cut should always be made with the 45° cutter.

60°

(cont'd)

BACK

6-47

Cylinder Head Valve Seat Reconditioning (cont'd) 4. Insert the intake and exhaust valves in the head and measure the valve stem installed height (A). Intake Valve Stem Installed Height: Standard (New): 46.75-47.55 mm (1.841-1.872 in.) Service Limit: 47.80 mm (1.882 in.) Exhaust Valve Stem Installed Height: Standard (New): 46.68-47.48 mm (1.838-1.869 in.) Service Limit: 47.73 mm (1.879 in.)

5. If the valve stem installed height is over the service limit, replace the valve and recheck. If it is still over the service limit, replace the cylinder head; the valve seat in the head is too deep.

6-48

BACK

Valves, Springs and Valve Seals Installation Special Tools Required

• Valve Spring Compressor Attachment 07757-PJ1010A or 07VAE-001010A • Commercially available Valve Spring Compressor K0383 with No.32 jaws, commercially available • Commercially available Valve Guide Seal Remover K03372, commercially available

5. Install the valve spring and valve retainer. Place the end of the valve spring with closely wound coils toward the cylinder head. 6. Install the valve spring compressor. Compress the spring and install the valve keepers.

1. Coat the valve stems with engine oil. Install the valves in the valve guides. 2. Check that the valves move up and down smoothly. 3. Install the spring seats on the cylinder head. 4. Install the new valve seals (A) using the valve guide seal installer (8). NOTE: Exhaust valve seals (C) have a black spring (0) and intake valve seals (E) have a white spring (F); they are not interchangeable.

two

7. Lightly tap the end of each valve stem or three times with a plastic mallet (A) to ensure proper seating of the valve and valve keepers. Tap the valve stem only along its axis so you do not bend the stem.

)

E

c

BACK

6-49

Cylinder Head Camshaft/Rocker Arms, Camshaft Seal, and Pulley Installation 1. Apply a light coat of oil around the camshaft oil seal.

5. Loosen the valve adjusting screws.

2. Gently tap the new camshaft oil seal (A) into the cylinder head. -1 Tap the camshaft oil seal in squarely. -2 Tap the oil seal into the cylinder head about 0.5 -1.5 mm (0.02-0.06 in.) from the surface of the cylinder head. 3. Insert the camshaft (8) into the cylinder head, then install the camshaft thrust cover (C). Always use a new O-ring (D).

6. Set the rocker arm assembly in place and loosely install the bolts. Make sure that the rocker arms are properly positioned on the valve stems. 7. Tighten each bolt 2 turns at a time in the sequence shown below to ensure that the rockers do not bind on the valves. Specified torque: 8x1.2Smm 24 N·m (2.4 kgf.m, 17 Ibf·ft) Apply engine oil to the bolt threads and flange

4. Check that the oil seal lips are not distorted.

®

®

®

CD

CD

(j)

8x 1.25 mm

27·m '2.2 kgf·m, 1. I.,·ftl

'(0

~D

/0

/"

C

®

®

8. Install the injector base (A). Always use a new gasket (8). A

\ ax 1.25 mm 22 N·m (2.2 kgf·m, 16 Ibf.ft)

6-50

BACK

Cylinder Head Installation 9. Install the back cover (A), then install the camshaft pulley (8). ax 1.25 mm 22 N·m (2.2 kgf·m, 16Ibf·ft)

Install the cylinder heads in the reverse order of removal: 1. Clean the cylinder heads and block surface. 2. Clean and install the oil control orifices (A) with new O-rings (8). 3. Install the dowel pins (C) and new cylinder head gaskets (D).

12x 1.25 mm 90 N·m (9.2 kgf.m, 67 Ibf·ft) Apply engine oil to the bolt threads.

B A

(cont'd)

BACK

6-51

Cylinder Head Cylinder Head Installation (cont'd) 4. Clean the timing belt drive pulley. 5. Set the timing belt drive pulley to TOC by aligning the TOC mark (A) on the tooth ofthe timing belt drive pulley with the pointer (8) on the oil pump.

6. Clean the camshaft pulleys. Set the camshaft pulleys to TOC by aligning the TOC marks (A) on the camshaft pulleys with the pointers (8) on the back covers.

FRONT: A

B

REAR: A

6-52

BACK

B

7. Apply clean engine oil to the threads and flange of the cylinder head bolts. 8. Tighten the cylinder head bolts sequentially in three steps. Perform each step twice. 1st step torque: 39 N·m (4.0 kgf·m, 29 Ibf·ft) 2nd step torque: 69 N·m (7.0 kgf·m, 51 Ibf·ft) 3rd step torque: 98.1 N·m (10.0 kgf·m, 72.3 Ibf·ft) Use a beam-type torque wrench. When using a preset-type torque wrench, be sure to tighten slowly and not to overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt, and retighten it from the first step.

CYLINDER HEAD BOLTS TORQUE SEQUENCE:

9. Install the exhaust manifold and tighten the nuts in a crisscross pattern in two or three steps, beginning with the inner nut (see page 9-3). Always use a new exhaust manifold gasket. 10. Install exhaust pipe A and bracket, then install the cover (see page 9-4). 11. Install the timing belt (see page 6-22). 12. Adjust the valve clearance (see page 6-13). 13. Install the cylinder head covers. NOTE: • Before installing the cylinder head cover, clean the cylinder head contacting surfaces with a shop towel. • Take care not to damage the spark plug seals when installing the cylinder head cover. • Visually check the spark plug seals for damage. • Replace any washer that is damaged or deteriorated.

(cont'd)

BACK

6-53

Cylinder Head Cylinder Head Installation (cont'd) 14. Tighten the nuts in two or three steps. In the final step, tighten all nuts, in sequence, to 12 N·m (1.2 kgf.m, 8.7 Ibf.ft).

CD

®

16. Install the intake manifold. Tighten the bolts and nuts sequentially in two or three steps. Always use a new intake manifold gasket. Specified torque: 8x 1.25 mm 22 N·m (2.2 kgf·m, 16 Ibf·ft)

~====~~~============~

® 15. Install the water passage (A). Always use a new Dring (8) and new gaskets (C). B

17. After installation, check that all tubes, hoses and connectors are installed correctly. 18. Enter the anti-theft code for the radio, then enter the customer's radio station presets.

8x 1.25 mm 22 N·m(2.2 kgf·m, 16Ibf·ft)

6-54

BACK

Toe Sensor Replacement 1. Set the No.1 piston at TDC (see page 6-22l.

7. Remove the TDC 1/TDC 2 sensor from the back cover.

2. Remove the upper covers. 3. To hold the timing belt adjuster in its current position, thread in the battery clamp bolt hand-tight (see step 14 on page 6-21l. 4. Loosen the idler pulley bolt about 5 or 6 turns, then remove the timing belt from the front camshaft pulley (see step 16 on page 6-22l. 5. Remove the front camshaft pulley.

8. Install the TDC 1/TDC 2 sensor in reverse order of removal. Reinstall the timing belt and other removed components (see page 6-22l. 12x 1.25 mm 90 N·m (9.2 kgf.m, 67 Ibf.tt) Apply engine oil to the bolt threads.

6. Disconnect the TDC 1/TDC 2 sensor connector, then remove the back cover.

8x 1.25mm 22 N·m (2.2 kgf·m, 16 Ibf·tt)

BACK

6-55

Cylinder Head CKP Sensor Replacement 1. Move the auto-tensioner to remove tension from the alternator belt, then remove the alternator belt (see step 5 on page 6-19). 2. Loosen the adjusting bolt, locknut and mounting bolt, then remove the power steering (PIS) pump belt (see step 6 on page 6-20). 3. Remove the dipstick and tube (see step 9 on page 6-20). 4. Remove the crankshaft pulley (see step 10 on page 6-20). 5. Remove the upper and lower covers (see step 12 on page 6-21). 6. Remove the CKP sensor from the oil pump.

:---6 x 1.0 mm 12 N·m 11.2 kgf·m,

8.7Ibf·ftl

7. Install the CKP sensor in the reverse order of removal.

6-56

BACK

Engine Mechanical Engine Block Special Tools ................................................................. Component Location Index ......................................... Drive Plate Removal and Installation .......................... Connecting Rod and Crankshaft End Play Inspection .................................................................... Crankshaft Main Bearing Replacement ...................... Connecting Rod Bearing Replacement ...................... Crankshaft and Pistons Removal ................................ Crankshaft Inspection .................................................. Block and Piston Inspection ........................................ Cylinder Honing ............................................................ Piston, Pin, and Connecting Rod Replacement ......... Piston Rings Replacement ........................................... Connecting Rod Bolt Inspection .................................. Crankshaft and Piston Installation .............................. Pulley End Crankshaft Seallnstallation-In-car ........... Transmission End Crankshaft Seal Installation-In-car ........................................................

BACK

7-2 7-3 7-6 7-7 7-8 7-10 7-12 7-14 7-15 7-17 7-18 7-21 7-23 7-23 7-28 7-28

Engine Block Special Tools Ref. No.

CD @

®

Tool Number 07 LAD-PT30 1OA 07VAD-P8A010A 077 49-00 10000

Description Oil Seal Driver Oil Seal Driver Attachment, 80 mm 1.0. Driver

®

CD

7-2

BACK

Oty 1 1 1

Component Location Index OIL PAN Install, page 7-23

OIL SCREEN

ENGINE BLOCK END COVER

~ /

CRANKSHAFT OIL SEAL

Installation, page 7-23 and page 7-28

~"o=~

DRIVE PLATE BOLT

OIL PUMP Overhaul, page 8-7

\

Torque sequence, page 7-6

(cont'd)

BACK

7-3


MAIN BEARING CAPS

CRANKSHAFT /

End play, page 7-7 Inspection, page 7-14 Installation, page 7-23

~"'''--

MAIN BEARINGS Oil clearance, page 7-8 Selection, page 7-8

DOWEL PIN

7-4

BACK

~

~L ~

PISTON RINGS Replacement, page 7-21

/ )0 __ SNAP RING

~ a

ev~ PISTON PIN

(7 0

Removal, page 7-18 Installation, page 7-18 Inspection, page 7-18

d

LJ

~

~~PISTON Removal, page 7-12 Measurement, page 7-15

CONNECTING ROD End play, page 7-7 Small end measurement, page 7-18

ENGINE BLOCK Cylinder bore inspection, page 7-15 Warpage inspection, page 7-15 Cylinder bore honing, page 7-17 Ridge removal, page 7-12

~ ~

..

CONNECTING ROD BEARING

.4 ~DOWELPIN / 4

Clearance, page 7-10 Selection, page 7-10

CONNECTING ROD BEARING CAP Installation, page 7-23

CONNECTING ROD BOLT Inspection, page 7-23 Tightening, page 7-23

BACK

7-5

Engine Block Drive Plate Removal and Installation 1. Remove the transmission (see page 14-114). 2. Remove the eight drive plate bolts, then separate the drive plate from the crankshaft flange. After installation, tighten the bolts in the sequence shown.

12x1.0mm 74N·m (7.5 kgf·m, 54 Ibf·ft)

3. Install the transmission (see page 14-121).

7-6

BACK

Connecting Rod and Crankshaft End Play Inspection 1. Remove the oil pump (see page 8-8). 2. Remove the baffle plate (see step 6 on page 7-12). 3. Measure the connecting rod end play with a feeler gauge (A) between the connecting rod (8) and crankshaft (e). Connecting Rod End Play: Standard (New): 0.15-0.35 mm (0.006-0.014 in.) 0.45 mm (0.018 in.) Service Limit:

c

A

4. Ifthe connecting rod end play is out-of-tolerance, install a new connecting rod, and recheck. If it still out-of-tolerance, replace the crankshaft (see step 6 on page 7-12).

BACK

5. Push the crankshaft firmly away from the dial indicator, and zero the dial against the end of the crankshaft. Then pull the crankshaft firmly back toward the indicator; dial reading should not exceed the service limit. Crankshaft End Play: Standard (New): 0.10-0.35 mm (0.004-0.014 in.) Service Limit: 0.45 mm (0.018 in.)

6. If end play is excessive, replace the thrust washers and recheck. If it is still out-of-tolerance, replace the crankshaft.

7-7

Engine Block Crankshaft Main Bearing Replacement Main Bearing Clearance Inspection 1. To check main bearing-to-journal oil clearance, remove the main caps and bearing halves. 2. Clean each main journal and bearing half with a clean shop towel. 3. Place one strip of plastigage across each main journal. NOTE: If the engine is still in the car when you bolt the main cap down to check the clearance, the weight ofthe crankshaft and drive plate will flatten the plastigage further than just the torque on the cap bolt and give you an incorrect reading. For an accurate reading, support the crank with a jack under the counterweights, and check only one bearing at a time.

6. If the plastigage measures too wide or too narrow, (remove the engine if it's still in the car), remove the crankshaft, and remove the upper half of the bearing. Install a new, complete bearing with the same color code, and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance. 7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.

4. Reinstall the bearings and caps, then torque the bolts (see page 7-23). Do not rotate the crankshaft. 5. Remove the caps and bearing halves, and measure the widest part of the plastigage. Main Bearing-to-Journal Oil Clearance: Standard (New): 0.020-0.044 mm (0.0008-0.0017 in.' Service limit: 0.050 mm (0.0020 in.)

7-8

BACK

Main Bearing Selection

3. Use the crankshaft bore codes and journal codes to select the appropriate main bearings from the table.

Crankshaft Bore Code Location -----t.~

Larger crank bore

1. Letters or Bars have been stamped on the end of the block as a code for the size of each of the four main journal bores. ---I.~

If you cannot read the codes because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

10r'

Red! Pink

Pink

Pink! Vellow

Vellow

20rll

Pink

Pink! Veil ow

Vellow

Vellow! Green

3 or III

Pink! Vellow

Veil ow

Vellow! Green Green

4orlll'

Vellow

Vellow! Green Green

Sorlllll

Vellow! Green Green

60rllllll

Green

Smaller main Journal

Main Journal Code Locations



Green! Brown

Green! Brown Brown

Green! Brown Brown

Brown! Black

NOTE: • When using bearing halves of different colors, it does not matter which color is used in the top or bottom . • Color code is on the dege of the bearing.

2. Number or bars have been stamped on the crankshaft No.1 web as a code for the main journal sizes.

B BB ~ ~~ 333 3

NO.'JOU"~ (PULLEV END)

No.4 JOURNAL (DRIVE PLATE END)

BACK

7-9

Engine Block Connecting Rod Bearing Replacement Rod Bearing Clearance Inspection 1. Remove the connecting rod cap and bearing half. 2. Clean the crankshaft rod journal and bearing half with a clean shop towel. 3. Place a strip of plastigage across the rod journal. 4. Reinstall the bearing half and cap, and torque the bolts (see page 7-23). Do not rotate the crankshaft.

6. If the plastigage measures too wide or too narrow, remove the upper half ofthe bearing, install a new, complete bearing with the same color code, and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance. 7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.

5. Remove the rod cap and bearing half and measure the widest part of the plastigage. Connecting Rod Bearing-to-Journal Oil Clearance: Standard (New): 0.020-0.044 mm (0.0008-0.0017 in.) Service Limit: 0.050 mm (0.0020 in.) PLASTIGAGE STRIP

7-10

BACK

Rod Bearing Selection

4. Use the connecting rod bore codes and journal codes to select the appropriate rod bearing from the table.

1. Inspect the connecting rods for cracks and heat damage.

Bearing Identification

Connecting Rod Bore/Journal Code Locations 2. Each rod has a tolerance range (from 0 to 0.024 mm (0.0009 in.), in 0.006 mm (0.0002 in.) increments) depending on the size of its big end bore. It's then stamped with a code (1,2,3, or 4/1, II, 11I,0r 1111) indicating the range. You may find any combination of 1,2,3, or 4/1, II, III, or 1111 in any engine. Half ofthe code is stamped on the bearing cap and the other half is stamped on the rod. If the codes are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

Color code is on the edge of the bearing ---I.~


Aorl

Pink

Pink! Yellow

B or II

Pink! Yellow

Yellow Yellow! Green Green

Corlll

Yellow

Yellow! Green Green

Green! Brown

o or 1111

Yellow! Green Green

Green! Brown

Brown

E or 11111

Green

Green! Brown

Brown

Brown! Black

For 111111

Green! Brown

Brown

Brown! Black Black

Yellow Yellow! Green

Normal Bore Size: 56.0 mm (2.20 in.)

Smaller rod Journal

Half of number or bar is stamped on bearing cap and the other half is stamped on rod.


NOTE: When using bearing halves of different colors, it does not matter which color is used in the top or bottom.

Connecting Rod Journal Code Locations 3. Letters or bars have been stamped on the crankshaft No.1 web as a code for the rod journal sizes.


No.6 JOURNAL (DRIVE PLATE END)

BACK

7-11

Engine Block Crankshaft and Piston Removal 1. Remove the engine assembly (see page 5-2).

6. Remove the oil screen (A), baffle plate (B) and oil pump (C).

2. Remove the transmission (see page 14-114). 3. Remove the CKP sensor (A) from the oil pump, then remove the timing belt drive pulley (B).

C

4. Remove the oil pan.

7. If you can feel a ridge of metal or hard carbon around the top of any cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. Ifthe ridge is not removed, it may damage the piston as it is pushed out.

5. Remove the engine block end cover.

7-12

BACK

8. Remove the connecting rod caps after setting the crank pin at 8DC for each cylinder. Remove the piston assembly by pushing on the connecting rod. Take care not to damage the crank journal or cylinder with the connecting rod. CORRECT

9. Remove the bearing from the cap. Keep all caps/ bearings in order. 10. Remove the upper bearing halves from the connecting rods and set them aside with their respective caps.

11. After removing a piston/connecting rod assembly, reinstall the cap on the rod. 12. To avoid mixup during reassembly, mark each piston/connecting rod assembly with its cylinder number. 13. Remove the bearing cap bolts (A) and bearing cap side bolts (8), then remove the bearing cap (C). A

INCORRECT

x B

(cont'd)

BACK

7-13

Engine Block Crankshaft and Piston Removal (cont'd)

Crankshaft Inspection Straightness

14. Lift the crankshaft (A) out of the cylinder block, being careful not to damage the journals. A

1. Remove the crankshaft from the engine block (see page 7-12). 2. Clean the crankshaft oil passages with pipe cleaners or a suitable brush. . 3. Check the keyway and threads. 4. Support the crankshaft with a V-blocks.

5. Measure runout on all main journals to make sure the crank is not bent. Rotate the crankshaft two complete revolutions. The difference between measurements on each journal must not be more that the service limit. Crankshaft Total Runout: Standard (New): 0.020 mm (0.0008 in.) max. Service Limit: 0.030 mm (0.0012 in.)

15. Reinstall the main caps and bearings on the cylinder block in the proper order.

7-14

BACK

Block and Piston Inspection Out-of-Round and Taper

1. Remove the piston from the cylinder block (see page 7-12).

1. Measure out-of-round at the middle of each rod and main journal in two places. The difference between measurements on each journal must not be more than the service limit. Journal Out-of-Round: Standard (New): 0.005 mm (0.0002 in.) max. Service Limit: 0.010 mm (0.0004 in.)

2. Check the piston for distortion or cracks. 3. Measure the piston diameter at a point 16.0 mm (0.63 in.) from the bottom of the skirt. Piston Diameter: Standard (New): 85.975-85.985 mm (3.3848-3.3852 in.) Service Limit: 85.965 mm (3.3844 in.)

16.0 mm ~----~ SKIRT DIAMETER (0.63 in.)

o o

o

o

o o

2. Measure taper at the edges of each rod and main journal. The difference between measurements on each journal must not be more than the service limit. Journal Taper: Standard (New): 0.005 mm (0.0002 in.) max. Service Limit: 0.010 mm (0.0004 in.)

(cont'd)

BACK

7-15

Engine Block Block and Piston Inspection (cont'd) 4. Measure wear and taper in directions X and Y at three levels in each cylinder as shown. • If the measurements in any cylinder are beyond the oversize bore service limit, replace the cylinder block. • If the block is to be rebored, refer to Piston Clearance Inspection after reboring (refer to step 5).

Oversize 0.25: 86.250-86.265 mm (3.3957-3.3963 in.) 0.50: 86.500-86.515 mm (3.4055-3.4061 in.) Bore Taper Limit: (Difference between first and third measurement) 0.05 mm (0.002 in.) 5. Check the top of the cylinder block for warpage. Measure along the edges and across the center as shown.

Cylinder Block Warpage: Standard (New): 0.07 mm (0.003 in.) max. Service Limit: 0.10 mm (0.004 in.)

E


Cylinder Bore Size: Standard (New): 86.000-86.015 mm (3.3858-3.3864 in.) Service Limit: 86.065 mm (3.3884 in.) Reboring Limit: 0.50 mm (0.02 in.)

7-16

BACK

Cylinder Honing 6. Calculate the difference between the cylinder bore diameter and piston diameter. Piston-to-Block Clearance: Standard (New): 0.015-0.040 mm (0.0006-0.0016 in.) Service Limit: 0.08 mm (0.003 in.)

1. Measure the cylinder bores (see page 7-15).lfthe cylinder block is to be reused, hone the cylinders and remeasure the bores. Only scored or scratched cylinder bores must be honed. 2. Hone the cylinder bores with honing oil and a fine (400 grit) stone in a 60 degree crosshatch pattern. NOTE: • Use only a rigid hone with 400 grit or finer stone, such as Sunnen, Ammco, or equivalent. • Do not use stones that are worn or broken.

SERVICE LIMIT

0.08 mm (0.003 in.)

3»-

60·

xxx

I""""' \.

Oversize Piston Diameter 0.25: 86.225-86.235 mm (3.3947-3.3951 in.) 0.50: 86.475-86.485 mm (3.4045-3.4049 in.) 3. When honing is complete, thoroughly clean the cylinder block of all metal particles. Wash the cylinder bores with hot soapy water, then dry and oil them immediately to prevent rusting. Never use solvent, it will only redistribute the grit on the cylinder walls. 4. If scoring or scratches are still present in the cylinder bores after honing to the service limit, rebore the cylinder block. Some light vertical scoring and scratching is acceptable if it is not deep enough to catch your fingernail and does not run the full length of the bore.

BACK

7-17

Engine Block Piston, Pin and Connecting Rod Replacement Disassembly

3. Heat the piston and connecting rod assembly to about 158°F (70°C), then remove the piston pin.

1. Apply engine oil to the piston pin snap rings (A) and turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (8). NOTE: Take care not to damage the ring grooves.

A

B

2. Remove both snap rings (A). Start at the cutout in the piston pin bore. Remove the snap rings carefully so they do not go flying or get lost. Wear eye protection. A

7-18

BACK

Inspection

3. Check the difference between the piston pin diameter and piston pin hole diameter in the piston.

NOTE: Inspect the piston, piston pin and connecting rod when they are at room temperature. 1. Measure the diameter of the piston pin.

Piston Pin-to-Piston Clearance: Standard (New): -0.0050 to +0.0010 mm (- 0.00020 to + 0.00004 in.) 0.004 mm (0.0002 in.) Service Limit:

Piston Pin Diameter: Standard (New): 21.962-21.965 mm (0.8646-0.8648 in.) 21.954 mm (0.8643 in.) Service Limit:

4. Measure the piston pin-to-connecting rod clearance.

2. Zero the dial indicator to the piston pin diameter.

Piston Pin-to-Connecting Rod Clearance: Standard (New): 0.005-0.014 mm (0.0002 - 0.0006 in.) Service Limit: 0.019 mm (0.0007 in.)

r" \

(cont'd)

BACK

7-19

Engine Block Piston, Pin and Connecting Rod Replacement (cont'd) Reassembly

4. Install the piston pin (A). Assemble the piston (8) and connecting rod (C) with the embossed marks (D) on the same side.

1. Install a piston pin snap ring (A). A

o

o

/ZA

2. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with engine oil. 3. Heat the piston to about 158°F (70°C).

5. Install the remaining snap ring.

7-20

BACK

Piston Ring Replacement 1. Remove the piston from the cylinder block (see page 7-12). 2. Using a piston, push a new ring (A) into the cylinder bore 15-20 mm (0.6-0.8 in.) from the bottom.

A

15-20mm (0.6-0.8 in.)

3. Measure the piston ring end-gap (B) with a feeler gauge: • If the gap is too small, check to see if you have the proper rings for your engine . • If the gap is too large, recheck the cylinder bore diameter againstthe wear limits (see page 7-15).

4. Using a ring expander (A), remove the old piston rings (B). B

\ -------=----

5. Clean all the ring grooves throughly with a squared-off broken ring or ring groove cleaner with a blade to fit the piston grooves. File down the blade if necessary. Top ring groove and 2nd ring grooves are 1.2 mm (0.05 in.) wide, and the oil ring groove is 2.8 mm (0.11 in.) wide. Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with the cleaning tool. NOTE: If the piston is to be separated from the connecting rod, do not install new rings yet .

If the bore is over the service limit, the cylinder block must be rebored. Piston Ring End-Gap: Top Ring Standard (New): 0.20-0.35 mm (0.008-0.014 in.) Service Limit: 0.60 mm (0.024 in.) 2nd Ring Standard (New): 0.40-0.55 mm (0.016-0.022 in.) Service Limit: 0.70 mm (0.028 in.) Oil Ring Standard (New): 0.20-0.70 mm (0.008-0.028 in.) 0.80 mm (0.031 in.) Service Limit: (cont'd)

BACK

7-21

Engine Block Piston Ring Replacement (cont'd) 6. Install the rings as shown. The top ring (A) has a 1B and the 2nd ring (B) is marked 2B. The manufacturing marks (e) must be facing upward. A

B

/

7. After installing a new set of rings, measure the ring-to-groove clearance: Top Ring Clearance Standard (New): 0.035-0.060 mm (0.0014-0.0024 in.) Service Limit: 0.13 mm (0.005 in.) 2nd Ring Clearance Standard (New): 0.030-0.055 mm (0.0012-0.0022 in.) Service Limit: 0.13 mm (0.005in.)

c

8. Rotate the rings in their grooves to make sure they do not bind. 9. Position the ring end gaps as shown: DO NOT position any ring gap at piston thrust surfaces.

Piston Ring Dimensions:

gf A

Top Ring (Standard) A: 3.1 mm (0.12 in) B: 1.2 mm (0.05 in) 2nd Ring (Standard) A: 3.4 mm (0.13 in) B: 1.2 mm (0.05 in)

OIL RING GAP TOP RING GAP DO NOT position any ring gap in line with piston pin hole.

7-22

BACK

OIL RING GAP

Connecting Rod Bolt Inspection

Crankshaft and Piston Installation

1. Measure the diameter of each connecting rod bolt at point A and point B. 35mm (1.38in.)

Special Tools Required • Driver 07749-0010000 • Oil Seal Driver Attachment, 80 mm I.D. 07V AD-P8AO 1OA

A

1. Check the connecting rod bearing clearance with plastigage (see page 7-10). 2. Check the main bearing clearance with plastigage (see page 7-8). 20mm (0.79 in.)

3. Inspect the connecting rod bolts (see page 7-23). 4. Apply engine oil to the main bearings and rod bearings. 5. Install the bearing halves in the cylinder block and connecting rods. 6. Lower the crankshaft (A) into the block.

2. Calculate the difference in diameter between point A and point B. Point A - Point B = Difference in Diameter Difference in Diameter: Specification: 0-0.1 mm (0-0.004 in.)

3. If the difference in diameter is out of tolerance, replace the connecting rod bolt.

7. Oil the thrust washer surfaces. Install the thrust washers (A) in the No.3 journal.

A

(cont'd)

BACK

7-23

Engine Block Crankshaft and Piston Installation (cont'd) 8. Install the bearings (A) and bearing caps (B) with the arrow (C) facing the timing belt end of the engine. 0

0

Y-

"-

0

N

~

'"

0

0

""" 0

10. Set the crankshaft to BDC for the cylinder you are working on. 11. Remove the connecting rod caps. Install the ring compressor, and check that the bearing is securely in place. 12. Install the piston with the arrow (A) facing the timing belt side of the engine.

-.-.

A

c E 10x80 mm

13. Position the piston in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore. A

E 10x80 mm

E 10x60mm

9. Apply engine oil to the bolt threads and flange, then install the bearing cap bolts (D) and bearing cap side bolts (E).

14. Stop after the ring compreJsor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.

7-24

BACK

15. Line up the mark (A) on the connecting rod and cap, then install the cap. 16. Apply engine oil to the bolt threads. Torque the bolts (B) to 20 N·m (2.0 kgf·m, 14Ibf·ft).

~B

19. Torque the bearing cap bolts (A), then torque the bearing cap side bolts (B). Follow the numbered sequence shown. NOTE: Whenever any crankshaft or connecting rod bearing is replaced, it is necessary after reassembly to run the engine at idling speed until it reaches normal operating temperature, then continue to run it for about 15 minutes. A

B

11 x 1.5mm 76 N·m (7.8 kgf·m,

49 N·m (5.0 kgf.m,

56lbf·ftl

36lbf·ftl

10x 1.25 mm

~

A

17. Mark the connecting rod (A) and bolt head (B) as shown. B


(cont'd)

BACK

7-25

Engine Block Crankshaft and Piston Installation (cont'd) 20. The seal mating surface on the engine block end cover should be dry. 21. Drive the crankshaft oil seal sequarely into the left side cover.

23. Clean and dry the left side cover mating surfaces. Apply a light coat of grease the crankshaft and to the lip ofthe seal. 24. Apply liquid gasket, part No. 08718-0001 or 08718-0003, evenly to the block mating surface of the left side cover and to the inner threads of the bolt holes. Install the dowel pins (A), new O-ring (8) and the engine block end cover (C) on the cylinder block. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the old residue.

07VAD-PSA010A

A

22. Confirm that the clearance is equal all the way around with a feeler gauge.

Clearance: 0.5-0.8 mm (0.02-0.03 in.)

O.S-O.Smm (0.02-0.03 in. I

-+----1

6x1.0mm 12 N·m (1.2 kgf·m, S.7Ibf·ftl

B

25. After assembly, wait at least 30 minutes before filling the engine with oil.

7-26

BACK

26. Clean and dry the oil pump mating surfaces.

30. Apply liquid gasket, part No. 08718-0001 or 08718-0003, evenly to the oil pan mating surface of the block and to the inner threads of the bolt holes, then install the oil pan.

27. Install the oil pump (A). -1 Install a new crankshaft oil seal in the oil pump (see step 15 on page 8-9). -2 Apply liquid gasket, part No. 08718-0001 or 08718-0003, evenly to the block mating surface of the oil pump and to the inner threads of the bolt holes. -3 Grease the lip of the oil seal and apply oil to the new O-ring (B). -4 Install the dowel pins (C), then align the inner rotor with the crankshaft and install the oil pump. -5 Clean the excess grease off the crankshaft and check the seal for distortion. 6x 1.0mm 12N·m

/

11.2,\m. 8.7 'bf·ftl

NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue.

6X1.0mm 12N·m (1.2 kgf.m, 8.7Ibf·ft)

j ~;f@t~6§' ~D 'f? ,5--{ o 31. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence, to 12 N·m (1.2 kgf·m, 8.7 Ibf·ft).

CD

®

(j)

@

_--.JII;l---@

A

6x 1.0 mm 12 N·m (1.2 kgf·m, 8.7Ibf·ft)

28. Install the baffle plate (D), then install the oil screen (E).

I

@

29. Clean and dry the oil pan mating surfaces.

BACK

@

7-27

Engine Block Pulley End Crankshaft Seal Installation - In-car

Transmission End Crankshaft Seal Installation - In-car

Special Tools Required Oil Seal Driver 07LAD-PT3010A

Special Tools Required • Driver 07749-0010000 • Oil Seal Driver Attachment, 80 mm 1.0. 07VAD-P8A010A

1. Dry the crankshaft oil seal housing. 2. Apply a light coat of grease to the crankshaft and to the lip of the seal. 3. Using the seal driver, drive in the crankshaft oil seal until the driver bottoms against the oil pump. When the seal is in place, clean any excess grease off the crankshaft, and check that the oil seal lip is not distorted. 07LAD-PT3010A

1. Dry the crankshaft oil seal housing. 2. Apply a light coat of grease to the crankshaft and to the lip ofthe seal. 3. Using the special tools, drive the crankshaft oil seal into the engine block end cover until the driver attachment bottoms against the crankshaft. Align the hole in the driver attachment with the pin on the crankshaft.

07VAD-P8A010A

4. Clean any excess grease off the crankshaft, and check that the oil seal lip is not distorted.

7-28

BACK

Engine Mechanical Engine Lubrication Special Tools ................................................................. Component Location Index ......................................... Oil Pressure Switch Test .............................................. Oil Pressure Test ........................................................... Engine Oil Replacement .............................................. Engine Oil Filter Replacement ..................................... Oil Pump Overhaul .......................................................

BACK

8-2 8-3 8-4 8-4 8-5 8-5 8-7

Engine Lubrication Special Tools Ref. No.

Tool Number 07GAD-PH70201 07912-6110001

CD ®

Description Oil Seal Driver Oil Filter Wrench

' -"' , ~ ,

\

'-

'>,

-

- ,~

,

~--"-~-'

CD

8-2

BACK

Otv 1 1


~ OIL

.

CONTROL ORIFICES O-RING

C)/

"

OIL FILTER Replacement, page 8-5

OIL PUMP Overhaul pa Inspect"' ge 8-7 lon, page 8-7

"-

OIL SCREEN

/

e

DRAIN BOLT/ <;lauge Circuit ~~WITCH In the '98-02 A lagram, page 22-60 51'itch test, pa~~oJ~4 Service Manual I pressure test, page 8-4 OILPRESSUR

WASHER

\

OIL PAN Installation, page 8-7

BACK

8-3

Engine Lubrication Oil Pressure Switch Test 1. Remove the YEL/RED wire (A) from the engine oil pressure switch (B). B

C

Oil Pressure Test Ifthe oil pressure warning light stays on with the engine running, check the engine oil level. Ifthe oil level is correct: 1. Connect a tachometer or a Honda PGM tester.

2. Remove the engine oil pressure switch and install an oil pressure gauge (A).

2. Check for continuity between the positive terminal (C) and the engine (ground). There should be continuity with the engine stopped. There should be no continuity with the engine running.

3. If the switch fails to operate, check the engine oil level. If the engine oil level is OK, check the engine oil pressure.

3. Start the engine. Shut it off immediately if the gauge registers no oil pressure. Repair the problem before continuing. 4. Allow the engine to reach operating temperature (fan comes on at least twice). The pressure should be: Engine Oil Temperature: 176°F (SOOe) Engine Oil Pressure: At Idle: 70 kPa (0.7 kgf/cm2, 10 psi) minimum At 3,000 rpm: 490 kPa (5.0 kgf/cm2, 71 psi) minimum 5. If oil pressure is NOT within specifications, inspect these items: • Check the oil filter for clogging . • Check the oil pump (see page 8-7).

8-4

BACK

Engine Oil Replacement

Engine Oil Filter Replacement

NOTE: Under normal conditions, the oil filter should be replaced at every other oil change. Under severe conditions, the oil filter should be replaced at each oil change.

Special Tools Required Oil Filter Wrench 07912-6110001

Change interval: Every 7,500 miles (12,000 km) or 12 months (Normal conditions) Every 3,750 miles (6,000 km) or 6 months (Severe conditions).

1. Remove the oil filter with the special oil filter wrench. 2. Inspect the threads (A) and rubber seal (B) on the new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. Use only filters with a built-in bypass system. B

1. Warm up the engine.

A 39 N·m (4.0 kgf·m, 29 Ibf·ftl Do not overtighten.

3. Reinstall the drain bolt with a new washer (B). 4. Refill with the recommended oil (see page 3-2). Capacity 4.0 g (4.2 US qt, 3.5 Imp qt) at oil change. 4.4 g (4.6 US qt, 3.9 Imp qt) at oil change including filter. 5.0 g (5.3 US qt, 4.4 Imp qt) after engine overhaul. 5. Run the engine for more than 3 minutes, then check for oil leakage.

(cont'd)

BACK

8-5

Engine Lubrication Engine Oil Filter Replacement (cont'd) 3. Install the oil filter by hand. 4. After the rubber seal seats, tighten the oil filter clockwise with the special tool.

Tighten: 7/8 turn clockwise. Tightening torque: 22 N·m (2.2 kgf·m, 16Ibf·ft)

5. If 8 numbers (1 to 8) are printed around the outside of the filter, use the following procedure to tighten the filter. • Spin the filter on until its seal lightly seats against the block, and note which number is at the bottom . • Tighten the filter by turning it clockwise 7 numbers from the one you noted. For example, if number 2 is at the bottom when the seal is lightly seated, tighten the filter until the number 1 comes around to the bottom.

Number when rubber seal is seated.

Number after tightening.

Number when rubber seal is seated

1

2

3

4

5

6

7

8

Number after tightening

8

1

2

3

4

5

6

7

6. After installation, fill the engine with oil up to the specified level, run the engine for more than 3 minutes, then check for oil leakage.

8-6

BACK

Oil Pump Overhaul Exploded View

k.';. .'"

6x 1.0 mm

~_~6"11N.m '0.6

ENGINE OIL PRESSURE SWITCH 18 N·m (1.8 kgf·m,13Ibf·ft) 1/8 in. BSPT (British standard pipe taper) 28 threads/inch. Use the proper liquid sealant.

/

O-RING Replace.

~ PUMP COVER

OUTER ROTOR

INNER ROTOR

~

OIL SEAL Replace.

RELIEF VALVE Valve must slide freely in the housing bore. Replace if it is scored.

SPRING

I~

~

~

~PUMPHOUSING

Apply liquid gasket to the mating surface of the cylinder block when installing.

--------6x1.0mm 12 N·m (1.2 kgf·m, 8.7 Ibf·ft) SEALING BOLT 39 N·m (4.0 kgf.m, 29 Ibf.ft)

(cont'd)

BACK

8-7

Engine Lubrication Oil Pump Overhaul (co nt'd) Special Tools Required Oil Seal Driver 07GAD-PH70201 Removal 1. Drain the engine oil. 2. Turn the crankshaft so that the No.1 piston is at TDC (see page 6-22). 3. Remove the timing belt (see page 6-19).

Inspection 10. Check the inner-to-outer rotor radial clearance between the inner rotor (A) and outer rotor (8). If the inner-to-outer rotor clearance exceeds the service limit, replace the oil pump assembly. Inner Rotor-to-Outer Rotor Radial Clearance Standard (New): 0.04-0.16 mm (0.002-0.006 in.) Service Limit: 0.20 mm (0.008 in.)

4. Remove the idler pulley. 5. Remove the CKP sensor, then remove the timing belt drive pulley (see page 6-56). 6. Remove the VTEC solenoid valve and oil filter assembly (see page 6-9). 7. Remove the oil pan and the oil screen (A).

11. Check the housing-to-rotor axial clearance between the rotors (A) and pump housing (8). If the housingto-rotor axial clearance exceeds the service limit, replace the oil pump assembly. Housing-to-Rotor Axial Clearance Standard (New): 0.02 - 0.07 mm (0.001- 0.003 in.) Service Limit: 0.12 mm (0.005 in.) 8. Remove the mounting bolts and the oil pump assembly (8). 9. Remove the screws from the pump housing, then separate the housing and cover.

8-8

BACK

12. Check the housing-to-outer rotor radial clearance between the outer rotor (A) and pump housing (B). If the housing-to-outer rotor radial clearance exceeds the service limit, replace the oil pump assembly. Housing-to-Outer Rotor Radial Clearance Standard (New): 0.14-0.19 mm (0.006-0.007 in.) Service Limit: 0.20 mm (0.008 in.)

Installation 17. Reassemble the oil pump.

18. Check that the oil pump turns freely. 19. Clean and dry the oil pump mating surfaces. 20. Install the oil pump (A). -1 Apply liquid gasket part No. 08718-0001 or 08718-0003 evenly to the block mating surface of the oil pump and to the inner threads of the bolt holes. -2 Grease the lip of the oil seal and apply oil to the new O-rings (B). -3 Install the dowel pins (C), then align the inner rotor with the crankshaft and install the oil pump. -4 Clean the excess grease off the crankshaft, and check the seal for distortion. A

13. Inspect both rotors and the pump housing for scoring or other damage. Replace parts if necessary. 14. Remove the old oil seal from the oil pump. 15. Gently tap in the new oil seal until the special tool bottoms on the pump. 12N·m (1.2 kgf·m, 8.7Ibf·ft)

21. Install the oil screen (D).

07GAD-PH70201

16. Apply liquid thread lock to the pump housing screws.

(cont'd)

BACK

8-9

Engine Lubrication Oil Pump Overhaul (cont'd) 22. Clean and dry the oil pan mating surfaces. 23. Apply liquid gasket, part No. 08718-0001 or 087180003, evenly to the oil pan mating surface of the block and to the inner threads of the bolt holes, then install the oil pan. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue.

24. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence, to 12 N·m (1.2 kgf.m, 8.7 Ibf·ft).

®

CD

®

®

_.-JI.I.~--®

®

8-10

@

®®®

®

@

BACK

,-... \

Engine Mechanical Intake Manifold and Exhaust System Intake Manifold Removal and Installation ................. 9-2 Exhaust Manifold Removal and Installation .............. 9-3 Exhaust Pipe and Muffler Replacement ..................... 9-4

BACK

Intake Manifold and Exhaust System Intake Manifold Removal and Installation NOTE: • Use new a-rings and gaskets when reassembling. • Check for folds or scratches on the surfaces of the gaskets. • Replace with a new gasket if damaged.

INTAKE MANIFOLD CHAMBER Replace if it is cracked or ifthe mating surfaces is damaged.

6x1.0mm 12 N·m 11.2 kgf·m, 8.7Ibf·tt)

/Y

BOOSTP%LAE INTAKEAIR TEMPERATURE

l~Pk~::~~3Rlbf.tt)

O-RING

e--- Replace. -

12 x. 1 5 mm -~---~ 26N·m 12.7 kgf·m, 20 Ibf·tt) ('98-99 models)

INTAKE MANIFOLD Replace if it is cracked or if the mating surfaces is damaged.

SPACER

9-2

BACK

THROTTLE BODY

r

Exhaust Manifold Removal and Installation NOTE:

• Use new gaskets and self-locking nuts when reassembling. • Check for folds or scratches on the surfaces of the gaskets. • Replace with a new gasket if damaged. FRONT: SELF·LOCKING NUT 8x 1.25mm 31 N·m /3.2 kgf·m, 23Ibf·ft) Apply engine oil to the nut threads. Replace.

8x 1.25mm 22 N·m /2.2 kgf·m,

T~

REAR: REAR EXHAUST MANIFOLD

\ ~GASm Replace.

SELF·LOCKING NUT

8x 1.25mm 22 N·m /2.2 kgf·m, 16lbf·ftl

8x 1.25 mm 31 N·m /3.2 kgf·m, 23 Ibf·ftl Apply engine oil to the nut threads. Replace.

BACK

9-3

Intake Manifold and Exhaust System Exhaust Pipe and Muffler Replacement NOTE: Use new gaskets and self-locking nuts when reassembling.

HEAT SHIELD

GASKETS Replace.

SELF-LOCKING NUTS 10x 1.25 mm 54N·m (5.5 kgf.m, 40 Ibf·tt) Replace.

6x1.0mm \ 12 N·m (1.2 kgf·m, 8.7Ibf·tt)

(W

~

EXHAUST PIPE B

PRIMARY HEATED OXYGEN SENSOR 44 N·m (4.5 kgf·m, 33 Ibf·tt)

~~SECONDARY HEATED ~ OXYGEN SENSOR ~

SELF-LOCKING NUT 10x 1.25 mm 33N·m (3.4 kgf.m, 25 Ibf·tt) Replace.

:II'()'II'Ii

44N·m (4.5 kgf·m, 33 Ibf·tt)

/

~'<~\ ~ ------GASKET ~ Replace. THREE WAY CATALYTIC CONVERTER (TWC)

EXHAUST PIPE A GASKET Replace. SELF-LOCKING NUTS 10 x 1.25 mm 54N·m (5.5 kgf·m, 40 Ibf·tt) Replace. SELF-LOCKING NUT 10x 1.25 mm 33N·m (3.4 kgf.m, 25 Ibf·tt) Replace.

9-4

THREE WAY CATALYTIC CONVERTER (TWC) TIGHTENING SEQUENCE

10x1.25mm 38 N·m (3.9 kgf·m, 28 Ibf·tt)

BACK

6x 1.0 mm 9.8 N·m (1.0 kgf·m, 7.2Ibf·tt)

Engine Cooling Cooling System Component Location Index ......................................... Coolant Temperature Gauge Testing ......................... Sending Unit Testing ................................................... Radiator Cap Test ......................................................... RadiatorTest ................................................................. Fan Motor Test .............................................................. Thermostat Test ........................................................... Water Pump Inspection ............................................... Water Pump Replacement ........................................... Coolant Replacement ................................................... Thermostat Replacement ............................................ Radiator and Fans Replacement .................................

10-2 10-5 10-7 10-7 10-8 10-8 10-9 10-9 10-10 10-10 10-12 10-13

Fan Controls Component Location Index ......................................... Symptom Troubleshooting Index ............................... Circuit Diagram ............................................................. Radiator Fan Circuit Troubleshooting ........................ Radiator Fan Switch A Circuit Troubleshooting ........ Fan control Module Input Test .................................... Radiator Fan Switch (A or B) Test ...............................

BACK

10-14 10-15 10-16 10-17 10-19 10-20 10-21

Cooling System Component Location Index

RADIATOR CAP

RADIATOR Replacement, page 10-13

ATFCOOLER HOSES

~I

~ RADIATOR FAN Replacement, page 10-13 RADIATOR FAN SHROUD Replacement, page 10-13

10-2

BACK

AIC CONDENSER FAN ASSEMBLY Replacement, page 10-13 Fan Motor Test, page 10-8

WATER BYPASS HOSES HEATER HOSES

THERMOSTAT COVER

WATER PASSAGE

RADIATOR

LOWER RADIATOR HOSE

(cont'd)

BACK

10-3

Cooling System Component Location Index (cont'd)

RADIATOR FAN SWITCH B

ENGINE COOLANT TEMPERATURE (ECT) SENSOR

WATER PUMP Inspection, page 10-9 Replacement, page 10-10

O-RINGS

'98-99 models: COOLANT TEMPERATURE GAUGE SENDING UNIT Test, page 10-7

RADIATOR FAN SWITCH A

'_____ /CONNECTINGPIPE

10-4

BACK

r' ,

Coolant Temperature Gauge Test '98-99 models:

'00-02 models:

1. Check the No.9 (7.5A) fuse in the under-dash fuse/ relay box before testing.

Coolant Temperature Gauge Needle Does Not Move at All

2. Make sure the ignition switch is OFF, then disconnect the YEL/GRN wire (A) from the coolant temperature gauge sending unit (B), and ground it with a jumper wire.

1. Turn the ignition switch OFF, and connect Powertrain Control Module (PCM) connector terminal A 1 to body ground with a jumper wire. PCM CONNECTOR A (32P)

A

nVEL/GRN 11 12

3

4

5

1/

6

/

8

17 18 19 20 21 112 113 14 15 25 26 Z1 28 29 30

/

9

10

1/

23

/"1 24 1

32

'---

-'-

=



After 30 seconds or more, does the temperature gauge needle move to the Hot side?

B

3. Turn the ignition switch ON (II). Check that the pointer of the coolant temperature gauge starts moving toward the "H" mark. Turn the ignition switch OFF before the pointer reaches "H" on the gauge dial. Failure to do so may damage the gauge.

YES-Substitute a known-good PCM and recheck, refer to '98-02 Accord Service Manual (see page 115). Ifthe symptom/indication goes away, replace the original PCM. NO - Go to step 3.

• If the pointer of the gauge does not move at all, check for an open in the YEL/GRN wire. If the wires are OK, replace the coolant temperature gauge . • If the coolant temperature gauge works, test the coolant temperature gauge sending unit.

3. Turn the ignition switch OFF, and disconnect PCM connector A (32P).

I"" \

(cont'd)

BACK

10-5

Cooling System Coolant Temperature Gauge Test (cont'd) 4. Turn the ignition switch ON (11), and measure voltage between PCM connector terminal A 1 and body ground. PCM CONNECTOR A (32P)

Coolant Temperature Gauge Needle Goes Past the Hot Mark 1. Turn the ignition switch OFF, and disconnect PCM connector A (32P). 2. Turn the ignition switch ON (1I).and watch the coolant temperature gauge.

Does the temperature gauge needle move at al/ ? (you may have to watch it for about 30 seconds.)


Is there about 5V ? YES- Replace the fuel and temperature gauge assembly .•

YES - Go to step 3. NO-Substitute a known-good PCM and recheck, refer to '98-01 Accord Service Manual (see page 11-5). If the symptom/indication goes away, replace the original PCM .• 3. Turn the ignition switch OFF, then turn it ON (II) again, and watch the coolant temperature gauge.

Does the temperature gauge needle immediately go past the Hot mark?

NO-Go to step 5. 5. Turn the ignition switch ON (11), and measure voltage between PCM connector terminal A1 and body ground. PCM CONNECTOR A (32P)

GAUGE CONNECTOR C (16P)

YES- Replace the fuel and temperature gauge assembly.• NO-The temperature gauge needle went past the Hot mark after about 30 seconds or more.Go to step 4. 4. Turn the ignition switch OFF, and disconnect the gauge assembly connector C (16P). 5. Check for continuity between PCM connector terminal aaA 1 and gauge assembly connector terminal C2. PCM CONNECTOR A (32P)


Is there continuity? YES- Replace the fuel and temperature gauge assembly.•

NO - Repair open in the wire between PCM connector terminal A 1 and gauge connector terminal C2 .•


Is there continuity? YES- Replace short in the wire between PCM connector terminal A 1 and gauge connector terminal C2 .• NO- Replace the fuel and temperature gauge assembly.•

10-6

BACK

Sending Unit Test

Radiator Cap Test

'98-99 models:

1. Disconnect the YEL/GRN wire (A) from the coolant temperature gauge sending unit (8). A

1. Remove the radiator cap (A), wet its seal with engine coolant, then install it on the pressure tester (8) (commercially available).

B

2. Apply a pressure of93-123 kPa (0.95-1.25 kgf/cm2, 14-18 psi). 2. Using an ohmmeter, measure the change in resistance between the positive terminal (C) and the engine (ground) with the engine cold and with the engine at operating temperature. Temperature Resistance ( Q )

133°F (56°C) 137

3. Check for a drop in pressure. 4. If the pressure drops, replace the cap.

185°F (85°C)212°F (100°C) 46-30

3. If the obtained readings are substantially different from the specifications above, replace the sending unit.

BACK

10-7

Cooling System Radiator Test

Fan Motor Test

1. Wait until the engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant to the top of the filler neck.

1. Disconnect the 2P connectors from the radiator fan motor (A) and condenser fan motor (8). Terminal side of male terminals LOCK

2. Attach the pressure tester (A) (commercially available) to the radiator and apply a pressure of 93-123 kPa (0.95-1.25 kgf/cm', 14-18 psi).

A~

2. Test the motor by connecting battery power to the 8 terminal, and ground to the A terminal. 3. Inspect for engine coolant leaks and a drop in pressure.

3. If the motor fails to run or does not run smoothly, replace it.

4. Remove the tester and reinstall the radiator cap. 5. Check for engine oil in the coolant and/or coolant in the engine oil.

10-8

BACK

Thermostat Test

Water Pump Inspection 1. Remove the timing belt (see page 6-19).

Replace the thermostat if it is open at room temperature.

2. Turn the water pump pulley counterclockwise. Check that it turns freely.

To test a closed thermostat: 1. Suspend the thermostat (A) in a container of water. Do not let the thermometer (8) touch the bottom of

the hot container.

3. Check for signs of seal leakage. A small amount of "weeping" from the bleed holes (A) is normal. A

~·~------------B

A

2. Heat the water and check the temperature with a thermometer. Check the temperature at which the thermostat first opens, and at which it is fully open.

3. Measure the lift height of the thermostat when it is fully open. STANDARD THERMOSTAT Lift height: above 10.0 mm (0.39 in.) Starts opening: '98-00 models: 169-176°F (76-80°C) 163-171°F (73-77°C) '01 model: Fully open: '98-00 models: 194°F (90°C) 190°F (88°C) '01 model:

BACK

10-9

Cooling System Water Pump Replacement 1. Remove the timing belt (see page 6-19).

Coolant Replacement

2. Remove the timing belt tensioner.

1. Set the heater temperature control dial to maximum heat. Make sure the engine and radiator are cool to the touch.

3. Remove the water pump (A) by removing 5 bolts.

2. Remove the radiator cap. 3. Loosen the drain plug (A), and drain the coolant. A

A

" 1.0mm 6x 12 N·m (1.2 kgf·m, 8.7Ibf·ftl

4. Inspect, repair and clean the O-ring groove and mating surface on the cylinder block. 5. Install the water pump with a new O-ring (8) in the reverse order of removal. 6. Clean up any spilled engine coolant.

4. Install a rubber hose (A) on the drain bolt (8) located at the rear of the cylinder block, then loosen the drain bolt.

5. When the coolant stops draining, tighten the drain bolt. 6. Tighten the radiator drain plug securely.

10-10

BACK

7. Remove, drain, and reinstall the reservoir. Fill the tank to the MAX mark with Honda All Season Antifreeze/Coolant Type 2.

9. Install the radiator cap loosely. 10. Start the engine and let it run until it warms up (the radiator fan comes on at least twice). 11. Turn off the engine. Check the level in the radiator, and add Honda All Season. Antifreeze/Coolant Type 2 if needed. 12. Put the radiator cap on tightly, then run the engine again and check for leaks.

8. Pour Honda All Season Antifreeze/Coolant Type 2 into the radiator up to the base of the filler neck. NOTE:

• Always use Honda All Season Antifreeze/Coolant Type 2. Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail. • Honda All Season Antifreeze/Coolant Type 2 is a mixture of 50 % antifreeze and 50 % water. Premixing is not required. Engine Coolant Refill Capacity [including the reservoir capacity of

(0.6 ~ (0.6 US qt, 0.5 Imp qtllJ 5.6 ~ (5.9 US qt, 4.9 Imp qt)

BACK

10-11

Cooling System Thermostat Replacement PIN RUBBER SEAL Replace.

6x 1.0mm 12 N·m (1.2 kgf·m, 8.7Ibf·ft)

THERMOSTAT Install with pin up.

THERMOSTAT COVER

10-12

BACK

Radiator and Fans Replacement 1. Drain the engine coolant. 2. Remove the upper and lower radiator hoses, and ATF cooler hoses. UPPER RADIATOR HOSE

LOWER RADIATOR HOSE

~

~

RADIATOR CAP

/

"-

~

6x 1.0mm 9.8 N·m (1.0 kgf·m,

~Ibf.ft) UPPER BRACKET AND CUSHION

~~~~II~RADIATOR ~

__

-O-RING

6x1.0mm 7 N·m (0.7 kgf·m, 5Ibf·ft) ------------ DRAIN PLUG

6x1.0mm 9.8 N·m (1.0 kgf.m, 7.2Ibf·ft)

~ RADIATOR FAN SHROUD

4.4N·m (0.45kgf·m, 3.3Ibf·ft)

AIC CONDENSER FAN ASSEMBLV

6x 1.0 mm 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft) FAN CONNECTORS

3. Disconnect the fan motor connectors. 4. Remove the radiator upper brackets, then pull up the radiator. 5. Remove the fan shroud assemblies and other parts from radiator. 6. Install the radiator in the reverse order of removal. 7. Set the upper and lower cushions securely. 8. Fill the radiator with engine coolant and bleed the air.

BACK

10-13

Fan Controls Component Location Index

CONDENSER FAN RELAY Test, page 22-52 in the '98-02 Accord Service Manual RADIATOR FAN RELAY Test, page 22-52 in the '98-02 Accord Service Manual

RADIATOR FAN CONTROL MODULE Inputtest, page 10-20 /

RADIATOR FAN SWITCH A Test, page 10-21

RADIATOR FAN SWITCHB Test, page 10-21

RADIATOR FAN ASSEMBLY Motor Test, page 10-8

10-14

BACK

r\

Symptom Troubleshooting Index Before performing any troubleshooting procedures check: • Fuses • Grounds • Cleanliness and tightness of all connectors

SYMPTOM

PROCEDURE

Radiator fan does not run at all.

Radiator Fan Circuit Troubleshooting (see page 10-17)

Both fans (radiator and condenser) do not run for engine cooling, but they do run with the AlC on.

Radiator Fan Switch A Circuit Troubleshooting (see page 10-19)

Both fans do not run with AlC on.

Radiator and Condenser Fans Common Circuit Troubleshooting, refer to '98-02 Accord Service Manual, (see page 21-14)

BACK

10-15

Fan Controls Circuit Diagram IGNITION SWITCH

UNDER-HOOD FUSEIRELAY BOX SATTERY

+

No.41 (100A)

No.42 (SOA) WHT

NO.57 (20A)

IG2HOTIn

NO.58 (20A)

r-
~-----~ 'I

YEl

M-----~

RADIATOR FAN RELAY

BlKlYEl

No.3 (7.5A)


No.6 (15A)

CONDENSER FAN RELAY BlKlYEl

BLUlBlK

h

YEL

BlUIYEl GRN

BlKlYEl

BlKlYEl

7 RADIATOR FAN CONTROL MODULE

~I

4 ....---GRN

GRN

BlK

BlK

1 G201

10-16

BlK

AIR CONDITIONING SYSTEM

RADIATOR FAN SWITCH B

RADIATOR FAN SWITCH A Above] [ Closed: 199·F (93·C)

CONDENSER FAN MOTOR

RADIATOR FAN MOTOR

Above ] [ Closed: 225·F (107·C)

BlK

BlK

I 1

I

BlK

G101

BACK

G401

Radiator Fan Circuit Troubleshooting 1. Check the No. 57 (20A) fuse in the under-hood fuse/ relay box.

Is the fuse OK?

4. Connect the No.1 and No.2 terminals of the radiator fan relay 4P socket with a jumper wire. RADIATOR FAN RELAY 4PSOCKET

YES-Go to step 2.

n

1

NO- Replace the fuse and recheck.•

2

2. Remove the radiator fan relay from the under-hood fuse/relay box, and test it. Refer to the '98-02 Accord Service Manual (see page 22-52).

3

4

Is the relay OK?

YES - Go to step 3.


NO- Replace the radiator fan relay .•

Does the radiator fan run? 3. Measure the voltage between the No.1 terminal of the radiator fan relay 4P socket and body ground.

YES-Go to step 9. NO - Go to step 5.


5. Disconnect the jumper wire. 6. Disconnect the radiatorfan connector.

2

7. Check for continuity between the No.2 terminal of the radiator fan relay 4P socket and the No.2 terminal of the radiator fan connector.

3 4 Terminal side of female terminals

RADIATOR FAN RELAY 4PSOCKET Terminal side of female terminals


BLU/BLK

NO- Replace the under-hood fuse/relay box.• Wire side of female terminals RADIATOR FAN CONNECTOR

Is there continuity? YES-Go to step 8. NO- Repair open in the BLU/BLK wire between the under-hood fuse/relay box and the radiator fan .•

(cont'd)

BACK

10-17

Fan Controls Radiator Fan Circuit Troubleshooting (cont'd) 8. Check for continuity between the No.1 terminal of the radiator fan connector and body ground.

11. Measure the voltage between the No.1 terminal of . the radiator fan control module and body ground. RADIATOR FAN CONTROL MODULE 8P CONNECTOR

RADIATOR FAN CONNECTOR

1 2 3 4



=



YES- Replace the radiator fan motor.•

YES-Repair open in the VEL wire between the under-hood fuse/relay box and the radiator fan control module .•

NO-Check for an open in the BlK wire between the radiator fan connector and body ground. If the wire is OK, check for a poor ground at G201 .•

NO- Perform the radiator fan control module input tests (see page 10-20).•

9. Disconnect the jumper wire, and turn the ignition switch on (II). 10. Measure the voltage between No.3 terminal of the radiator fan relay 4P socket and body ground. RADIATOR FAN RELAY 4P SOCKET

2

3 4 Terminal side of female terminals

= /s there battery voltage?

YES- Replace the under-hood fuse/relay box.• NO-Go to step 11.

10-18

BACK

Radiator Fan Switch A Circuit Troubleshooting 1. Disconnect the radiator fan switch A connector.

5. Check the cooling system.


Is the cooling system OK?

3. Measure the voltage between the No.2 terminal on the radiator fan switch connector and body ground.

YES- Replace the radiator fan switch A .• NO-Repair the cooling system .•

RADIATOR FAN SWITCH CONNECTOR

1-----iGRN


= Is there battery voltage? YES - Go to step 4. NO-Repair open in the GRN wire between the radiator fan switch A and under-hood fuse/relay box.• 4. Turn the ignition switch OFF, and check for continuity between the No.1 terminal on the radiator fan switch A connector and body ground. RADIATOR FAN SWITCH CONNECTOR


= Is there continuity? YES - Go to step 5. NO-Check for an open in the BlK wire between the radiator fan switch A connector and body ground. If the wire is OK, check for poor ground at G101 .•

BACK

10-19

Fan Controls Fan Control Module Input Test Perform the following tests with the radiator fan control module 8P connector connected, the ignition switch ON (II) and the AlC switch OFF. If you find the cause of a problem, correct it before you continue. BLK/VEL'

VEL/WHT

BLK


GRN

BLK/VEL'

Wire color BLK

Test condition Check for voltage to body

Desired result There should be less than 1V.

~round.

WHT

BLK/YEL'

BLK/YEL2

VEL/WHT

VEL

GRN

WHT/GRN

10-20

Check for battery voltage to body ground.

There should be battery voltage.

Check battery voltage to body ground: Ignition switch-ON (II) Check battery voltage to body ground: Ignition switch-ON (II) Check battery voltage to body ground: Ignition switch-ON (II) Check battery voltage to body ground: Ignition switch-ON (III) Connect body ground: Ignition switch-ON (II)

Radiator fan and condenser fan should come on.

Check for voltage: Engine coolant temperature below 225°F (107°C)

There should be approx. 11 V.

BACK

Possible cause if desired result is not obtained • Poor ground (G401) • An open in the wire • Blown No. 58 (20 A) fuse in the under-hood fuse/relay box • An open in the wire • Blown No.6 (15 A) fuse in the under-dash driver's fuse/relay box • An open in the wire • Blown No.3 (7.5 A) fuse in the under-dash driver's fuse/relay box • An open in the wire • Faulty radiator fan control module • An open in the wire

• Faulty radiator fan relay or condenser fan relay • An open in the wire • Faulty radiator fan switch B • Faulty radiator fan control module

Radiator Fan Switch (A or B) Test NOTE: Bleed air from the cooling system after installing the radiatorfan switch (see page 10-10). 1. Remove radiator fan switch A from the water passage and radiator fan switch B from the cylinder head (see page 10-2). 2. Suspend each radiator fan switch (A) in a container of coolant as shown. C

o A

WATER

3. Heat the coolant and check the temperature with a thermometer (B). Do not let the thermometer touch the bottom of the hot container. 4. Measure the continuity between the A terminal (C) and B terminal (D) according to the table.

1\

Terminal

Operation ON SWITCH

A

B

196-203°F (91-95°C)

\ A

B

0--0

5-15°F (3-S0C) lower OFF than the temperature when it goes on ON

SWITCH

Temperature

217-232°F (103-111°C)

0--0

5-23° (3-13°) lower OFF than the temperature when it goes on

BACK

10-21

BACK

Fuel and Emissions Fuel and Emissions Systems Special Tools .................................................................... DTC Troubleshooting Index ............................................ Symptom Troubleshooting Index .................................. System Descriptions ........................................................

11-2 11-3 11-6 11-7

PGM-FI System Component Location Index ............................................. DTC Troubleshooting ...................................................... Injector Replacement ....................................................... Primary H02S Replacement ........................................... Secondary H02S Replacement ......................................

11-50 11-52 11-81 11-85 11-85

Idle Control System Component Location Index ............................................. 11-86 Idle Speed Adjustment .................................................... 11-87

Fuel Supply System

II"""""

Component Location Index ............................................. Fuel Pressure Relieving ................................................... Fuel Pressure Test ............................................................ Fuel Lines Inspection ....................................................... Fuel Pressure Regulator Replacement ........................... Fuel Gauge Test ...............................................................

11-88 11-88 11-90 11-92 11-93 11-95

Intake Air System Component Location Index ............................................. Throttle Body Test ............................................................ Air Cleaner Element Replacement .................................. Throttle Cable Adjustment .............................................. Throttle Body Removal/Installation ................................ Throttle Body Assembly/Reassembly ............................ Intake Air Bypass Control Valve Test .............................

11-96 11-97 11-99 11-100 11-101 11-102 11-103

PCVSystem PCV Valve Inspection and Test ....................................... 11-104

EVAPSystem Component Location Index ............................................. 11-105

Refer to the 1998-02 Accord Service Manual, PIN 61S8400, for the items not shown in this section. Outline of Accord V6 Model Change

I J30A 1 engine has been added.

Fuel and Emissions Systems Special Tools Ref. No.

CD ® ®

Tool Number A973X-041-XXXXX 07VAJ-0040100 07406-004000A

Description Vacuum Pump/Gauge, 0-30 in.Hg Fuel Pressure Gauge Attachment Fuel Pressure GauQe

CD

11-2

Qty 1 1 1

®

BACK

OTC Troubleshooting Index DTC (MIL indication*) P0107 (3)

Temporary DTe

Detection Item

--

P0108 (3)

--

P0112(10)

--

P0113 (10)

--

P0116 (86)

P0116

P0117 (6)

--

P0118 (6)

--

P0122 (7)

--

P0123 (7)

--

P0128 (87)*' P0131 (1)

---

P0132 (1)

--

P0133 (61)

P0133

P0135 (41)

--

P0137 (63)

P0136

P0138 (63)

P0136

P0139 (63)

P0136

P0141 (65)

--

P0171 (45)

P0170

Manifold Absolute Pressure (MAP) Circuit Low Voltage Manifold Absolute Pressure (MAP) Circuit High Voltage Intake Air Temperature (lAT) Circuit Low Voltage Intake Air Temperature (lAT) Circuit High Voltage Engine Coolant Temperature (ECT) Sensor Range/Performance Problem Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage Engine Coolant Temperature (ECT) Sensor Circuit High Voltage Throttle Position (TP) Sensor Circuit Low Voltage Throttle Position (TP) Sensor Circuit High Voltage Thermostat Range/Performance Problem Primary Heated Oxygen Sensor (Primary H02S) (Sensor 1) Circuit Low Voltage Primary Heated Oxygen Sensor (Primary H02S) (Sensor 1) Circuit High Voltage Primary Heated Oxygen Sensor (Primary H02S) (Sensor 1) Slow Response Primary Heated Oxygen Sensor (Primary H02S) (Sensor 1) Heater Circuit Malfunction Secondary Heated Oxygen Sensor (Secondary H02S) (Sensor 2) Circuit Low Voltage Secondary Heated Oxygen Sensor (Secondary H02S) (Sensor 2) High Voltage Secondary Heated Oxygen Sensor (Secondary H02S) (Sensor 2) Slow Response Secondary Heated Oxygen Sensor (Secondary H02S) (Sensor 2) Heater Circuit Malfunction Fuel System Too Lean

P0172 (45)

P0170

Fuel System Too Rich

Note Refer to the '98-02 Accord Manual (see page 11-47) Refer to the '98-02 Accord Manual (see page 11-48) Refer to the '98-02 Accord Manual (see page 11-50) Refer to the '98-02 Accord Manual (see page 11-51) Refer to the '98-02 Accord Manual (see page 11-52) Refer to the '98-02 Accord Manual (see page 11-52) Refer to the '98-02 Accord Manual (see page 11-53) (see page 11-52)

Service Service Service Service Service Service Service

Refer to the '98-02 Accord Service Manual (see page 11-57) (see page 11-55) (see page 11-56) (see page 11-57) (see page 11-58) (see page 11-61)

(see page 11-59) (see page 11-60) (see page 11-63) (see page 11-61) Refer to the '98-02 Accord Service Manual (see page 11-69) Refer to the '98-02 Accord Service Manual (see page 11-69) (see page 11-64)

P0300 and P1399 Random Misfire some of P0301 (71) P0302(72) P0303 (73) P0304 (74) P0305 (75) P0306 (76) *: These DTCs are rndlcated by a blrnkrng Malfunction Indicator Lamp (MIL) when the SCS service slgnallrne jumped with the Honda PGM Tester. **: The D4 indicator light and the MIL may come on simultaneously. *4: '02 model

IS

(cont'd)

BACK

11-3

.Fuel and Emissions Systems OTe Troubleshooting Index (cont'd) DTC (MIL indication*) P0301 (71)

Temporary DTe

Detection Item

P1339

No.1 Cylinder Misfire

P0302(72)

P1339


P0303 (73)

P1339


P0304 (74)

P1339


P0305 (75)

P1339


P0306 (76)

P1339


P0335 (4)

--

P0336 (4)

--

P0401 (80)

P0401

P0420(67)

P0420

P0451 (91)*'

P0451

P0452 (91)

P0450

P0453 (91)

P0450

P0505 (14)

P0505

Crankshaft Position (CKP) Sensor No Signal Crankshaft Position (CKP) Sensor Intermittent Interruption Exhaust Gas Recirculation (EGR) Insufficient Flow Catalyst System Efficiency Below Threshold Fuel Tank Pressure (FTP) Sensor Range/ Performance Problem Fuel Tank Pressure (FTP) Sensor Circuit Low Voltage Fuel Tank Pressure (FTP) Sensor Circuit High Voltage Idle Control System Malfunction

P0560 (34)

--

P0700** (70) P0715** (70) P0720** (70) P0730** (70) P0740** (70) P0753** (70) P0758** (70) P0763** (70) P0780** (70) P1106 (13)

--

Powertrain Control Module (PCM) Back up Circuit Low Voltage Automatic Transaxle System Malfunction

Note *1: (see page 11-65) *2: (see page 11-69) * 1: (see page 11-65) *2: (see page 11-69) *1: (see page 11-65) *2: (see page 11-69) *1: (see page 11-65) *2: (see page 11-69) *1: (see page 11-65) *2: (see page 11-69) *1: (see page 11-65) *2: (see page 11-69) (see page 11-74) (see page 11-74) Refer to the '98-02 Accord Service Manual (see page 11-138) Refer to the '98-02 Accord Service Manual (see page 11-137) Refer to the '98-02 Accord Service Manual (see page 11-145) Refer to the '98-02 Accord Service Manual (see page 11-146) Refer to the '98-02 Accord Service Manual (see page 11-147) Refer to the '98-02 Accord Service Manual (see page 11-101) Refer to the '98-02 Accord Service Manual (see page 11-76) Refer to the Automatic Transmission DTC Troubleshooting Index

Barometric Pressure (BARD) Sensor Refer to the '98-02 Accord Service Range/Performance Problem Manual (see page 11-77) -P1107 (13) Barometric Pressure (BARD) Sensor Refer to the '98-02 Accord Service Manual (see page 11-77) Circuit Low Input -P1108 (13) Barometric Pressure (BARD) Sensor Refer to the '98-02 Accord Service Manual (see page 11-77) Circuit High Input P1121 (7) Throttle Position (TP) Sensor Lower (see page 11-76) P1121 Than Expected *: These DTCs are indicated by a blinking Malfunction Indicator Lamp (MIL) when the SCS service signal line IS jumped with the Honda PGM Tester. **: The D4 indicator light and the MIL may come on simultaneously. *1: '98-99 models *2: '00-02 models

11-4

P1106

BACK

DTe (Mil indication*) P1122 (7)

Temporary DTe P1122

P1128 (5)

P1128

P1129 (5)

P1129

P1259 (22) P1297 (20)

--

P1298 (20)

--

P1361 (8)

--

P1362 (8)

--

P1366 (58)

--

P1367 (58)

--

P1456 (90)

P1456 (90)

P1457 (90)

P1457 (90)

P1491 (12)

P1491 (12)

P1498 (12)

--

P1519 (14)

--

P1607 (-)

--

--

Detection Item Throttle Position (TP) Sensor Higher Than Expected Manifold Absolute Pressure (MAP) Sensor Lower Than Expected Manifold Absolute Pressure (MAP) Sensor Higher Than Expected VTEC System Malfunction Electrical Load Detector (ELO) Circuit Low Voltage Electrical Load Detector (ELD) Circuit High Voltage Top Dead Center (TOC) 1 Sensor Intermittent Interruption Top Dead Center Sensor (TOC) 1 No Signal Top Dead Center Sensor (TOC) 2 Intermittent Interruption Top Dead Center Sensor (TOC) 2 No Signal Evaporative Emission (EVAP) Control System Leakage (Fuel Tank System) Evaporative Emission (EVAP) Control System Leakage (EVAP Canister System) Exhaust Gas Recircuration (EGR) Valve Insufficient Lift Exhaust Gas Recircuration (EGR) Valve Position Sensor Circuit High Voltage Idle Air Control (lAC) Valve Circuit Malfunction Powertrain Control Module (PCM) Internal Circuit Malfunction FPTOR Signal Line Malfunction FPTOR Signal Line Malfunction Automatic Transaxle System Malfunction

Page (see page 11-76) Refer to the '98-02 Accord Manual (see page 11-49) Refer to the '98-02 Accord Manual (see page 11-49) (see page 6-6) Refer to the '98-02 Accord Manual (see page 11-84) Refer to the '98-02 Accord Manual (see page 11-85) (see page 11-77)

Service Service

Service Service

(see page 11-77) (see page 11-77) (see page 11-77) Refer to the '98-02 Accord Service Manual (see page 11-149) Refer to the '98-02 Accord Service Manual (see page 11-152) Refer to the '98-02 Accord Service Manual (see page 11-138) Refer to the '98-02 Accord Service Manual (see page 11-142) Refer to the '98-02 Accord Service Manual (see page 11-102) Refer to the '98-02 Accord Service Manual (see page 11-90) (see page 11-79) (see page 11-79) Refer to the Automatic Transmission OTC Troubleshooting Index

-P1676 (35)*3 -P1678 (35)*3 -P1705** (70) P1706** (70) P1706 P1738** (70) P1739** (70) P1750** (70) P1751 ** (70) P1753** (70) P1768** (70) P1773** (70) *: These OTCs are indicated by a blinking Malfunction Indicator Lamp (MIL) when the SCS service signal line jumped with the Honda PGM Tester. **: The 04 indicator light and the MIL may come on simultaneously. *3: '01-02 models

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IS

11-5

Fuel and Emissions Systems Symptom Troubleshooting Index These symptoms DO NOT trigger Diagnostic Trouble Codes (DTCs) and cause the Malfunction Indicator Lamp (MIL) to come on. If the MIL is reported on, check for DTCs. If the vehicle has one of these symptoms, do the diagnostic procedure for it, in the sequence listed, until you find the cause. SvmDtom Engine will not start (MIL works OK, no DTCs set)

.. Engine will not start (MIL comes on and stays on, or never comes on at all, no DTCsset) Engine will not start (immobilizer indicator light comes on) Hard starting (MIL works OK, no DTCs set)

Cold fast idle too low (MIL works OK no DTCs set) Cold fast idle too high (MIL works OK, no DTCs set) Idle speed fluctuates (MIL works OK, no DTCs set) Low power (MIL works OK, no DTCs set) Engine stalls (MIL works OK, no DTCs set)

Difficult to refuel (MIL works OK, no DTCs set)

Fuel overflows during refueling (No DTCs set)

11-6

Diagnostic procedure Testthe battery (see page 22-30). Testthe starter (see page 4-7). Test the fuel pump, refer to the '98-02 Accord Service Manual (see page 11-117). 4. Test the ignition wires for '98-99 models (see page 4-22). 5. Test the ignition coil for '98-99 models (see page 4-22), or for '00-02 models (see page 4-23). 6. Check the ignition control module (lCM) inputs for '98-99 models (see page 4-21). 7 . Troubleshoot the PGM-FI main relay circuit, refer to the '98-02 Accord Service Manual (see page 11-112). Troubleshoot the MIL circuit, refer to the '98-02 Accord Service Manual (see page 11-91). 1. 2. 3.

Troubleshoot the immobilizer system, refer to the '98-02 Accord Service Manual (see page 22-206). 1. Test the battery (see page 22-30). 2. Check the fuel pressure (see page 11-90). 3. Test the ignition wires for '98-99 models (see page 4-22). 4. Test the ignition coil for '98-99 models (see page 4-22), or for '00-02 models (see page 4-23). 5. Check the ignition control module (lCM) input for '98-99 models (see oaoe 4-21 ). Check/adjust the idle speed (see page 11-87). 1. Check/adjust the idle speed (see page 11-87). 2. Inspect/adjust the throttle cable (see page 11-100). 3. Inspect and test the throttle body (see page 11-97). 1. Check/adjust the idle speed (see page 11-87). 2. InspeCt/adjust the throttle cable (see page 11-100). 3. Insoect and test the throttle bodv (see oaoe 11-97). 1. Check the fuel pressure (see page 11-90). 2. Inspect and test the throttle body (see page 11-97). 3. Insoect/adiust the throttle cable (see paoe 11-100). 1. Check the fuel pressure (see page 11-90). 2. Test the ignition wires for '98-99 models (see page 4-22). 3. Check/adjust the idle speed (see page 11-87). 4. Troubleshoot the brake switch signal circuit. 1. Test the fuel tank vapor control valve, refer to the '98-02 Accord Service Manual (see page 11-160). 2. Inspect the fuel tank signal tube between the fuel pipe and the fuel tank vapor control valve. 3. Inspect the fuel tank vapor vent tube between the EVAP control canister and the fuel tank vapor control valve. 4. Check the EVAP canister, refer to the '98-02 Accord Service Manual (see page 11-138). Replace the fuel tank vapor control valve, refer to the '98-02 Accord Service Manual (see page 11-162).

BACK

Also check for Low compression No ignition spark Intake air leaks Locked up engine Slippedl broken timing belt • Contaminated fuel • • • • •

• Low compression • Intake air leaks • Contaminated fuel

Intake air leaks

Low compression

• Intake air leaks • Faulty harness and sensor connectors

System Descriptions Electronic Control System The functions of the fuel and emission control systems are managed by the Powertrain Control Module (PCM). Fail-safe Function When an abnormality occurs in the signal from a sensor, the PCM ignores that signal and assumes a pre-programmed value for that sensor that allows the engine to continue to run. Back-up Function When an abnormality occurs in the PCM, the injectors are controlled by a back-up circuit independent of the system in order to permit minimal driving. SeN-diagnosis When an abnormality occurs in the signal from a sensor, the PCM supplies ground for the Malfunction Indicator Lamp (MIL) and stores the Diagnostic Trouble Code (DTC) in erasable memory. When the ignition is first turned on, the PCM supplies ground to the MIL for 2 seconds ('98-01 models) or 15 to 20 seconds ('02 models) to check the MIL bulb condition. Two Driving Cycle Detection Method To prevent false indications, the "two driving cycle detection method" is used for some self-diagnostic functions. When an abnormality occurs, the PCM stores it in its memory. When the same abnormality recurs after the ignition switch is turned OFF and ON (II) again, the PCM turns on the MIL.

(cont'd)

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11-7

Fuel and Emissions Systems System Descriptions (cont'd) PCM Data You can retrieve data from the PCM by connecting the OBD II scan tool or the Honda PGM Tester to the Data Link Connector (DLC). The items listed in the table below conform to SAE recommended practice. The Honda PGM Tester also reads data beyond that recommended by SAE to help you find the causes of intermittent problems. NOTE: • The "operating values" listed are approximate and may vary depending on the environment and the individual vehicle . • Unless noted otherwise, "at idle speed" means idling with the engine completely warmed up, transmission in Park or neutral, and the AlC and all accessories turned off. Data Diagnostic Trouble Code (DTC)

Engine Speed

Vehicle Speed Manifold Absolute Pressure (MAP)

Engine Coolant Temperature (ECT)

Primary Heated Oxygen Sensor (Primary H02S) (Sensor 1), Secondary Heated Oxygen Sensor (Secondary H02 S) (Sensor 2)

11-8

Description Ifthe PCM detects a problem, it will store it as a code consisting of one letter and four numbers. Depending on the problem, an SAE-defined code (POxxx) or a Honda-defined code (P1xxx) will be output to the tester. The PCM computes engine speed from the signals sent from the Crankshaft Position (CKP) sensor. This data is used for determining the time and amount of fuel injection. The PCM converts pulse signals from the countershaft speed sensor into speed data. The absolute pressure caused in the intake manifold by engine load and speed.

Operating Value If no problem is detected, there is no output.

Nearly the same as tachometer indication At idle speed: 680±50 rpm Nearly the same as speedometer indication With engine stopped: Nearly the same as atmospheric pressure. At idle speed: 20-34 kPa (150-260 mmHg, 6-10 in.Hg), 0.9 - 1.0 V With cold engine: Same The ECT sensor converts coolant temperature into voltage, and sends a voltage signal to the PCM. as ambient temperature The sensor is a thermistor whose internal resistance and IAT With engine warmed up: changes with coolant temperature. The PCM uses about 176 - 212°F (80the voltage signals from the ECT sensor to 100°C), 0.9 - 1.0 V determine the amount of iniected fuel. 0.0-1.25 V The H02S detects the oxygen content in the At idle speed: exhaust gas and sends voltage signals to the PCM. about 0.1-0.9 V Based on these signals, the PCM controls the air/ fuel ratio. When the oxygen content is high (that is, when the ratio is leaner than the stoichiometric ratio), the voltage signal is lower. When the oxygen content is low (that is, when the ratio is richer than the stoichiometric ratio), the voltage signal is higher.

BACK

Freeze Data YES

YES

YES YES

YES

NO

Data Fuel System

Short Term Fuel Trim

long Term Fuel Trim

Intake Air Temperature ((AT) Throttle Position Ignition Timing

Calculated Load Value (ClV)

Description Fuel system status is indicated as "open" or "closed". Closed: Based on the H02S output, the PCM determines the air/fuel ratio and controls the amount of injected fuel. Open: ignoring H02S output, the PCM refers to signals from the Throttle Position (TP), Manifold Absolute Pressure (MAP), Intake Air Temperature (fAT), Barometic Pressure (BARO), and Engine Coolant Temperature (ECT) sensors to control the amount of injected fuel. The air/fuel ratio correction coefficient for correcting the amount of injected fuel when Fuel System Status is "closed". When the ratio is leaner than the stoichiometric ratio, the PCM increases short term fuel trim gradually, and the amount of injected fuel increases. The air/fuel ratio gradually gets richer, causing a lower oxygen content in the exhaust gas. Consequently, the short term fuel trim is lowered, and the PCM reduces the amount of injected fuel. This cycle keeps the air/fuel ratio close to the stoichiometric ratio when in closed loop status. long term fuel trim is computed from short term fuel trim and indicates changes occuring in the fuel supply system over a long period. If long term fuel trim is higher than 1.00, the amount of injected fuel must be increased. If it is lower than 1.00, the amount of injected fuel must be reduced. The IAT sensor converts intake air temperature into voltage and signals the PCM. When intake air temperature is low, the internal resistance of the sensor increases, and the voltaQe siQnal is hiRher. Based on the accelerator pedal position, the opening angle ofthe throttle valve is indicated. Ignition timing is the ignition advance angle set by the PCM. The PCM matches ignition timing to the driving conditions.

ClV is the engine load calculated from the MAP data.

Operating Valve At idle speed: closed

Freeze Data YES

0.73-1.47

YES

0.81-1.19

YES

With cold engine: Same as ambient temperature and ECT

YES

At idle speed: approx.10% At idle speed: 10o ±2° BTDC with the SCS service signal jumped with the Honda PGM Tester At idle speed: 16-33% At 2,500 rpm with no load: 17-25%

YES NO

YES

(cont'd)

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11-9

Fuel and Emissions Systems System Descriptions (cont'd) PCM Electrical Connections (cont'd) PGM-FI MAIN RElAY

1=

®

Ifdil;

®

IGNmON SWITCH

®

B IG1 ST

CD

@ ,..--.

j@ rru

@

B1IGP1

@)

1

@

TOC SENSOR 1 TOC SENSOR 2 CKP SENSOR

PG2810

'--- A24STS

IMOFLRA15

PUMP:

~ ~.

-

INJECTORS

B22LG2

No.1

INJ1 B11

_. - -----

------------- - -----

C20TOC1P

INJ2 B5

C21 TOC1M

INJ3 B15

C29T0C2P

INJ4B4

To SPEEDOMETER

INJ& B&

MILA18

0

No.4

C8CKPP

A9VSSOUT

E

r----<> No.3

C30TOC2M

A30ELD

ToELD

>-----<>- No.2

r---<> No.5 INJ5 B3 r---<>

C9CKPM

r.::

>---j-

B20 LG1

---_._------ - -----

~

r; ~

821 VBU

IACV B23

r--

No.6

-~~

f' . ., ~

lAC VALVE

100

DATA UNK CONNECTOR

A21 KoUNE

ACCA17 ~ ToAIC CLUTCH RELAY ~ To RADIATOR FAN RELAY, RADIATOR FAN SWITCH ACSA27 ~ To AIC SWITCH

FANCA20

~I<> C

....

A10SCS

ALTCC2 ALTFCS

USES: BACK UP, ACC (40A)*A STOP (20A)*A ACGS (15A) * A BATTERY (100A) *A IG MAIN (50A)*A No.1 FUEL PUMP (15A)*8 No.9 BACK UP LIGHT INSTRUMENT LIGHT (7.5A) * 8 No.6 ECU (PCM) CRUISE CONTROL (15A)*8 No.11 IG COIL (15A) * 8 4l» No.13 STARTER SIGNAL (7.5A) * 8 II]) No.13 CLOCK BACKUP (7.5A)*C

IMOLMPA12

I->---

HJ~

ALT

~UZER

,

INDICATOR UGHT

02. o'MTRTW A1

To ECTGAUGE

~ *1 '98-99 models *2 '00 model *3 '01-02 models

*A : In the under-hood fuse/relay box

*8 : In the driver'a under-ciaah fuse/relay box *C: in the passenger's under-ciash fuse/relay box

11-10

-.<2

>---

PGl B2 ;>-

B91GP2

~ +1 ------~

lflL

®

:

~ATTERY

~

1=

®

STARTER CUT

~ RELAY

...

BACK

~ TP

C28VCC2

S ENSOR

C27TPS

·'ICM B13

C18SG2

r--

EGR VALVE PosmON S ENSOR

l!:~

EGR VALVE

FTP S ENSOR

B7E·EGR

CRSA5

! -D

TO GAUGE ASSEMBLY, ABS/TCS .3 CONTROLUNIT TEST TACHOMETER CONNECTOR To CRUISE CONTROL UNIT

EVAP CANISTER PURGE VALVE A29PTANK

MAP

I nEC~SENSOR -.

ToCUMATE CDNTRDL UNIT

NEPA19

ICM

ijI

I

S ENSOR

CSEGRL

~ 1

ENGINE /,Ir,UNT CONTROL SOLENOID VALVE

C19VCCl

MCSA2

C17MAP

VBSDLD5

'W

C7SGl EVAP BlI SS SOLENOID VALVE 2WBSA3 VSVA4

C2BECT

VTSB12

IA!.SENSDR

-.

PCSA6

EVAP~ j!!TER VENT SHUT VALVE VTECSOL ~OIDVALVE . v

1

C25IAT

PSP;;;;'CH

~

A2BPSPSW

F

Iii BRAKE PEDAL PosmON

~

~PP~ A32BKSW

B

S~H

'-7

II

.1#.

IF/'

'j,

'2,'3 IGPLS5 C12

- ...... _-

'2, '3IGPLS& C23

C1 P02SHTC

_.. _-----

>--

~ n

~

ICM

To

j

~':~~:K

No. 21GNmON COIL ... • 3

I~J - II ~

C1&PH02S

PLUG

ICM

To

~I

;:~~:K

No.3 IGNITION COIL .2, .3

SECONDARY HO2S (SENSOR 2)

[C~

I

!~

To

~ .. "PARK

No.lIGNmON COIL .2,.3

02, '3IGPLS4 C13

~ ----- ...

ICM

.2••3IGPLS3 C3 C10VTM

E PRIMARY HO2S (SENSOR 1)

~~ ..u

....3IGPLS1C4 t2,'3IGPLS2 C14

VTEC PRESSURE

I~l

A8S02SHTC

----------

------ --------

A23SH02S

BARO SENSOR (BulK Into tho PCM)

U-t

ICM

~I

No.4 IGNmON COIL .2, .3

.-----. ICM

il

~

To

~ =~~K

To

~

~':~~:K

No. SIGNmON COIL .2, .3

I~l

U-t

ICM

To

~I

~ =~~:K

No. 61GNmON COIL .2, .3 ~

(cont'd)

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11-11

Fuel and Emissions Systems System Descriptions (cont'd) PCM Electrical Connections (cont'd)

~ 2ND~_L_UT,CH

UNIT

TO~r:.0BILIZER TolMMOBIUZER To MULTIPLEX CONTROL UNIT (DRIVER'S)

PRESSURE SWITCH

::=======~~~~~~kL.~::·:·:'~'·d=~~~~~~~1 A251MOCD

pP2SW B14,

oi"3

-U

Ai3,A:iIMOEN

3RDgCH PRESSURE SWITCH

A281LU

OP3SW B24

I

""t' "I ......,

~

TORQUE CONVERTER CLUTCH crCC) SOLE~ VALVE ASSEMBLY LCDl SHAD7

SHI";'~LENOID(SS)VALVEASSEMBLY A 'UO

GAUGE ASSEMBLY

A14D41ND

SHIFT...§9!.ENOID (SS) VALVE ASSEMBLY B SHBD2 SHI..;.jtLENOID (SS) VALVE ASSEMBLY C SHCD3

'00

~

B~ D13·ATPNP

I

D8ATPR

LSA+B17

D9ATPD4

II If

LSA

B8

I

'W

AUTOMATIC TRANSAXLE CAmCLUTCH PRESSURE CONTROL SOLENOID VALVE ASSEMBLY A

D8ATPD3 D14ATP2

LSB+B25

D15ATPl

LSB

B18

I

AUTOMA~ri~RANSAXLE CAm CLUTCH PRESSURE

CONTROL SOLENOID VALVE ASSEMBLY B

OJ

C

TRANSMISSION RANGE SWITCH NMD11 NMSGD12 NCD10 NCSGD18

.3 ATSFTP A11 .3VREFA7 ABSfTCS CONTROL UNIT·3

.3 THLOUT A31 .3PFINHA13 .3FPTDRA22

PCM B (25P)

PCM A (32P)

PCM C (31P)

PCM D (16P)

TERMINAL LOCATIONS

11-12

BACK

PCM Inputs and Outputs at Connector A (32P)

~

tk

12 IMO LMP

13

~

5

3 4 l!MlS VSV 14

D6 !NO 25

IMe

CD

litO FLR

16 IMO EN

~

27 />CS

CRS

6 7 PCS VREF

17 ICC

18 MIL

28

IW

8 9 S02S VSS HTC ClJT

10

scs

20 21 22 NEP FANC IH.i1IE FPItfI 19

29

PTANK

30 ELD

~

23

SH02S

11 AlSFTP

24

STS

32

BKSW


NOTE: Standard battery voltage is 12 V. Terminal name Terminal Wire color number MTRlW 1*" *' VEL/GRN 2

GRN/WHT

3

BLU

4 5

LTGRN/ WHT BLU/GRN

6

RED/VEL

7*'

ORN/GRN

8

BLK/WHT

9

BLU/WHT

10

BRN

MCS (ENGINE MOUNT CONTROL SOLENOID VALVE) 2WBS (EVAP BVPASS SOLENOID VALVE) VSV (EVAP CANISTER VENT SHUT VALVE) CRS (CRUISE CONTROL SIGNAL) PCS (EVAP CANISTER PURGE VALVE)

Description Sends engine coolant temDerature sianal. Drives engine mount control solenoid valve. Drives EVAP bypass solenoid valve. Drives EVAP canister vent shut valve. Detects cruise control signal.

With ignition switch ON (II): pulses

Drives EVAP canister purge valve.

With engine running, engine coolant, below 147GF (64 GC): battery voltage With engine running, engine coolant, above 147GF (64 GC): duty controlled With ignition switch ON (II): about 5 V With ianition switch OFF: 0 V With ignition switch ON (II): battery voltage With fully warmed up engine running: duty controlled

VREF (REFERRENCE VOLTAGE) S02SHTC(SECONDARV HEATED OXYGEN SENSOR HEATER CONTROL) VSSOUT (VEHICLE SPEED SENSOR OUTPUT SIGNAL] SCS (SERVICE CHECK SIGNAL)

Provides reference voltage to ABSrrCS control unit. Drives secondary heated oxygen sensor heater.

LTGRN

ATSFTP (TRANSMISSION RANGE SWITCH)

Sends transmission gear switch signal.

12

PNK

13*" *'

BLU

IMOLMP (lMMOBLlZER INDICATOR LIGHT) IMOEN (lMMOBILZER ENABLE SIGNAL) D41ND (04 INDICATOR)

Drives immobilizer indicator light. Sends immobilizer enable sianal. Drives 04 indicator light.

IMO FLR (IMMOBILIZER FUEL PUMP RELAV) IMOEN (IMMOBILIZER ENABLE SIGNAL) ACC (AiC CLUTCH RELAV)

Drives fuel pump relay.

11*'

14

GRN/BLK

15

GRN/VEL

16*'

BLU

17

RED

Signal

Sends vehicle speed sensor signal. Detects service check connector signal (the signal causing a DTC indication).

Sends immobilizer enable signal. Drives AlC clutch relay.

*1..'98-99 models *2: '00 model *3: '01-02 models

At idle: OV Above idle: battery voltaae With ignition switch ON (II): battery voltage With ignition switch ON (II): battery voltage With ignition switch ON (II): pulses

Depending on vehicle speed: pulses With the service check signal shorted with the Honda PGM Tester: 0 V With the service check signal opened: about 5 V or battery voltage With engine running in park position: about 4 V With the service check signal opened: about 5 V or battery voltage With immobilizer indicator light turned ON: 0 V With immobilizer indicator light turned OFF: battery voltage

With 04 indicator light turned ON: 0 V With 04 indicator liaht turned OFF: battery voltaae oV for two seconds after turning ignition switch ON (II) then battery voltage

With compressor ON: 0 V With compressor OFF: battery voltage

(cont'd)

BACK

11-13

Fuel and Emissions Systems System Descriptions (cont'd) PCM Inputs and Outputs at Connector A (32P)

~

2 MCS

3

~

4 VSV

12 13 14 16 IMO IMO 1110 IMO 05 LMP EWfINH INO FLR EN 25 27 26 IMO PSP5W M:;S CD

5

CRS

6 7 PCS VREF

17 ACC

18 MIL

8 9 S02S VSS HTC OUT

19 20 21 22 NEP FANC K-UNE FPTDR

28 29 30 ILU PTANK ELO

~

10

11

scs

AlSFTP

23 SH02S

24 STS

32 BKSW



Wire color GRN/ORN

19 20

BLU GRN

21

GRY

Terminal name MIL (MALFUNCTION INDICATOR LIGHT) NEP (ENGINE SPEED PULSE) FANC (RADIATOR FAN CONTROL) K-LiNE FPTDR (FRAME TO POWERTRAIN TORQUE DOWN REQUEST) SH02S (SECONDARY HEATED OXYGEN SENSOR, SENSOR 2) STS (STARTER SWITCH SIGNAL) IMOCD (IMMOBILIZER CODE) PSPSW (PIS PRESSURE SWITCH SIGNAL)

Description Drives MIL.

With MIL turned ON: 0 V With MIL turned OFF: battery voltage OutPuts enoine speed pulse. With enoine runnino: pulses With radiator fan running: 0 V Drives radiator fan relay. With radiator fan stopped: batterv voltaoe Sends and receives scan With ignition switch ON (II): pulses tool si~Jnal. Detects engine retard With TCS operating: about 5 V With TCS not operating: about 2.5 V request signal.

22*'

GRN/RED

23

WHT/RED

24

BLU!ORN

25 26

RED GRN

27

BLU/RED

ACS (NC SWITCH SIGNAL)

Detects AlC switch signal.

28

WHT/RED

29

LTGRN

Sends Interlock control sional. Detects FTP sensor signal.

30

GRN/RED

ILU (INTERLOCK CONTROL UNIT) PTANK (FUEL TANK PRESSURE SENSOR) ELD (ELECTRICAL LOAD DETECTOR)

31*'

YEL/GRN

Sends TP sensor signal.

32

WHT/BLK

THLOUT (THROTTLE POSITION SENSOR OUTPUT SIGNAL) BKSW (BRAKE PEDAL POSITION SWITCH)

,

Detects secondary heated oxygen sensor (sensor 2) sional. Detects starter switch signal. Detects immobilizer sional. Detects PSP switch signal.

Detects ELD signal.

Detects brake pedal position switch sional.

*1: 98-99 models *2: '00 model *3: '01-02 models

11-14

Signal

BACK

With throttle fully opened from idle with fully warmed up engine: above 0.6 V With throttle quicklv closed: below 0.4 V With starter switch ON (II): battery voltage With starter switch OFF: 0 V At idle with steering wheel in straight ahead position: 0 V At idle with steering wheel at full lock: battery voltage With AlC switch ON: 0 V With AlC switch OFF: about 5V With ignition switch ON (II) and brake pedal pressed: about 0 V With ignition switch ON (II) and fuel fill cap: opened: about 2.5 V With parking lights turned on at idle: about 2.53.5V With low beam headlights turned on at idle: about 1.52.5V With throttle fully open: about 4.8 V With throttle fully closed: about 0.5 V With brake pedal released: 0 V With brake pedal pressed: batterv voltaoe

PCM Inputs and Outputs at Connector B (25P)

1 IGP1

2 PG1

9

10 PG2

IGP2

/

20 LG1

3 INJ5 11 INJ1

12

VTS 21

VBU

7 8 6 INJ6 E-EGR LSA-

4 5 INJ4 INJ2

~

13 15 leM ATPN.... INJ3 22 LG2

/

23 lACY

17

18

LSA+ LSB-

24 OP 39N

25

LSB+



Terminal name

VEL/BlK

IGP1 (POWER SOURCE)

7

BlK BlK/RED VEL RED WHT/BlU PNK

PG1 (POWER GROUND) INJ5 (No.5 INJECTOR) INJ4 (No. 4 INJECTOR) INJ2 (No.2 INJECTOR) INJ6 (No. 6 INJECTOR) E-EGR

8

WHT

lSA - (AfT CLUTCH PRESSURE CONTROL SOLENOID VALVE A - SIDE) IGP2 (POWER SOURCE)

2 3 4 5 6

9

VEL/BlK

10 11 12

BlK BRN GRN/YEl

13*'

VEL/GRN

14*'

BLU/BlK

14*~

*'

BLU/WHT

17

BlU RED

18

GRN

20 21

BRN/BlK WHT/yEl

22 23

BlK*' BRN/BlK*' BlK/BlU

24

BlU/WHT

25

ORN

15

r

Wire color

PG2 (POWER GROUND) INJ1 (No.1 INJECTOR) VTS (VTEC SOLENOID VALVE) ICM (IGNITION CONTROL MODULE) OP2SW (2ND Oil PRESSURE SWITCH) ATPNP (TRANSMISSION RANGE SWITCH) INJ3 (No. 3 INJECTOR) lSA + (AfT CLUTCH PRESSURE CONTROL SOLENOID VALVE A + SIDE) (AfT CLUTCH lSB PRESSURE CONTROL SOLENOID VALVE B - SIDE) lG1 (lOGIC GROUND) VBU (VOLTAGE BACK UP)

lG2 (lOGIC GROUND) IACV (IDLE AIR CONTROL VALVE) OP3SW (3RD Oil PRESSURE SWITCH) lSB + (AfT CLUTCH PRESSURE CONTROL SOLENOID VALVE B + SIDE)

Description Power source for the PCM circuit. Ground for the PCM circuit. Drives No.5 injector. Drives No.4 injector. Drives No.2 iniector. Drives No.6 iniector. Drives EGR valve.

AfT clutch pressure control solenoid valve A power supplynegative terminal Power source for the PCM circuit. Ground for the PCM circuit. Drives No.1 iniector. Drives VTEC solenoid valve. Sends ignition pulse.

Signal With the ignition switch ON (II): battery voltage With the ignition switch OFF: about 0 V less than 1.0 V at all times With engine running: pulses

With EGR operating: duty controlled With EGR not operatinQ: about 0 V With the ignition switch ON (II): pulses

With the ignition switch ON (II): battery voltage With the ignition switch OFF: 0 V less than 1.0 V at all times With engine running: pulses With engine at low rpm: 0 V With engine at high rpm: battery voltage With the ignition switch ON (II): battery voltage With engine running: about 10 V (depending on engine speed) With the ignition switch ON (II): battery voltage

Detects 2nd oil pressure switch. Detects transmission range switch signal. Drives No.3 iniector. AfT clutch pressure control solenoid valve A power supply positive terminal AfT clutch pressure control solenoid valve B power supply negative terminal Ground for the PCM circuit. Power source for the PCM circuit. Power source for the DTC memory. Ground for the PCM circuit.

With the ignition switch ON (II): pulses

Drives lAC valve.

With engine running: pulses

Detects 3rd oil pressure switch. AfT clutch pressure control solenoid valve B power supply positive terminal

With the ignition switch ON (II): battery voltage

In Park or Neutral: 0 V In anv other position: battery voltaae With enaine runninQ: pulses With the ignition switch ON (II): pulses

less than 1.0 V at all times Battery voltage at all times

less than 1.0 V at all times

With the ignition switch ON (II): pulses

* 1..'98-99 models *2: '00 model *3: '01-02 models

(cont'd)

BACK

11-15

Fuel and Emissions Systems System Descriptions (cont'd) PCM Inputs and Outputs at connector C (31P)

1

4 3 2 P02S ALTC IG'lS3 1GI'l.S1 HTC

V

12 13 1GPI.S5 IGPI.S4

V

23 1GI'l.S6

d& 25

IAT

7 5 6 ALTF EGRL 931

V~ 26 ECT

17 MAP

18 932

9 10 8 CKPP CKPM VTM 19 20 VCCl TDC1P n:i:11M

27 28 TPS VCC2

TDC2P ~ 29

V V



Wire color

Terminal name

BlK/WHT

2

WHT/GRN

P02SHTC (PRIMARY HEATED OXYGEN SENSOR HEATER CONTROL) AlTC (ALTERNATOR CONTROL) IGPlS 3 (No. 3 IGNITION COil PULSE) IGPlS 1 (No.1 IGNITION COil PULSE) AlTF (ALTERNATOR FR SIGNAL) EGRl (EGR VALVE LIFT SENSOR) SG1 (SENSOR GROUND) CKPP (CKP SENSOR P SIDE) CKPM (CKP SENSOR M SIDE) VTM (VTEC PRESSURE SWITCH SIGNAL) IGPlS 5 (No. 5 IGNITION COIL PULSE) IGPlS 4 (No. 4 IGNITION COIL PULSE) IGPlS 2 (No. 2 IGNITION COIL PULSE) PH02S (PRIMARY HEATED OXYGEN SENSOR, SENSOR 1) MAP (MANIFOLD ABSOLUTE PRESSURE SENSOR) SG2 (SENSOR GROUND) VCC1 (SENSOR VOLTAGE)

3*" *3

WHT/BLU

4*" *3

YEL/GRN

5

WHT/RED

6

WHT/BlK

7 8 9 10

GRN/WHT BlU WHT BlU/BlK

12*~

*3

BlK/RED

13*~

*3

BRN

14*~

*3

BlU/RED

16

WHT

17

RED/GRN

18 19

GRN/BlK YEL/RED

20

GRN

21

RED

23*~

*3

BRN/WHT

25

RED/YEL

26

RED/WHT

27

RED/BlK

28

YEL/BLU

29

YEl

30

BlK

,

TDC1P (TDC SENSOR 1P SIDE) TDC1 M (TDC SENSOR 1M SIDE) IGPlS 6 (No. 6 IGNITION COil PULSE) IAT (INTAKE AIR TEMPERATURE SENSOR) ECT (ENGINE COOLANT TEMPERATURE SENSOR) TPS (THROTTLE POSITION SENSOR) VCC2 (SENSOR VOLTAGE) TDC2P (TDC2 SENSOR P SIDE) TDC2M (TDC2 SENSOR M SIDE)

Description Drives primary heated oxygen sensor heater. Sends alternator control s19nal. Drives No.3 ignition coil.

With ignition switch ON (II): battery voltage With fully warmed up engine running: duty controlled With engine running: about 0 V 5 V (depending on electrical load) With ignition switch ON (II): 0 V With engine running: pulses

Drives No.1 ignition coil. Detects alternator FR signal. Detects EGR valve lift sensor signal. Ground for MAP sensor. Detects CKP sensor. Ground for CKP sensor. Detects VTEC pressure switch sianal. Drives No.5 ignition coil.

With engine running: about 0 V-5 V (depending on electrical load) At idle: about 1.2 V less than 1.0 V at all times With enaine runni~ulses With With With With

engine at low rpm: 0 V enaine at hiah rom: battery voltaae ignition switch ON (II): OV engine running: pulses

Drives No.4 ignition coil. Drives No.2 ignition coil. Detects primary heated oxygen sensor (sensor 1) sianal. Detects MAP sensor signal. Sensor around. Power source to MAP sensor. Detect TDC sensor 1.

With throttle fully opened from idle with fully, warmed up engine: above 0.6 V With throttle auicklv closed: below 0.4 V With ignition switch ON (II): about 3 V At idle: about 1.0 V (deoendina on enaine soeed) less than 1.0 V at all times. With ignition switch ON (II): about 5 V With ignition switch OFF: 0 V With engine running: pulses

G round for TDC sensor 1. Drives No.6 ignition coil. Detects IAT sensor signal. Detects ECT sensor signal. Detects TP sensor signal. Provides sensor voltage. Detects TDC sensor 2. Ground for TDC sensor 2.

*2: 00 model *3: '01-02 models

11-16

Signal

BACK

With ignition switch ON (II): OV With enaine run nina: oulses With ignition switch ON (II): about 0.1 4.8 V (deoendina on intake airtemoerature) With ignition switch ON (II): about 0.1- 4.8 V (deoendina on enaine coolant temoerature) With throttle fully open: about 4.8 V With throttle fullv closed: about 0.5 V With ignition switch ON (II): about 5 V With ianition switch OFF: 0 V With engine running: pulses

PCM Inputs and Outputs at Connector D (16P)

r---

/

1 LC

2 SHB

6 ATPR

7 8 9 SHA ATPD3 ATPD4

10 NC

15

16 NCSG

13

f\TPN~

14

bP25W"' ATPD2 ATP1

3 SHC

5 VBSOL 11 NM

12 NMSG

'---



Wire color VEL

Terminal name

Description

LC (TORQUE CONVERTER CLUTCH SOLENOID VALVE) SHB (SHIFT SOLENOID VALVE B)

Drives torque converter clutch solenoid valve. Drives shift solenoid valve B.

2

GRN/WHT

3

GRN

SHC (SHIFT CONTROL SOLENOID VALVE C)

Drives shift control solenoid valve C.

5

BLK/YEL

6

WHT

7

BLU/YEL

VBSOL (BATTERV VOLTAGE FOR SOLENOID VALVE) ATPR (TRANSMISSION RANGE SWITCH) SHA (SHIFT SOLENOID VALVE A)

Power source for solenoid valve. Detects transmission range switch signal. Drives shift solenoid valve A.

8

PNK

9

VEL

10

BLU

11

RED

12

WHT

ATPD3 (TRANSMISSION RANGE SWITCH) ATPD4 (TRANSMISSION RANGE SWITCH) NC (COUNTERSHAFT SPEED SENSOR) NM (MAINSHAFT SPEED SENSOR) NMSG (MAINSHAFT SPEED SENSOR GROUND) ATPNP (TRANSMISSION RANGE SWITCH) OP2SW (2ND OIL PRESSURE SWITCH) ATP2 (TRANSMISSION RANGE SWITCH) ATP1 (TRANSMISSION RANGE SWITCH) NCSG(COUNTERSHAFT SPEED SENSOR GROUND)

Detects transmission range switch siqnal. Detects transmission range switch signal. Detects countershaft speed sensor signals. Detects mainshaft speed sensor siqnals. Ground for mainshaft speed sensor. Detects transmission range switch signal. Detects 2nd oil pressure switch. Detects transmission range switch signal. Detects transmission range switch sifjnal. Ground for countershaft soeed sensor.

13*"*'

BLU/WHT

13*2,*3

BLU/BLK

14

BLU

15

BRN

16

GRN

Signal With lock-up ON: battery voltage With lock-u~OFF: 0 V With engine running in 1st, 2nd gears: battery voltage With en~ne runnirmin 3rd 4th qears: about 0 V With engine running in 1st and 3rd gears: battery voltage With enqine runninq in 2nd and 4th qears: 0 V With ignition switch ON (II): battery voltage In R position: 0 V In anv other oosition: batterv voltaqe With engine running in 2nd, 3rd gears: battery voltage With enqine runninq in 1st, 4th qears: about 0 V In D3 position: 0 V In any other position: battery voltaqe In D4 position: 0 V In any other position: about 5 V or battery voltage With ignition switch ON (II), and front wheels rotating: battery voltage With engine running: pulses

In Park or Neutral: 0 V In any other position: battery voltaqe With the ignition switch ON (II): battery voltage In 2nd position: 0 V In any other position: battery voltaqe In 1st position: 0 V In any_other~osition: batt~ry voltage

*1: 98-99 models *2: '00 model *3: '01-02 models

(cont'd)

BACK

11-17

Fuel and Emissions Systems System Descriptions (cont'd) Vacuum Hose Routing - '98-99 models: CRUISE CONTROL DIAPHRAGM

/

VACUUM TANK

To EVAPORATIVE EMISSION (EVAP) CONTROL CANISTER

EVAPORATIVE EMISSION (EVAP) PURGE CONTROL SOLENOID VALVE

FRONT OF VEHICLE

FUEL INJECTION AIR (FIA) CONTROL VALVE

11-18

BACK

'00-02 models:

CRUISE CONTROL DIAPHRAGM


~

To ENGINE MOUNT CONTROL SOLENOID VALVE

CHECK VALVE

/

/VACUUM TANK

To EVAPORATIVE EMISSION (EVAP) CANISTER


FRONT OF VEHICLE FUEL PRESSURE REGULATOR INTAKE AIR BYPASS CONTROL VALVE

(cont'd)

BACK

11-19

Fuel and Emissions Systems System Descriptions (cont'd) Vacuum Distribution - '98-99 models:

@

I====J& @

CD PRIMARY HEATED OXYGEN SENSOR (PRIMARY

H02S) (SENSOR 1) ® SECONDARY HEATED OXYGEN SENSOR (SECONDARY H02S) (SENSOR 2) ® MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR @ENGINECOOLANTTEMPERATURE (ECT) SENSOR ® INTAKE AIR TEMPERATURE (lAT) SENSOR @ FUEL INJECTION AIR (FIA) CONTROL VALVE (j) IDLE AIR CONTROL (lAC) VALVE ® THROTTLE BODY (TB) ® FUEL INJECTOR @ FUEL PULSATION DAMPER ® FUEL FILTER @ FUEL PRESSURE REGULATOR @ FUEL PUMP (FP) @FUEL TANK @ AIR CLEANER @RESONATOR ® EXHAUST GAS RECIRCULATION (EGR) VALVE and LIFT SENSOR

11-20

@ POSITIVE CRANKCASE VENTILATION (PCV) VALVE @THREEWAYCATALYTICCONVERTER ®l EVAPORATIVE EMISSION (EVAP) CONTROL CANISTER ® EVAPORATIVE EMISSION (EVAP) CONTROL CANISTER FILTER @ EVAPORATIVE EMISSION (EVAP) PURGE CONTROL SOLENOID VALVE @ EVAPORATIVE EMISSION (EVAP) CONTROL CANISTER VENT SHUT VALVE ® EVAPORATIVE EMISSION (EVAP) TWO WAY VALVE @ EVAPORATIVE EMISSION (EVAP) BYPASS SOLENOID VALVE @ FUEL TANK PRESSURE SENSOR ® ONBOARD REFUELING VAPOR RECOVERY (ORVR) VENT SHUT VALVE @ ONBOARD REFUELING VAPOR RECOVERY (ORVR) VAPOR RECIRCULATION VALVE @ ENGINE MOUNT CONTROL SOLENOID VALVE

BACK

'00-02 models:

To

:J29

ENGINE += MOUNT

To

10

+=

¥':~~UM

, .. _ .. _.@ .. - ..*1

~

r=ilr:::--l~r;-:-,

.L

.. _

!

i i ~ i *2 .. _ .. _ .. _ .. --' ,... .. _ .. _ .. _ .. _ .. ---, . @ : : !

i

.L

.. _ .. _ .. _ .. _

*1: *2:

CD PRIMARY HEATED OXYGEN SENSOR (PRIMARY H02S) (SENSOR 1) ® SECONDARY HEATED OXYGEN SENSOR (SECONDARY H02S) (SENSOR 2) ® MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
i i .. --'

'00 model '01-02 models

@ POSITIVE CRANKCASE VENTILATION (PCV) VALVE @THREEWAYCATALYTICCONVERTER ®l EVAPORATIVE EMISSION (EVAP) CANISTER ® EVAPORATIVE EMISSION (EVAP) CANISTER FILTER @EVAPORATIVEEMISSION (EVAP) CANISTER PURGE VALVE @ EVAPORATIVE EMISSION (EVAP) CANISTER VENT SHUT VALVE @ EVAPORATIVE EMISSION (EVAP) TWO WAY VALVE @EVAPORATIVEEMISSION(EVAP) BYPASS SOLENOID VALVE @ FUEL TANK PRESSURE SENSOR ® FUEL TANK VAPOR CONTROL VALVE @ FUEL TANK VAPOR RECIRCULATION VALVE @ ENGINE MOUNT CONTROL SOLENOID VALVE

(cont'd)

BACK

11-21

Fuel and Emissions Systems System Descriptions (cont'd) PGM-FI System

Engine Coolant Temperature (ECT) Sensor

The Programmed Fuel Injection (PGM-FI) system is a sequential multi port fuel injection system.

The ECT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the Engine Coolant temperature increases.

Air Conditioning (A/C) Compressor Clutch Relay

When the PCM receives a demand for cooling from the AlC system, it delays the compressor from being energized, and enriches the mixture to assure smooth transition to the AlC mode. Air Conditioning (A/C) Switch

The AlC switch signals the PCM whenever there is a demand for cooling. Alternator Control

The alternator signals the Powertrain Control Module (PCM) during charging. The PCM then controls the voltage generated at the alternator assording tothe electrical load determined by the Electrical Load Detector (ELD) and driving mode. This reduces engine load to improve fuel economy.

THERMISTOR

Ignition Timing Control

The PCM contains the memory for basic ignition timing at various engine speeds and manifold absolute pressure. It also adjusts the timing according to engine coolant temperature.

Barometric Pressure (BARO) Sensor

The Baro sensor is inside the PCM. It converts atmospheric pressure into a voltage signal that modifies the basic duration of the fuel injection discharge.

Injector Timing and Duration

Crankshaft Position (CKP) Sensor

The CKP sensor determines timing for fuel injection of each cylinder and also detects engine speed. The PCM detects misfiring by using the CKP sensor to monitor fluctuations in crankshaft speed. It will then set DTCs depending on how much misfiring occurs.

11-22

The PCM contains the memory for basic discharge duration at various engine speeds and manifold pressures. The basic discharge duration, after being read out from the memory, is further modified by signals sent from various sensors to obtain the final discharge duration. By monitoring long term fuel trim, the PCM detect long term malfunctions in the fuel system and set a Diagnostic Trouble Code (DTC).

BACK

Intake Air Temperature (lAT) Sensor The IAT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature increases.

Primary Heated Oxygen sensor (Primary H02S) The primary H02S detects the oxygen content in the exhaust gas and sends signals to the PCM which varies the duration of fuel injection accordingly. To stabilize its output, the sensor has an internal heater. The primary H02S is installed in the exhaust manifold. By controlling the air fuel ratio with primary H02S and secondary H02S, the deterioration of the primary H02S can be evaluated by its feedback period. When the feedback period exceeds a certain value during stable driving conditions, the sensor is considered deteriorated and the PCM sets a DTC.

THERMISTOR

Malfunction Indicator Lamp (MIL) Indication (In relation to Readiness Codes)('01-02 models) The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems. Ifthe vehicle's battery has been disconnected or gone dead, if the DTCs have been cleared, or if the PCM has been reset, these codes are reset to complete. In some states, part of the emissions testing is to make sure these codes are set to complete. If all of them are not set to complete, the test cannot be finished. To check ifthe readiness codes are set, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15 - 20 seconds. If it then goes off, the readiness codes are set. If it blinks several times, one or more readiness codes are not set to complete. To set each code, drive the vehicle or run the engine as described in the procedures to set them. Refer to the '98-02 Accord Service Manual (see page 11-42).

ZIRCONIA ELEMENT

SENSOR TERMINALS

HEATER

HEATER TERMINALS

Secondary Heated Oxygen sensor (Secondary H02S) The secondary H02S detects the oxygen content in the exhaust gas downstream of the Three Way Catalytic Converter (TWC) and sends signals to the PCM which varies the duration of fuel injection accordingly. To stabilize its output, the sensor has an internal heater. The secondary H02S is installed in the TWC. ZIRCONIA ELEMENT

SENSOR TERMINALS

HEATER

HEATER TERMINALS

Manifold Absolute Pressure (MAP) Sensor The MAP sensor converts manifold absolute pressure into electrical signals to the PCM. SENSOR UNIT

Starting Control When the engine is started, the PCM provides a rich mixture by increasing injector duration. (cont'd)

BACK

11-23

Fuel and Emissions Systems System Descriptions (cont'd) Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the PCM. The TP sensor is not replaceable apart from the throttle body. HOLDER

Idle Control System When the engine is cold, the AlC compressor is on, the transmission is in gear, the brake pedal is pressed, the PIS load is high, or the alternator is charging, the PCM controls current to the lAC valve to maintain the correct idle speed. Refer to the System Diagram to see the functional layout of the system. Brake Pedal Position Switch The brake pedal position switch signals the PCM when the brake pedal is pressed.

TERMINAL

Idle Air Control (lAC) Valve To maintain the proper idle speed, the lAC valve changes the amount of air bypassing the throttle body in response to an electrical signal from the PCM. From AIR CLEANER

To INTAKE MANIFOLD

Top Dead Center (TOC) Sensor The TDC1/TDC2 sensor determines ignition timing at start up (cranking) and when crank angle is abnormal. TDC2SENSOR

I VALVE

Power Steering Pressure (PSP) Switch The PSP switch signals the PCM when the power steering load is high. Starter (Ignition) Switch The starter switch signals the PCM when the engine is cranking.

11-24

BACK

r Fuel Supply System

Intake Air System

Fuel Cut-off Control During deceleration with the throttle valve closed, current to the fuel injectors is cut off to improve fuel economy at speeds over 1,100 rpm. Fuel cut-off action also occurs when engine speed exceeds 6,600 rpm, regardless of the position of the throttle valve, to protect the engine from over-rewing. When the vehicle is stopping, the PCM cuts the fuel at engine speed over 5,000 rpm.

Refer to the System Diagram to see the functional layout of the system.

Fuel Pump Control When the ignition is turned on, the PCM grounds the PGM-FI main relay which feeds current to the fuel pump for 2 seconds to pressurize the fuel system. With the engine running, the PCM grounds the PGM-FI main relay and feeds current to the fuel pump. When the engine is not running and the ignition is on, the PCM cuts ground to the PGM-FI main relay which cuts current to the fuel pump.

Intake Air Bypass Control System (Fuel Air (FIA) Control System) When the engine is running, the Intake Air Bypass control valve sends air to the fuel injectors.

,

'98-99 models:

INJECTOR

-----...."'

..

~~

...::.....:......

,,:INTAKE AIR _ _ _ _ _ INTAKE AIR BYPASS CONTROL VALVE

PGM-FI Main Relay The PGM-FI relay contains two separate relays. One is energized whenever the ignition is on. It supplies battery voltage to the PCM, power to the fuel injectors, and power for the second relay. The second relay is energized to supply power to the fuel pump for 2 seconds when the ignition is switched ON (11), and when the engine is running.

VALVE

'00-02 models:

o

~INTAKEAIR

__-----'--__

BYPASS CONTROL VALVE

To <:=>~~TO INJECTORS INJECTORS <:=>From AIR CLEANER VALVE

(cont'd)

BACK

11-25

Fuel and Emissions Systems System Descriptions (cont'd) Positive Crankcase Ventilation (PCV) System

Throttle Body The throttle body is a single-barrel side draft type. The lower portion of the throttle valve is heated by engine coolant from the cylinder head. The idle adjusting screw, which increases/decreases bypass air, is located on the top of the throttle body.

The PCV valve prevents blow-by gasses from escaping into the atmosphere by venting them into the intake manifold.

IDLE ADJUSTING

:

FRESH AIR

PCV VALVE

Evaporative Emission Control System Catalytic Converter System

Refer to System Diagram to see the functional layout of the system.

Three-Way Catalytic Converter (TWC) The TWC converts hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) in the exhaust gas to carbon dioxide (C02), dinitrogen (N2), and water vapor.

EVAP Canister The EVAP canister temporarily stores fuel vapor from the fuel tank until it can be purged back into the engine and burned. EVAP Canister Purge Valve When the engine coolant temperature is above 167°F (75°C), the PCM controls the EVAP canister purge valve which provides vacuum to the EVAP canister. Fuel Tank Pressure (FTP) Sensor The FTP sensor converts fuel tank absolute pressure into an electrical input to the PCM. SENSOR CHIP

THREE-WAY CATALYSTS

Exhaust Gas Recirculation System Refer to System Diagram to see the functional layout of the system. EGRValve The EGR valve lowers peak combustion temperatures and reduces oxides of nitrogen emissions (NOx) by recirculating exhaust gas through the intake manifold and into the combustion chambers.

11-26

BACK

Idle Control System Diagram The idle speed of the engine is controlled by the lAC (Idle Air Control) valve: • After the engine starts, the lAC valve opens for a certain amount of time. The amount of air is increased to raise the idle speed by about 150-300 rpm . • When the engine coolant temperature is low, the lAC valve is opened to obtain the proper fast idle speed. The amount of bypassed air is thus controlled in relation to engine coolant temperature .

.(~J~Ir-"-~ \

INTAKE MANIFOLD

'----_ _ _ _ YELl BLK

'----_ _ BLK/

BLU

PCM

VARIOUS SENSORS

BLK

~

Intake Air System Diagram This system supplies air to the engine. A resonator in the intake air duct provides additional silencing as air is drawn into the system. '98-99 models:

,

INTAKE MANIFOLD IACVAbLEACL

L-____

~ INTAKE AIR

~~~~______

~---=l'ir;;;~:""'-;;'r--.

DUCT

-----RESONATOR

From PGM-FI MAIN RELAY

'----_ _ _ YELl BLK

[BLK

BLK/ BLU

PCM

~VARIOUS

~SENSORS

BLK

.-L (cont'd)

BACK

11-27

Fuel and Emissions Systems System Descriptions (cont'd) '00-02 models: INTAKE MANIFOLD

I . _. _._y

THROTTLE BODY

f

fAIR CLEANER

lAC VALVE

AIR INTAKE DUCT

~

~:::::~~.~~:;:6

!

I

J

i

...____RESONATOR

J ~~~~~~~~:i~JI1.... _ .._ .. _ ..~ ~~griENT

~"-"_"_~VAIR INTAKE

!1:V~:ONATOR

AIR CLEANER BLK

From

~~---~~k' BLK/ BLU

... ~~~rll

~LA:ARIOUS

y

~ SENSORS

BLK

J.. =

=

*1: *2:

'00 model '01-02 models

Exhaust Gas Recirculation (EGR) System Diagram The EGR system reduces oxides of nitrogen (NOx) emissions by recirculating exhaust gas through the EGR valve and the intake manifold into the combustion chambers. The PCM memory includes the ideal EGR valve position for varying operating conditions. The EGR valve position sensor detects the amount of EGR valve lift and sends it to the PCM. The PCM then compares it with the ideal lift in its memory (based on signals sent from other sensors). If there is any difference between the two, the PCM cuts current to the EGR valve. EGRVALVE POSITION SENSOR

,..-_ _ _ _ _ _ _ GRN/ _ _ _ _--¢ BLK PCM

BLK

-L

11-28

BACK

~VARIOUS

~ SENSORS

Evaporative Emission (EVAP) Control Diagram The EVAP controls minimize the amount offuel vapor escaping to the atmosphere. Vapor from the fuel tank is temporarily stored in the EVAP canister until it can be purged from the canister into the engine and burned. • The EVAP canister is purged by drawing fresh air through it and into a port on the intake manifold. The purging vacuum is controlled by the EVAP canister purge valve, which is open whenever engine coolant temperature is above 14JOF (64°C). • When vapor pressure in the fuel tank is higher than the set value of the EVAP two way valve, the valve opens and regulates the flow of fuel vapor to the EVAP control canister. • During refueling, the fuel tank vapor control valve opens with the pressure in the fuel tank, and feeds the fuel vapor to the EVAP canister.

FUEL TANK VAPOR RECIRCULATION VALVE FUEL TANK SIGNAL TUBE

/

\

From No.6 ECU(PCM) _ _ _ _~....... CRUISE ....... CONTROL

~~~~~~~~~~~~~~~~~~====~~~

\~d t);jn~ ~~

LTGRN/ WHT PCM

FUEL FILL CAP

EVAP CANISTER FILTER FUEL TANK VAPOR RECIRCULATION TUBE

(in the driver's

(15A) under~

dash fuse/relay box)

~VARIOUS

~SENSORS

RED/ VEL

BLK~

BACK

11-29

Fuel and Emissions Systems Circuit Diagram PCM Circuit Diagram - '98-99 models:

ftI:5l =1 p

VELIRED

'F=--- RED/GRN~r----------------------I

MAP SENSOR F"'---GRN/WHr.

REDIWHT

GRN/BLK ECTSENSOR

To CLIMATE CONTROL UNIT RED/VEL'

GRN/BL IATSENSOR

VELIBlU RED/BlK

TPSENSOR JUNCTION CONNECTOR

WHT/BlK'

.~

VELIBlU

~~~~Gt~ PNK'

f'~' A

Cl05

GRN~LK'!-----t:t::::::j

JUNCTION CONNECTOR

C

(To page 11-31 )

11-30

BACK

EGRVAlVE

r ( From page 11-30 )

BLKIWHr=E~~ GRN/BLKZ BLK/YEL

PRIMARY H02S (SENSOR 1)

JUNCTION CONNECTOR

' r - - - - BLK/YEL £BLK/YEL

GRN/yE~ -~::~~-------------------~-------C104

~-=

1

SOLENOIO VALVE

m

BLK3-----~-----i---------~~" JUNCTION CONNECTOR

G101

__ .GRN. __________ _

:_~_:t.::===----------=========

BLK'-r-------=-----== REDS

__ • YELZ. ____:__

~ ~ YEVGRN _______________________________

J

[1__

ICM-----.JI

r

(cont'd)

BACK

11-31

Fuel and Emissions Systems Circuit Diagram (cont'd) PCM Circuit Diagram (co nt'd) - '98-99 models:

\"~"WHT/GRN'_-----I[[:J r---WHT/RED'-

•

~ ALT

•!~::~:Cv

BLUIWHT'

LOCK·UP CONTROL SOLENOID VALVE

[~

LC VEL' SHA

BLU/VEL

SHIFT CONTROL SOLENOID VALVE A

G

SHB

GRNlWH-rl BLK2

® ®

SOLENOID VALVE B

GRN' BLI<'

SOLENOID VALVE C

E

WHr. MAINS HAFT SPEED SENSOR

~~---GRN'~------------------------------------~J:==~ COUNTERSHAFTSPEEDSENSOR

:~~~===::~===========================================:I:~::::~~I

A/TCLUTCH PRESSURE CONTROL SOLENOID VALVE A

~~__- :::,------------------------------------~~

I

A/TCLUTCH PRESSURE CONTROL SOLENOID VALVE B

11-32

BACK

]1

VEL/BLK'

,

\----BRN

No.1 FUEL INJECTOR

YEL/BlK' -

,

~l

RED

No.2 FUEL INJECTOR

YEl/BlK'

~I

'\----Blu'

No.3 FUEL INJECTOR

YEL/BlK'

,

Ir

).~IN::.J4.:....._ _ VEL

~I

No. 4 FUEL INJECTOR

YEL/BlK'

I[ ~I

INJ5 1 - - - - - B l K lRED

No.5 FUEL INJECTOR

. - - VEL/BlK' ).:1;,.:;NJ:.:6_ _ _ WH

1r

T/BlU

~I

No.6 FUEL INJECTOR

H -YEL/BlK'I)....---BLKIBLU BlK'-

~ lAC VALVE

Cl~ l....--

\,;.;IG;;.P_l_ _ _ V EL/BlK'-

IGP2

I---~

JUNCTION CONNECTOR

VEL/BlK'

'--

r I

(cant'd)

BACK

11-33

Fuel and Emissions Systems Circuit Diagram (cont'd) PCM Circuit Diagram (cont'd) - '98-99 models:

I~.:;:..;c::'-"-BW/BLK - - - - - - - - - - - - - - - - - - - - I I E - - : "

I

1

2ND CLUTCH PRESSURE SWITCH -

O-=:-=~BW/WHr'------------~IF--:"

I


1-=

~~~_RE~'-------------------+~} ;r:MOBIUZER

~=~-BLU'-------------------+~

UNIT

MIL GRWORN-----------------i

~GRWBLK'------------------I

1------1-.... P

r--------BLKlBW

r-~r_-----------W~

~

I------+-l R I------+-l N

ED::LK~EE:~:K LU'

BLU'

RN'

C103

0,

1 - - - -.... 0,

BRN' C302

CONNECTOR K WHr''---+-+--.

YEL'

BLKlBLU

GAUGE ASSEMBLY

-f

4+-------- WHr'----L

DRIVER'S

~----C_:~:::O~L_ ~_:_:~_R_:~_AS_:~ __

C103

PNK'

'-+-+------ BLKlBLU '-+------ RED/BLK

BLU'

BR.~-----~~----------~

AIT GEAR POSITION SWITCH

11-34

BACK

C204

t-:-:- :-:-:- [-=-=- =-=-=- =-=-=- =-l-=-=-=- =-~-~- ~-~-~- ~-~-~- ~- ~~~:m


C302

BLKlYEL - ,

GRNiWHT':j I - - - - - - - - - - - + - + - - G R N . I W H T ' - - l

U

ENGINE MOUNT

~g~:~g,~ VALVE RED/YEL'-----------REDIYEL'JITl

RED/YEL'

I

o

BLKlYEL

EVAP PURGE

~g~~g,~VALVE

II

BLU/GRN'

CRUISE CONTROL UNIT

'}""=""--PNK' ~

~WHTIYEL

I

IMMO¥UZER INDICATOR UGHT To TACHOMETER

+

IF'---BLu'

GAUGE ASSEMBLY

C302

o

'-----l

BLu' [


iF=----WHT/RED'----------------------jIQI::::::J MULTIPLEX CONTROL UNIT (DRIVER'S)

1 :~:2=JE51 PSPSWITCH

G202

GRN'-------------------------<'41

From RADIATOR FAN RELAY, RADIATOR FAN SWITCH

(cont'd)

BACK

11-35

Fuel and Emissions Systems Circuit Diagram (cont'd) PCM Circuit Diagram (cont'd) -- '98-99 models: CIDI }-V;.;;;SV"---_ LT GRNlWHT

LTGRIIVWHT~

I #l

BLK/YEL --~E:::V:::AP:=C:::O:::NT=ROL CANISTER VENT SHUT VALVE ~=-LTGRN

L---t--f----~:~:::=_j ~I

----I


F-=--BW'-----I

BW'

C1D4

+----BLKlYEL

---rOJ ----l

EVAPBYPASS SOLENOID VALVE

D

0i 0i

CONNECTORF

-.J

'~l

GRN/BLK'

DRIVER'S UNDER-DASH FUSI!IRELAYBOX

r-

i--

0 r---<

'-------BLKIYEL

f---

'-----------BLKlYEL

f---

'--+------------WHTIYEL

'-------------~"j[

f---

-

B

, . . . - - - - - - - - - BLKlYEL

BR~, _ _ _ _ _ _ _R_ _ _ _ _ _ _ _ _ _CO_N_N_EC_T_O,R[K

A

f--C

BLU/ORN - - - - - - - - - - - - - - - - - - \ . HHA32}=;.:.;....-WHT/BLK'-------------------1

~

-

~-u ~rLAY i

IGNmON

SWITCH

FUSES A: No. 9 BACK UP UGHT INSTRUMENT UGHT (7.5A) B : No.8 ECUCPcM) CRUISE CONTROL (1&A) C: No. 13 STARTER SIGNAL (7.5A)

D: No. 1 FUEL PUMP (1&A)

11-36

BACK

D

\

Y (To page 11-37 )

I

( From page 11.:16 ) A

CONNECTOR I

~BIIN'~ I-BW/OIIN

-~ IIED/WHT BLKlYEL

~WHT/8LK'

f-f--

WHTIYEL

CONNECTOR N

r-1]C202

W H T - [ I-- '---

WHT

CONNECTORE

~

U

--

DRIVER'S UNOEII-DASH FUSEillELAY BOX

i

OIlY

BLKIYEL - { I--

C401

-~ r=

~

BIIN', BIINIILK WHT/ORN

DATA UNK CONNECTOR

BLK

0401

Y

WHT/BLK'=={~

~

':rJ I

C10S

WHTIYEL

BRAKE SWITCH

'---

WHT/GIIN~WHT/GR~l

'(

C1M

I

r=--:,,--=:[0 FUEL PUMP

G552

~~ILK'

BLK'_

811N1BLK'

BllNlBLK'

-

C301 RED/WHT-

GIINIYEL

-1

I

C401

T

BW/OIINORNIYELBLKlYEL-

l!}~

f---o-

PGM.... MAIN RELAY

(cont'd)

BACK

11-37

Fuel and Emissions Systems Circuit Diagram (cont'd) PCM Circuit Diagram (cont'd) - '98-99 models: o

N

C ONNECTOR B . - - + - - B L K IY E L -

'!

BLKIY E L -

E

.-f------- YEL '--_ _ _-11-1--____

-

BRNIB L K ' -

To AlC . . . - - BLU.I R E D PRESSURE SWITCH

CONNECTORG 'F":'---BLU/RED

------+-11---+--+- BLUI

'-

RED=! BRNIBLK'

-

WHTIYEL

lf1L.~

ONNECTOR H YEL---[

ONNECTOR I LWHT IYEL===[ ~-r~-----BRWBLK'

f----


Q

L

T

CONNECTOR C

~--;-+-;-----~

F

[~~~--,

CONNECTOR A G '-----WHT/GRN---[ 1 - -.............----.

o-C202

WHT/YEL-++-I

CONNECTOR B WHT/YEL---f

H I

' - - + - - - - - - Y E L - - - - - - - L I - -.............- - - - .

ELD

C204 GRN/RED,

L-~~-'~ ~~---RE~~ r---------+G202


FUSES E: No. 13 CLOCK BACK UP ('r.sA) F : IG MAIN (soA) G:ACGS (15A) H: STOP (20A) I : BACK UP ACC (40A) J : BATTERY (100A)

BATTERY

G1

11-38

BACK

J

'00-02 models:

YEVRED~=================---------------------------_r'-----~

,~=~I----=-------=====:j[~1 MAP SENSOR

RED/WHT---------

GRNIBLKZ~------1

t==:C:O:NTR=O:L:U:N~IT======_;::=---=-------IETCT-::S:-EN-SO:R ToCUMATE

RED/YELZ ______

GRNlBLKz--------'

IATSENSOR

JUNCTION CONNECTOR

YEV BLU

,r-_____

EGRVALVE POSITION

PN~-----~~-j~r_----------============~~~E~LIB~~B~LU~~-=-=-=-=-=-j~~==~, L

II-t::::::::::::::::::::::= GRWBL,.;---------.JSENSOR

EGRVALVE

A

(To page 11-40 )

'"

r

(cont'd)

BACK

11-39

Fuel and Emissions Systems Circuit Diagram (cont'd) PCM Circuit Diagram (cont'd) - '00-02 models: ( From page 11-39 )

PRIMARY H02S (SENSOR 1)

ClOB

BLKlYEL

--------1 LBLKlYEL

I

JUNCnON CONNECTOR

C104

'l-'-":..--GRNIYEL'---t------------t------i

BLU/BLK

~

~

o1

BLKlYEL

SOLENOID

~~

-

-

--------;:==============::::::;~___:==_:;__i1~~~ BRN/BLK'

~~~==--BRN/BL~--~~--_+------~

C105

B R N / B L K ' - - _ - - -..

JUNCTION CONNECTOR

BLK'----+-----l-+-4--. BL~----;_--~~;__+-~~

GlOl

BLK'

C107

I

JUNCnON CONNECTOR

TDC SENSOR 1

lDC

~~--B~---;_--------------__I CB

:~~~ ••••••• BLlJ"'",.•,:,:••""••:":.,:,:••""••:":.r:,••:":.",-, ••"" ••",.:,: ••,:,: ••""••:,:.,:,: ••"" ••",.:': ••"" ••"'••:':.':': ••""••:":.':': ••"" ••==."'•.-'"' ..:":'.::: •."' .."'..:':.':': ..""..:':.':'!'I ••

·~~--w~------------------___I

11-40

BACK

SENSOR 2

~ ~

~A~L~~~ ALTC

__ WMT/GRN, _________________________________________

r

WMTIREo'-

~[~ (25) •

ALT

VSSOUT

BLUIWHT'--------------------------------------------~. l;~cy TORQUE CONVERTER CLUTCH (Tee) SOLENOID VALVE ASSEMBLY

LC

SHA

YEL'

BLUIYEL

----------I[~ W

SHB

SHIFT SOLENOID (SS) VALVE ASSEMBLY A

GR~

r-

=

® ®

VALVE ASSEMBLY B

SHC

GRN' BLK'

VALVE ASSEMBLY C

E

~~ •••••••• RED"".",••,".",••,".",••:::.""••",.,".",••,".",••:::.",••:::."".,,,••,".,,,••,"."'••:::."'••:::.,.,.,."'."'••"'."'••:::.""••"'."'."'••"'.""••"'."'."'••"'."'••"'.",.",••,".n==:::;;:--1

011

~=-=----WHt.'-----------t-------::=:!~~~ 010

~: •••••••• BW'".",••,".",••:::.""••::":."".",••",.",••:::.""••",."".",••,,,.,,,••,,,.,,,••:::."'••:::.""."'••,,!.,.:::."'••:::."'."'••:::.""••"'."'."'••"'."'••:::.""."'••"'."'••:::.""••:-I"F='"

~~--GRN'-------------------------------===~~~~

~:~~~~=:::~======================================:I:I:::~:=~

AUTOMA11C TRANSAXLE (An) CLUTCH PRESSURE CONTROL SDLENOID VALVE ASSEMBLY A

~~~===::~====================================:I:I::~:~

AUTOMA11C TRANSAXLE (An) CWTCH PRESSURE CONTROL SOLENOID VALVE ASSEMBLY B

(cant'd)

BACK

11-41


VEL/BLK'

,

l[

INJ1 'r----BRN

]1

No.1 INJECTOR

VEL/BLK'

l[

}-1_NJ_2_ _ RED'

]1

No.2 INJECTOR

VEL/BLK'

l[

;}----BLu'

]1

No. 3 INJECTOR

VEL/BLK'

l[

)-IN_J_4_ _ VEL'

]1

No. 4 INJECTOR

~VEL/BLK' }'INJ"",,-S_ _ BLK!

II

RED

~I

NO.5 INJECTOR

-VEL/BLK'

l[

INJ6

}----WHT/BLU

]1

No. 6 INJECTOR

H

r - VEL/BLK' I}--'-'--- BLK/B LU BLK'-

~

~ ~ lAC VALVE

C12!.,

+--...---(Bl

IGP1

VEL/B L K ' -

JUNCT10N CONNECTOR

IGP2 } - - - - - V E L / BLK'

I

11-42

BACK

-

p--C· I

BLU/BLK - - - - - - - - - - - - - - - - 1 1

1

2ND CLUTCH PRESSURE -SWITCH ,}-"'-="--BLUIWIIT'------------ll

=-----------------4:}

puc·

I


1

l:MDBIUZER UNIT

Bur----------------~.

MIL

=[

GRNlDRN----~---lYEL

QRNlBLK'--------------------1 Ctoa

'--,~

ATPNP BWIWIIT'

-=-

-

WHY'-

R

~~~l~-

--D.

NIe'

PNIe'-

L~

BL~-

N'

C103

--N -~

--21

BAN'-

='==

C302

GAUGE ASSEMBLY

CONNECTDRK ATPR

WIlT'

BLKlBq-

WHY'

ATPD4

YEL'--

"--

....~~~

I~LKlBLU

BLKlBW

Ct03 ATPD3

f---

JUNCTION CONNECTDR

.1: '00 modol .2 : '01-112 modoIo

I

REO/BLKBur-

sw' BRi

f--r; -<> f--'N -<> l\ f--"D: -<> f--to,..." f--r;..." I..."

~

-

TRANSMISSION RANGE SWITCH BRri BRN'

Ct08

_....

t--BL~

I- -

BOX

I--~

BAN'

t--BLU'-

--I r--

=:

_

r-~~

BLKlBW -

ATP1

I r---

DRIVER'S

~

---PNIe'

.£!05

[]

BWIWHT'--PNK'--

-- WHY' ATP2

--rP

BLKlBLU -

CONNECTOR

WHY'~ ~

JUNCTION CONNECTOR

PNK' PNIe'

(cont'd)

BACK

11-43


:: ;-::ul

C204

----'

~------------~--------------------+__-------_l--=--=-=--=--=-=----

5E

L


N C302

BLKlYEL ---r~

GRNlWHTI:j I----------I--t--GRN!WHTI-l~ ENGINE MOUNT -- RED/YELl

REDIYELI

r-

~~~~VALVE REDIYELI1o:J BLKlYEL


K

BLU/GRN'-----------------;[c=J CRUISE CONTROL UNIT

}==-PNKI----------------------l

~

~WHT/YEL

- -

I

IMMOiiGZER INDICATOR LIGHT To B L u ' - - . . _ - - - - - - - - - - - - - - - - - - - l ~ TACHOMETER GAUGE ASSEMBLY C302

O

>------j

*2,- --l

1 - - - - - - - - - BLu'-------1[


i :-..- . - . - . - . - . - . - . -._-.. - . - . , :

C40I

C201

I ---IF-BLu'~BLu'

I

~!

_ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. J WHT/REDI--------------------I[c=J MULTIPLEX CONTROL UNIT (DRIVER'S)

1 ::=iE5J PSPSWITCH

G202 From G R N I ' - - - - - - - - - - - - - - - - - - -...... ~ RADIATOR FAN RELAY, RADIATOR FAN SWITCH

11-44

BACK

}VS=V_ _ LTGRNIWHT

r--------------LTGRN~T--r.===~~

II :}

BLK/YEL ----LE~V::A::::P:::::C;AN"'I~STER VENT SHIIT VALVE

'---r---l'----~::i£=-j BJ=I

p=-LTGIVI-----1

FTPSENSOR

F==--BW'-----I

1------+++----- BW'-----nF==;:--,

II :]

.....- - BLKlYEL --~EY::A::::P::::B:;YP"'AS~S.

C104 VBU

SOLENOID VALVE

D~cr GRNI BLK'

C204C,

CONNECTOR F

t0 I--

GRNlYELI

BLKlYEL

BLK' BLU

GRNlBLK'

.1----L

~ C104

VELIBLU


r-

CONNECTO AD YELIBLU

-

--

rrL---------BLKlYEL rGRNlBuc'

~--------BLK/YEL

BLK/VEL

-

'--I-----------WHT/YEL -

'------------~ r-

-

A",,-

RJ

~r---------.:::::.

B

-

C

RK BRN"-------------------BW/ORN----------------HHA32}=:.::....-WHT/BLK'-----------------

[:

-

D

~-~ ~~Y i

J

CONNECTORA

IGNJnON SWITCH

~+--- [~ FUSES A: No.l1IG COIL (1SA) B : No.9 BACK UP UGHT INSTRUMENT UGHT tT.sA) C : No. • ECU{PCM) CRUISE CONTROL (ISA) D: No. 13 STARTER SIGNAL (7,SA)

E: No. I FUEL PUMP (1SA)

\

E

Y (To page 11-46 )

1

(cont'd)

BACK

11-45

Fuel and Emissions Systems Circuit Diagram (cont'd) PCM Circuit Diagram (cont'd) - '00-02 models: (From page 11-45 )

~ CONNECTOR I

r--- BLU/ORN BRN'~ f---

-~ -

REDIWHT BLKlYEL . - - - WHT/BLK ' WHTIYEL

rl

CONNECTOR N C202

.WHT-[

WHT

--

CONNECTORE

~

U

'--

-

BLKlYEL-{


-

C401 NE

I

GRY

GRYBRN'BRNlBLK'WHT/GRN-

I

r

,

BLK

-

DATAUNK CONNECTOR _

=

G401

V

WHT/BLK':==[~

WHT/YEL

~ F

II

I C103

BRAKE PEDAL POSmON (BPP) SwrrCH

-

I

C104

WHT/GRN

I

~-L

0-

C201 WHT/GRN

r'W>a~O BLK

_

FUEL PUMP

G552

~-v~~'BLK'

BLK'-

BRN/BLK'

BRNlBLK'

C301 REDIWHT-

I

C401 FLR

GRNlYEL-1

~

~ ~

PGM-FI MAIN RELAY

T

11-46

BLU/ORNGRNIYELBLKlYEL-

BACK

N

r---t---

CONNECTORB BLK!Y E L BLK!Y E L -

11 F

r-+----- VEL

r--

L---------+-;----------BRWB L K ' -

+--

I-

To AIC BLUIR E D PRESSURE SWITCH

ACS

CONNECTORH

BW/RED

-------r-t--r--t- BWIR E D = f BRWBLK'

WHTIYEL

-

lflL-:

ONNECTORI YEL---{

1Y===r r--

LWHT

L--t~~---------BRNIBLK'


T

~ \

L__

CONNECTORC

WHT

G

[

CONNECTOR A WHT/GRN---{ C202

H

CONNECTOR B

~WHT~ YEL

J

K

C204

-~ RED'

'::"

G202

UNDER-HOOD FUSMIELAY BOX

FUSES F: No. 13 CLOCK BACK UP tr.5A) G: IG MAIN (5OA) H:ACGS (1SA) I : STOP (20A) J : BACK UP ACC (40A) K: BATTERY (100A)

BATTERY

Gl

(cant'd)

BACK

11-47


BlK/YE~ ~~~~~~~

IGPLS1 r=~~---------------------+------------YEVGRN3 BlK'

~==£.==:"":=:..J No. 1 IGNITION COil

1r=~~---------------------+~-------+--:~~~:~=f~'~;ARKI BLK'=---t~

PLUG.

No. 2 IGNITION COil

BlK/YE~ ~__-9_<~_~

IGPlS3 F..:;;;;.'-------------++t---+-WHT/BlU BlK'

BlKlYE=t

F..:;;;;.~-----------++rt--+---BRN

BLK'

C!==::==:""';:":::..J ~__~9_<~_~,

~==~==~::~

No. & IGNITION COil

Bl~~1 BlK'--L!

JUNCTION CONNECTOR

Gt01 Ct07

t

JUNCTION CONNECTOR

=-0C102

BlK/VEl

BlK/YEl

ECT GAUGE GAUGE

ASSEMBLY

11-48

BACK

,

..*2

r··

i i i i i i i i i i i i

C204 LTGRN'

LTClRN'

aRM/ClRN

aRM/ORN

YELlGRrI

YELlO....

aw'

aw'

GRNIRED

ORNIRED

~

•. _

.• _

•• _

.. _

.• _

•• _

.• _

.. _

.. _

_ _ _ _---1

BACK

BLU'

..

_ .. _

..

_ .. _ ..

r-----i i i i i i i i i i _ - .. - .. - ..- ..- .. j i AIISITCSCONTROLUNrr

..

11-49

PGM-FI System Component Location Index NOTE: The illustration shows '00-02 models,

ELECTRICAL LOAD DETECTOR (ELD) Troubleshooting, page 11-84 in the '98-02 Accord Service Manual AKE AIR TEMPERATURE (lAT) SENSOR Troubleshooting, page 11-50 in the '98-02 Accord Service Manual MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Troubleshooting, page 11-47 in the '98-02 Accord Service Manual THROTTLE POSITION (TP) SENSOR Troubleshooting, page 11-52 and page 11-57 in the '98-02 Accord Service Manual

TOP DEAD CENTER 1 (TDC1)1 TOP DEAD CENTER 2 (TDC2) SENSOR Troubleshooting, page 11-77

ENGINE COOLANT TEMPERATURE (ECT) SENSOR Troubleshooting, page 11-52 in the '98-02 Accord Service Manual

CRANKSHAFT POSITION (CKP) SENSOR Troubleshooting, page 11-74

PRIMARY HEATED OXYGEN SENSOR (PRIMARY H02S) (SENSOR 1) Troubleshooting, page 11-56 Replacement, page 11-85

"

j'"

!" . ..=-] '98-99 California model • • .. ...J and 'O~.)-02 models

",-""""1

~~lli'lt!. (, L.: ...:.... .. :.1 Except '98-99 California model and '00-02 models

SECONDARY HEATED OXYGEN SENSOR (SECONDARY H02S) (SENSOR 2) Troubleshooting, page 11-59 Replacement, page 11-85

11-50

n

BACK

NOTE: The illustration shows '00-02 models.

INJECTORS Replacement, page 11-81

POWERTRAIN CONTROL MODULE (PCM) General Troubleshooting Information, page 11-3 in the '98-02 Accord Service Manual Troubleshooting, page 11-90 in the '98-02 Accord Service Manual

DATA LINK CONNECTOR (DLC) General Troubleshooting Information, page 11-3 in the '98-02 Accord Service Manual Troubleshooting, page 11-95 in the '98-02 Accord Service Manual

BACK

11-51

PGM-FI System DTC Troubleshooting DTC P0122: TP Sensor Circuit Low Voltage

9. At the sensor side, measure resistance between TP sensor 3P connector terminals No.1 and No.2 with the throttle fully closed.

1. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then turn the ignition switch OFF.


2. Turn the ignition switch ON (II). 3. Check the throttle position with the scan tool.

Is there approx. 10% or 0.5 V when the throttle is fully closed and approx. 90% or 4.5 V when the throttle is fully opened? TPS

YES -Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the TP sensor and the PCM .•


Is there approx. 0.5- 0.9 kQ ?


YES-Go to step 10.

5. Disconnect the TP sensor connector.

NO- Replace the throttle body (The TP sensor is not available separately) .•

6. Turn the ignition switch ON (II). 7. Measure voltage between TP sensor 3P connector terminals No.1 and No.3.

10. Measure resistance between TP sensor 3P connector terminals No.2 and No.3 with the throttle fully closed.


SG2 (GRN/BLKI


VCC2 (VEL/BLUI TPS




Is there approx. 4.5k Q ?

YES-Go to step 8.

YES-Gotostep 11.

NO-Go to step 19.

NO- Replace the throttle body (The TP sensor is not available separately) .•

8. Turn the ignition switch OFF. 11. Disconnec the PCM connector C (31 PI connector.

11-52

BACK

12. At the wire harness side, check for continuity between TP sensor 3P connector terminal No.2 and body ground. TP SENSOR 3P CONNECTOR

15. Disconnect the ABS/TCS control unit 16P connector. 16. Check for continuity between body ground and PCM connector terminal A31. PCM CONNECTOR A (32P)

5 6 7 8 9 10 1112 3 4 11 1 112113 14 15 16 17 18 19 20 21 22 23 24 1 25 26 27 28 29 30 31 ~ THl OUT (VEl/GRN)

.Q

=

=



Is there continuity? Is there continuity? YES- Repair short in the wire between the PCM (C 27) and the TP sensor.. NO-Go to step 13 ('01-02 models), or step 17 ('98-00 models).

NO-Substitute a known-good ABS/TCS control unit and recheck. If the symptom/indication goes away, replace the original ABS/TCS control unit.•

13. Disconnect PCM connector A (32P). 14. Check for continuity between body ground and PCM connector terminal A31. PCM CONNECTOR A (32P)

8 9 10 5 6 7 11 12 3 4 112113 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32

YES- Repair short in the wire between the ABS/ TCS control unit and PCM (A31) .•

17. Connect PCM connectorterminal C27 and body ground with a jumper wire. PCM CONNECTOR C (31P)

5 6 7 8 9 10 L1 2 3 4 14 16 1 12 13 19 20 21 1/ 718 IL li' 23 / 25 262728 29 30 1/

111 24 1

-

THl lOUT (VEL/GRN)

TPS (RED/BlK) JUMPER WIRE

.Q

-=



Is there continuity? YES-Go to step 15. NO-Go to step 17.

(cont'd)

BACK

11-53

PGM-FI System OTe Troubleshooting (cont'd) 18. At the wire harness side, check for continuity between TP sensor 3P connector terminal No.2 and body ground. TP SENSOR 3P CONNECTOR


Is there continuity? YES-Substitute a known-good PCM and recheck. Refer to the '98-02 Accord Service Manual (see page 11-5). If the prescribed voltage is now available, replace the original PCM .• NO-Repair open inthewire between the PCM (C27) and the TP senso r.• 19. Measure voltage between PCM connector terminals C18 and C28. PCM CONNECTOR C (31P)

SG2 (GRN/BLK)

8 9 10 5 6 11 2 3 4 1/ 12 13 14 1/ 16 17 18 19 20 21 V 23 V 25 26 27 28 29 30 l,{ VCC2 (VEL/BLU)

L-oo---


Is there about 5 V? YES- Repair open in the wire between the PCM (C28) and the TP sensor.. NO-Substitute a known-good PCM and rechecki. Refer to the '98-02 Accord Service Manual (see page 11-5). If voltage is normal, replace the original PCM .•

11-54

BACK

DTe P0128: Rangel Performance Problem in Thermostat

1. Check the engine coolant level.

Is the engine coolant level low? NOTE: If the DTCs listed below are stored at the same time as DTC P0128, troubleshoot those DTCs first, then recheck for PO 128. P0107, P0108, P1129: MAP Sensor P1106, P11 07, P11 08: Barometric Pressure Circuit P1259: VTEC system P0401: EGR Flow Insufficient P1491: EGR Valve Position Insufficient· P1498: EGR Valve Position Sensor High Voltage P0116, P0117, P0118: Engine Coolant Temperature Circuit P0112, P0113: Intake Air Tenperature Circuit P0335, P0336, P1359: Crankshaft Position Sensor P0300: Random Misfire P0301, P0302, P0303, P0304, P0305, P0306: Cylinder 1,2,3,4,5 or 6 Misfire Detected P0505 :Idle Control System Malfuction P1519: Idle Air Control Valve DTC P0128 can occasionally set when the hood is opened.

YES-Refill the engine coolant. If necessary, check the cooling system .• NO-Go to step 2. 2. Turn the ignition switch ON (11), and make sure the AlC is off. 3. Check the radiator fan.

Dose the radiator fan keep running? YES-Check the radiator fan circuit (see page 1016), radiator fan switch circuit (see page 10-16), and the radiatorfan switch (see page 10-16). • If they are OK, substitute the PCM and recheck, refer to the '98-02 Accord Service Manual (see page 11-5). • If the symptom/indicator goes away, replace the original PCM .• NO-Test the thermostat, refer to the '98-02 Accord Service Manual (see page 10-9) .•

BACK

11-55

PGM-FI System DTC Troubleshooting (cont'd) DTC P0131: Primary H02S(Sensor 1) Circuit Low Voltage

11. Check for continuity between primary H02S (Sensor 1) 4P connector terminal No.1 and body ground.

1. Resetthe PCM.

PRIMARY H02S (SENSOR 1) 4P CONNECTOR


PH02S(WHT)

3. Check the primary H02S (Sensor 1) output voltage with the scan tool during acceleration using wide open throttle.

2

3

4

Does the voltage stay at 0.5 V or less? YES-Go to step 4. Wire side of female terminals

NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the primary H02S (Sensor 1) and the PCM .• 4. Check the fuel pressure (see page 11-90).

Is it normal? YES-Go to step 5.

Is there continuity? YES- Repair short in the wire between the PCM (C16) and the primary H02S (Sensor 1).• NO-Substitute a known-good PCM and recheck. Refer to the '98-02 Accord Service Manual (see page 11-5). If the symptom/indication goes away, replace the original PCM .•

NO- Repair the fuel supply system .• 5. Turn the ignition switch OFF. 6. Disconnect the primary H02S (Sensor 1) 4P connector. 7. Start the engine and let it idle. 8. Check the primary H02S (Sensor 1) output voltage with the scan tool.

Does it stay at 0.5 V or less? YES - Go to step 9. NO- Replace the primary H02S (Sensor 1).• 9. Turn the ignition switch OFF. 10. Disconnect PCM connector C (31 Pl.

11-56

BACK

DTC P0132: Primary H02S (Sensor 1) Circuit


High Voltage 10. Connect PCM connector terminals C16 and C18 with a jumper wire.

1. Reset the PCM. 2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on.

3. Check the primary H02S (Sensor 1) output voltage with the scan tool.

PCM CONNECTOR C (31P)

1 2 3 4 8 9 10 5 6 7 / 12 13 14 l-( 16 17 18 19 20 21 / 23 1/ 25 ,26 27 2~ 29 30 / PH02S (WHT)


SG2 (GRN/BLK)

JUMPER WIRE

YES-Go to step 4. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the primary H02S (Sensor 1) and the PCM .• 4. Turn the ignition switch OFF.


11. Turn the ignition switch ON (II). 12. Check the primary H02S (Sensor 1) output voltage with the scan tool.

5. Disconnect the primary H02S (Sensor 1) 4P connector.


6. Connect primary H02S (Sensor 1) 4P connector terminals No.1 and No.2 with a jumper wire. PRIMARY H02S (SENSOR 1) 4P CONNECTOR

YES-Substitute a known-good PCM and recheck. Refer to the '98-02 Accord Service Manual (see page 11-5). Ifthe symptom/indication goes away, replace the original PCM .• NO- Repair open in the wire between the PCM (C16 or C18) and the primary H02S (Sensor 1) .•

JUMPER WIRE

r--l

-

1

2

3

4

PH02S(WHT)

r--SG2( GRN/BLK)


7. Turn the ignition switch ON (II). 8. Check the primary H02S (Sensor 1) output voltage with the scan tool.

Is there 0.9 V or more? YES - Go to step 9. NO-Replace the primary H02S (Sensor 1).•

BACK

11-57

PGM-FI System OTC Troubleshooting (cont'd) DTC P0133: Primary H02S (Sensor 1) Circuit Slow Response NOTE: If DTC P0131, P0132 and/or P0135 are stored at the same time as DTC P0133, troubleshoot those DTCs first, then recheck for DTC P0133. 1. Reset the PCM. 2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on. 3. Test-drive under following conditions. • 55 mph (89 km/h) steady speed • Transmission in D4 position • Until readiness code or Temporary DTC P0133 comes on 4. Check for a Temporary DTC with the scan tool.

Is Temporary DTC P0133 indicated? YES-Replace the primary H02S (Sensor 1).• NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C104 (located at the right side of the engine compartment), the primary H02S (Sensor 1) and the PCM .•

11-58

BACK

DTe P0137: Secondary H02S (Sensor 2) Circuit Low Voltage

10. Check for continuity between the secondary H02S (Sensor 2) 4P connector terminal No.2 and body ground.

1. Reset the PCM. 2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on.

SECONDARY H02S (SENSOR 2) 4P CONNECTOR

2

3. Check the secondary H02S (Sensor 2) output voltage at 3,000 rpm with the scan tool.

3

SH02S (WHTIRED)

4

Does the voltage stay at 0.3 V or less? YES - Go to step 4. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C204 (located under the right side of the dash), C104 (located at the right side of the engine compartment), the secondary H02S (Sensor 2) and the PCM .• 4. Turn the ignition switch OFF. 5. Disconnect the secondary H02S (Sensor 2) 4P connector.


Is there continuity? YES - Repai r short in the wi re between the PCM (A23) and the secondary H02S (Sensor 2) .• NO-Substitute a known-good PCM and recheck. Refer to the '98-02 Accord Service Manual (see page 11-5). If the symptom/indication goes away, replace the original PCM.

6. Start the engine. 7. Check the secondary H02S (Sensor 2) output voltage with the scan tool.

Does the voltage stay at 0.3 V or less? YES-Go to step 8. NO - Replace the secondary H02S (Sensor 2) .• 8. Turn the ignition switch OFF. 9. Disconnect PCM connector A (32P).

r BACK

11-59

PGM-FI System OTC Troubleshooting (cont'd) DTC P0138: Secondary H02S (Sensor 2)


Circuit High Voltage 10. Connect PCM connector terminals A23 and C18 with a jumper wire.

1. Reset the PCM. 2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on. 3. Check the secondary H02S (Sensor 2) output voltage at 3,000 rpm with the scan tool.

PCM CONNECTORS A (32P)

5 6/ 8 9 10 / 1 11 12 3 4 112113 14 15 / 17 18 19 20 21 / 23 24 1 25 26 27 28 2930L ~

f~~¥~REO)


JUMPER WIRE C (31P)

I~G2 (GRN/BLK)

5 6 7 8 9 10 11 2 3 4 12 13 14 / 16 17 18 19 20 21 / 23 / 25 26 27 28 29 30 L

YES-Go to step 4.

V

NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C204 (located under the right side of the dash), C104 (located at the right side of the engine compartment), the secondary H02S (Sensor 2) and the PCM .•


11. Turn the ignition switch ON (II). 12. Check the secondary H02S (Sensor 2) output voltage with the scan tool.


Is there 0.8 V or more? 5. Disconnect the secondary H02S (Sensor 2) 4P connector. 6. Connect secondary H02S (Sensor 2) 4P connector terminals No.1 and No.2 with a jumper wire. SECONDARY H02S (SENSOR 2) 4P CONNECTOR

YES-Substitute a known-good PCM and recheck. Refer to the '98-02 Accord Service Manual (see page 11-5). If the symptom/indication goes away, replace the original PCM .• NO-Repair open in the wire between the PCM (A23 or C18) and the secondary H02S (Sensor 2) .•

JUMPER WIRE

2 SG2 (GRN/BLK)

SH02S (WHTIRED)

3

4


7. Turn the ignition switch ON (II). 8. Check the secondary H02S (Sensor 2) output voltage with the scan tool.

Is there 0.8 V or more? YES-Go to step 9. NO- Replace the secondary H02S (Sensor 2) .•

11-60

BACK

DTC P0135: Primary H02S (Sensor 1) Heater

Circuit Malfunction

7. Check continuity between body ground and H02S 4P connector terminals No.3 and No.4 individually.

DTC P0141: Secondary H02S(Sensor 2)

Heater Circuit Malfunction

H02S 4P CONNECTOR

NOTE: Information marked with an asterisk ( * ) applies to DTC P0141. 1. Reset the PCM. 2. Start the engine.

Is DTC P0135 or P0141 indicated?

=

YES - Go to step 3.


NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C204 (located under the right side of the dash), C1 01 or C102 (located at the left side of the engine compartment), the Primary H02S (Sensor 1), the Secondary H02S (Sensor 2), and the ECM/PCM .•

=

=

=


Is there continuity? YES- Replace the H02S (primary or secondary * ) (Sensor 1 or Sensor 2 * ).• NO-Go to step 7.

3. Check the No.6 ECU (PCM) CRUSE CONTROL (15A) fuse in the driver's under-dash fuse/relay box.

Is DTC P0135 or P0141 indicated?

8. Start the engine. 9. Measure voltage between H02S 4P connector terminal No.3 and No.4.

YES - Go to step 4. PRIMARV/SECONDARV*H02S (SENSOR 1/ SENSOR 2*) 4P CONNECTOR

NO - Replace the fuse and retest.• 4. Turn the ignition switch OFF.

*

5. Disconnect the H02S (primary or secondary * ) (Sensor 1 or Sensor 2 * ) 4P connector.

P02HTC (BLK/ WHT)

r-........-, 2

S02HTC (BLK/ WHT)

6. At the H02S side, measure resistance between H02S 4P connector terminals No.3 and No.4. H02S 4P CONNECTOR

c! 2 3 4

.Q


*,-Ellih

Q





NO-Go to step 13.

Isthere5-15Q (10-40Q)*? 10. Turn the ignition switch OFF. YES-Go to step 7. NO-Replace the primary H02S (Sensor 1) or secondary H02S (Sensor 2) * .• (cont'd)

BACK

11-61

PGM-FI System OTe Troubleshooting (cont'd) 14. Turn the ignition switch OFF.

11. Disconnect PCM connector C (31 P) (PCM connector A, 32P)*.

15. Reconnect the H02S 4P connector. 12. Check for continuity between PCM connector terminal C1 (A8)* and body ground.

16. Disconnectthe PCM connector C (31P) (PCM connector A, 32P) * .

PCM CONNECTORS


C(31P)

567

~..".....,..."..,

18. Measure voltage between the PCM connector terminals 82 and C1 (A8) * . PCM CONNECTORS

-

A (32P)

S02SHTC (BLK/WHT)*

lP02SHTC (BLK/WHT) C (31P)

I

8 9 10 5 6 7 11 1 1112 3 4 112113 14 15 16 17 18 1920 2122 23 24 1 25 26 27 28 29 30 31 ~ Wire side of female terminals

Is there continuity? YES-Repair short in the wire between the PCM (C1, A8*) and the H02S (Primary or Secondary*) (Sensor 1, Sensor 2*) .•

+ +

1 2 3 4

5 6 7

8 9 10

17 12 13 14 17 16 17 1819 20 21V 23 1/ 25 26 27 28 29 30 1/ ' " PG1 (BLK)

1 9

""7

B(25P)

3 4 5 2 6 7 8 10 11 12 1314 15 [7 17 18 20 ~~ 23 24 25 A (32P)

S02SHTC (BLK/WHT)*

567 8 9 10 1112 3 4 11 1 24 ] ~2T13 14 15 16 17 18 19 20 2122 23 25 26 27 28 29 3031 ~

NO-Substitute a known-good PCM and recheck (see page 11-5). Ifthe symptom/indication goes away, replace the original PCM .•


13. Measure voltage between H02S 4P connector terminal No.4 and body ground. PRIMARY /SECONDARY*H02S (SENSOR 1/ SENSOR 2*) 4P CONNECTOR

*

2 3 4

IG1

1---1--1 (BLK/YEL)

-= Wire side of female terminals

1 2

IG1 (BLK/YEL)

3 4

Is there battery voltage? YES-Substitute a known-good PCM and recheck (see page 11-5). Ifthe symptom/indication goes away, replace the original PCM . • NO- Repair open in the wire between the PCM (C1, A8*) and the H02S (primary or secondary*) (Sensor 1, Sensor 2*) .•

-= Terminal side of male terminals

Is there battery voltage? YES-Go to step 14. NO-Repair open in the wire between the No.6 ECU (PCM) CRUSE CONTROL (15A) fuse and the H02S .•

11-62

BACK

OTe P0139: Secondary H02S (Sensor 2) Circuit Slow Response 1. Reset the PCM. 2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on. 3. Check the secondary H02S (Sensor 2) output voltage at 3,000 rpm with the scan tool. Does the voltage stay within 0.3- 0.8 V for two minutes? YES - Replace the secondary H02S (Sensor 2) .• NO -Intermittent failure, system is OK at this time. Check for poor connections or loose wires at C204 (located under the right side of the dash), C104 (located at the right side of the engine compartment), the secondary H02S (Sensor 2), and the PCM .•

BACK

11-63

PGM-FI System OTe Troubleshooting (cont'd) DTC P0300: Random Misfire and Any Combination of the Following: DTC P0301: No.1 Cylinder Misfire DTC P0302: No.2 Cylinder Misfire DTC P0303: No.3 Cylinder Misfire DTC P0304: No.4 Cylinder Misfire DTC P0305: No.5 Cylinder Misfire DTC P0306: No.6 Cylinder Misfire NOTE: • If the misfiring is frequent enough to trigger detection of increased emissions during two consecutive driving cycles, the MIL will come on, and DTC P0300 (and some combination of P0301 through P0306) will be stored . • If the misfiring is frequent enough to damage the catalyst, the MIL will blink whenever the misfiring occurs, and DTC P0300 (and some combination of P0301 through P0306) will be stored. When the misfiring stops, the MIL will remain on. 1. Troubleshoot the following DTCs first, if any of them were stored along with the random misfire DTC(s): P0107, P0108, P1128, P1129: MAP Sensor P0131, P0132: Primary H02S P0171, P0172: Fuel metering P0401, P1491, P1498: EGR System P0505: Idle control system P1259: VTEC System P1361, P1362, P1366, P1367: TDC 1!TDC 2 Sensor P1519: lAC Valve 2. Test-drive the vehicle to verify the symptom. 3. Find the symptom in the chart below, and do the related procedures and checks, in the order listed, until you find the cause. Symptom Random misfire only at low RPM and under load Random misfire only during acceleration

Random misfire at high RPM and under load, or under random conditions

Procedure 1. Check fuel pressure (see page 11-90) 2. Inspect the ignition distributor housing* 1. 2. 3. 4.

Inspect and test ignition wires (see page 4-22). * Inspect the ignition distributor housing.* Check fuel pressure (see page 11-90). Test the ignition coil for '98-99 models (see page 4-22), or for '00-02 models (see page 4-23). 5. Testthe iQnition control module (see paQe 4-19).* 1. Check fuel pressure (see page 11-90). 2. Inspect and test ignition wires (see page 4-22).* 3. Inspect the ignition distributor housing.* 4. Test the ignition coil for '98-99 models (see page 4-22), or for '00-02 models (see page 4-23). Test the ignition control module (see page 4-21). *

*: '98-99 models

11-64

BACK

Also check for: • Low compression • Low quality fuel • Correct EGR valve function Malfunction in the VTEC system (see page 6-9)

Correct valve clearance (see page 6-13)

OTC P0301: No.1 Cylinder Misfire ('98-99 models)

7. Exchange the spark plug from the problem cylinder with one from another cylinder.


8. Test-drive the vehicle several times in the range of the freeze data or under various conditions if there was no freeze data.




Is OTe P0301, P0302, P0303, P0304, P0305, or P0306, or Temporary OTe P1399 indicated?


YES-Go to step 10.


NO-Intermittent misfire due to spark plug fouling, etc. (no misfire at this time) .•

1. Remove the intake manifold cover (see step 4 on page 6-31). 2. After checking and recording the freeze data, reset the PCM. If there is no freeze data of misfiring, just clear the DTC. 3. Start the engine, and listen for a clicking sound at the injector in the problem cylinder.

10. Determine which cylinder had the misfire.

Does the misfire occur in the cylinder where the spark plug was exchanged? YES-Replace the faulty spark plug .• NO-Gotostep 11. 11. Turn the ignition switch OFF.

Does the injector click?

YES - Go to step 4.

12. Exchange the injector from the problem cylinder with one from the another cylinder.

NO- Go to step 19.

13. Let the engine idle for 2 minutes.

4. Turn the ignition switch OFF. 5. Inspect the ignition wire on the problem cylinder (see page 4-22).

14. Test-drive the vehicle several times in the range of the freeze data or under various conditions if there was no freeze data. 15. Check for a DTC or Temporary DTC with the scan tool.

Is the ignition wire OK?

YES - Go to step 6.

Is OTe P0301, P0302, P0303, P0304, P0305, or P0306, or Temporary OTe P1399 indicated?

NO- Replace the faulty ignition wire .• YES-Gotostep 16. 6. Check the distributor cap for cracks, wear, damage, and fouling.


Is the distributor cap OK? YES-Go to step 7. NO- Clean or replace the distributor cap .•

(cont'd)

BACK

11-65

PGM-FI System .~

DTC Troubleshooting (cont'd) Is there battery voltage?



YES-Go to step 23. NO-Go to step 31.

YES - Replace the faulty injector (see page 11-81).•


NO-Gotostep 17.

24. Disconnect the injector 2P connector from the problem cylinder.

17. Turn the ignition switch OFF. 25. Measure resistance between injector 2P connector terminals No.1 and No.2.

18. Check the engine compression.

Is the engine compression OK?

INJECTOR 2P CONNECTOR

YES-Substitute a known-good PCM and recheck. Refer to the '98-02 Accord Service Manual (see page 11-5). If the symptom/indication goes away, replace the original PCM .• NO- Repair the engine .• 19. Turn the ignition switch OFF. Terminal side of male terminals

20. Disconnect PCM connector B (25P). 21. Turn the ignition switch ON (II).

Is there 10 Q - 13 Q ?

22. Measure voltage between body ground and the PCM connector terminal (see table).

YES-Go to step 26. NO-Replace the injector (see page 11-81).•

PCM CONNECTOR B (25P) INJ4(YEl)

INJ2(RED)

1 9 INJ5 (BlKI RED)

-

2 10 20

INJ3 (BLU)

Y.

Y.

=

=

=

11-66


DTC P0301 P0302 P0303 P0304 P0305 P0306

28. Test-drive the vehicle several times in the range of the freeze data or under various conditions ifthere was no freeze data.

INJ6 (WHTI BLU)

Y.

PROBLEM CYLINDER No.1 No.2 No.3 No.4 No.5 No.6

27. Let the engine idle for 2 minutes.

11 12 13 1415 21 22 24 25

INJ1 (BRN)

PCM TERMINAL B11 B5 B15 B4 B3 B6

26. Exchange the injector from the problem cylinder with one from another cylinder.

-

WIRE COLOR BRN RED BLU YEL BLK/RED WHT/BLU

=


Is DTC P0301, P0302, P0303, P0304, P0305, P0306, or Temporary DTC P1399 indicated? YES-Go to step 30. NO-Intermittent misfire due to injector fouling, etc.•

BACK

36. Check for continuity between body ground and the PCM connector terminal (see table).



PCM CONNECTOR B (25PI INJ4(VELI

YES- Replace the faulty injector.• NO-Substitute a known-good PCM and recheck Refer to the '98-02 Accord Service Manual (see page 11-5). Ifthe symptom/indication goes away, replace the original PCM .•

1

2

9

10

20 INJ1 (BRNI


-=

-=




33. Turn the ignition switch ON (II). 34. Measure voltage between injector 2P connector terminals No.2 and body ground. INJECTOR 2P CONNECTOR

DTC


P0301 P0302 P0303 P0304 P0305 P0306


Is there continuity? YES - Repai r short in the wi re between the PCM and the injector.• NO-Go to step 37. 37. Connect the injector 2P connector terminal No.1 to body ground with a jumper wire (see table).




r

YES-Go to step 35.

INJ

NO- Repair open in the wire between the injector and the PGM-FI main relay .•

2

JUMPER WIRE




DTC P0301 P0302 P0303 P0304 P0305 P0306

WIRE COLOR BRN RED BLU YEL BLK/RED WHT/BLU (cont'd)

BACK

11-67

PGM-FI System DTe Troubleshooting (co nt'd) 38. Check for continuity between body ground and the PCM connector terminals (see table). PCM CONNECTOR B (25P) INJ4 (YEL)

INJ2 (RED)

1 9

2 10 20

""'---'---'

INJ1 (BRN)

2122 INJ3

INJ6

(BLU)

(WHT/ BLU)



DTC P0301 P0302 P0303 P0304 P0305 P0306


WIRE COLOR BRN RED BlU YEl BlK/RED WHT/BlU

Is there continuity? YES-Replace the injector (see page 11-81). then recheck.• NO-Repair open in the wire between the PCM and the injector.•

11-68

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OTe P0301: No.1 Cylinder Misfire


('00-02 models) Does the misfire occur in the cylinder where the ignition coil was exchanged?


('00-02 models) VES- Replace the faulty ignition coil..


('00-02 models)

NO- Go to step 9.

OTe P0304: No.4 Cylinder Misfire ('00-02 models)

9. Turn the ignition switch OFF. 10. Exchange the spark plug from the problem cylinder with one from another cylinder.


('00-02 models) 11. Test-drive the vehicle several times in the range of the freeze data or under various conditions if there was no freeze data.


('00-02 models) 1. Remove the intake manifold cover and the ignition coil cover (see step 4 on page 6-31).


Is DTC P0301, P0302, P0303, P0304, P0305, P0306, or Temporary DTC P1399 indicated?

2. After checking and recording the freeze data, reset the PCM. If there is no freeze data of misfiring, just clear the DTC.

VES- Go to step 13. 3. Start the engine, and listen for a clicking sound at the injector in the problem cylinder.

NO-Intermittent misfire due to spark plug fouling, etc. (no misfire at this time) .•

Does the injector click? 13. Determine which cylinder had the misfire. VES- Go to step 4.

Does the misfire occur in the cylinder where the spark plug was exchanged?


VES- Replace the faulty spark plug .•

5. Exchange the ignition coil from the problem cylinder with one from another cylinder.


6. Test-drive the vehicle several times in the range of the freeze data or under various conditions if there was no freeze data. 7. Check for a DTC or Temporary DTC with the scan tool.

15. Exchange the injector from the problem cylinder with one from the another cylinder. 16. Let the engine idle for 2 minutes. 17. Test-drive the vehicle several times in the range of the freeze data or under various conditions if there was no freeze data.

Is DTC P0301, P0302, P0303, P0304, P0305, P0306, or Temporary DTC P1399 indicated? VES- Go to step 8. NO-Intermittent misfire due to ignition coil fouling, etc. (no misfire at this time) .•

(cont'd)

BACK

11-69

PGM-FI System DTe Troubleshooting (cont'd) 18. Check for a DTC or Temporary DTC with the scan tool.

25. Check for continuity between ignition coil 3P connector terminal No.2 and body ground. IGNITION COIL 3P CONNECTOR

Is OTC P0301, P0302, P0303, P0304, P0305, P0306, or Temporary OTC P1399 indicated?

1 2

YES-Gotostep 19.

GND (BLK)

3


Q. 19. Determine which cylinder had the misfire.



Is there continuity? YES- Replace the faulty injector (see page 11-83) .• NO-Go to step 20.

YES-Go to step 26. NO- Repair open in the wire between the ignition coil and G101 (or G102) .•

20. Turn the ignition switch OFF. 26. Disconnect PCM connector C (31 Pl. 21. Disconnect the ignition coil 3P connector from the problem cylinder.

27. Check for continuity between body ground and the PCM connector terminal (see table).


PCM CONNECTOR c (31P) IGPLS3 (WHT/BLU) IGPLS1 (VEL/GRN)

23. Measure voltage between ignition coil 3P connector terminal No.3 and body ground.

8 9 10

IGNITION COIL 3P CONNECTOR

1 2

3

IG1 (BLK/VEL)



Q.

= = PROBLEM CYLINDER No.1 No.2 No.3 No.4 No.5 No.6

=

=


DTC P0301 P0302 P0303 P0304 P0305 P0306

PCM TERMINAL C4 C14 C3 C13 C12 C23

= WIRE COLOR YEL/GRN BLU/RED WHT/BLU BRN BLK/RED BRN/WHT

YES - Go to step 24. Is there continuity? NO- Repair open or short in the wire between the No. 11 COIL (15 A) fuse and the ignition coil..

YES- Repair short in the wire between the PCM and the ignition coil..

24. Turn the ignition switch OFF. NO-Go to step 28.

11-70

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28. Connect the ignition coil 3P connector terminal No.1 to body ground with a jumper wire (see table).

30. Check the engine compression.

Is the engine compression OK? IGNITION COIL 3P CONNECTOR

YES-Substitute a known-good PCM and recheck. Refer to the '98-02 Accord Service Manual (see page 11-5). If the symptom/indication goes away, replace the original PCM .•

1

2 3

JUMPER WIRE

NO- Repair the engine .• 31. Turn the ignition switch OFF. Wire side of female terminals

32. Disconnect PCM connector B (25P). PROBLEM CYLINDER No.1 No.2 No.3 No.4 No.5 No.6

DTC P0301 P0302 P0303 P0304 P0305 P0306


WIRE COLOR YEL/GRN BLU/RED WHT/BLU BRN BLK/RED BRN/WHT

34. Measure voltage between body ground and the PCM connector terminal (see table). PCM CONNECTOR B (25P) INJ4 (VEL)

INJ2 (RED)

1 9

29. Check for continuity between body ground and the PCM connector terminal (see table). PCM CONNECTOR c (31P) IGPLS3 (WHT/BLU) IGPLS1 (YEL/GRN)

INJ5 (BLK/ RED)

2 10 20

'::L

8 9 10

21 22

INJ1 (BRN)

INJ3 (BLU)

'::L

INJ6 (WHT/ BLU)

'::L


PROBLEM CYLINDER No.1 No.2 No.3 No.4 No.5 NO.6

.Q Wire side of female terminals


DTC P0301 P0302 P0303 P0304 P0305 P0306

PCM TERMINAL C4 C14 C3 C13 C12 C23

WIRE COLOR YEL/GRN BLU/RED WHT/BLU BRN BLK/RED BRN/WHT

DTC P0301 P0302 P0303 P0304 P0305 P0306

PCM TERMINAL B11 B5 815 B4 B3 B6

WIRE COLOR BRN RED 8LU YEL BLK/RED WHT/BLU

Is there battery voltage? YES - Go to step 35. NO - Go to step 43.

Is there continuity? 35. Turn the ignition switch OFF. YES - Go to step 30. NO- Repair open in the wire between the PCM and the ignition coil..


(cont'd)

BACK

11-71

PGM-FI System DTe Troubleshooting (co nt'd) 37. Measure resistance between the injector 2P connector terminals No.1 and No.2.

46. Measure voltage between the injector 2P connector terminal No.2 and body ground.



~

2 IGP

INJ~IGP

'

=IYaJBLKJ

Terminal side of male terminals Wire side of female terminals

Is there 10 Q -13 Q? Is there battery voltage? YES-Go to step 38. NO-Replace the injector (see page 11-83) .•

YES-Go to step 47. NO- Repair open in the wire between the injector and the PGM-FI main relay .•

38. Exchange the injector from the problem cylinder with one from another cylinder. 39. let the engine idle for 2 minutes.


40. Test-drive the vehicle several times in the range of the freeze data or under various conditions if there was no freeze data.

48. Check for continuity between body ground and the PCM connector terminal (see table). PCM CONNECTOR B (25P) INJ4(YEL)


1 9

Is DTC P0301, P0302, P0303, P0304, P0305, P0306, or Temporary DTC P1399 indicated?

INJ5 (BLKI RED)

YES-Go to step 42. NO-Intermittent misfire due to injector fouling, etc .•

2 10 20 INJ1 (BRN)

=



Does the misfire occur in the other cylinder whose injector was exchanged? YES- Replace the faulty injector.• NO-Substitute a known-good PCM and recheck Refer to the '98-02 Accord Service Manual (see page 11-5). If the symptom/indication goes away, replace the original PCM .•


DTC P0301 P0302 P0303 P0304 P0305 P0306


WIRE COLOR BRN RED BlU YEL BlK/RED WHT/BlU

Is there continuity? 43. Turn the ignition switch OFF. 44. Disconnect the injector 2P connector from the problem cylinder.

YES- Repair short in the wire between the PCM and the injector.• NO-Go to step 49.


11-72

BACK

49. Connect the injector 2P connector terminal No.1 to body ground with a jumper wire (see table). INJECTOR 2P CONNECTOR

r

INJ

2

JUMPER WIRE_



DTC


P0301 P0302 P0303 P0304 P0305 P0306

50. Check for continuity between body ground and the PCM connector terminals (see table). PCM CONNECTOR B 125P) INJ4IVEL)

INJ2IRED)

1 9 INJ5 IBLK/ RED)

2 10 20

21 22

INJ1 IBRN)

INJ3 IBLU)

INJ6 IWHT/ BLU)

Q

= = PROBLEM CYLINDER No.1 No.2 No.3 No.4 No.5 No.6

=

=


DTC P0301 P0302 P0303 P0304 P0305 P0306


= =


Is there continuity? YES-Replace the injector (see page 11-83). then recheck.• NO- Repair open in the wire between the PCM and the injector.•

BACK

11-73

PGM-FI System OTe Troubleshooting (cont'd) OTC P0335: CKP Sensor No Signal OTC P0336: CKP Sensor Intermittent Interruption

6. Check for continuity between body ground and CKP sensor 2P connector terminals No.1 and No.2 individually. CKP SENSOR 2P CONNECTOR

1. Reset the PCM. 2. Start the engine. Is DTC P0335 and/or P0336 indicated?

CKPP

CKPM

YES- Go to step 3. NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the CKP sensor and the PCM .• Terminal side of male terminals

3. Turn the ignition switch OFF. Is there continuity?

4. Disconnect the CKP sensor 2P connector. YES- Replace the CKP sensor (see page 6-56) .• 5. Measure resistance between CKP sensor 2P connector terminals No.1 and No.2. CKP SENSOR 2P CONNECTOR

NO-Go to step 7. 7. Reconnect the CKP sensor 2P connector. a. Disconnect PCM connector C (31 Pl. 9. Measure resistance between PCM connector terminals ca and C9.

CKPP

CKPM

PCM CONNECTOR C (31PI

CKPP (BLUI


Is there 1,850- 2,450 Q ?

YES-Go to step 6.

It

CKPM (WHTI

1 2 3 4 8 9 10 5 6 7 1/ 12 13 14 / 16 17 18 19 20 21 / 23 1/ 25 29 30 / 26 27 28

NO- Replace the CKP sensor (see page 6-56) .• Wire side of female terminals

Is there 1,850- 2,450 Q ?

YES-Goto step 10. NO-Repair open in the wire between the PCM (Ca, C9) and the CKP sensor..

11-74

BACK

10. Check for continuity between body ground and PCM connector terminal C8. PCM CONNECTOR C (31P)

ICKPP(BLU)

1 2 3 4 8 9 10 5 6 7 ~ 12 13 14 1/ 16 17 18 19 20 21 V 23 L( 25 29 30 V 26 27 28 .Q = Wire side of female terminals

Is there continuity? VES- Repair short in the wire between the PCM (C8) and the CKP senscA NO-Substitute a known-good PCM and recheck. Refer to the '98-02 Accord Service Manual (see page 11-5). If the symptom/indication goes away, replace the original PCM .•

BACK

11-75

PGM-FI System DTC Troubleshooting (co nt'd) DTC P1121: TP Sensor Lower Than Expected

DTC P1122: TP Sensor Higher Than Expected





Is 13.7% or higher indicated when the throttle is fully opened?

Is 16,9% or less indicated when the throttle is fully closed?


YES-Intermittent failure, system is OK atthis time.•

NO- Replace the throttle body (The TP sensor is not available separately) . •

NO-Replace the throttle body (The TP sensor is not available separately) . •

11-76

BACK

DTC P1361: TOC1 Sensor Intermittent Interruption

6. Check for continuity to body ground on both terminals ofthe indicated sensor individually. TDC1/TDC2 SENSOR 4P CONNECTOR

DTC P1362: TOC1 Sensor No Signal DTC P1366: TOC2 Sensor Intermittent Interruption

TDC1P

DTC P1367: TOC2 Sensor No Signal

1

2

3

4

TDC1M

H-----,

1. Reset the PCM. 2. Start the engine.

Is DTC P1361, P1362, P1366, and/or P1367 indicated?


YES-Go to step 3.


NO -Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the TDC 1/TDC 2 sensor and the PCM .•

YES-Replace the TDC 1/TDC 2 sensor (see page 655) .• NO-Go to step 7.

3. Turn the ignition switch OFF. 7. Reconnect the TDC 1/TDC 2 sensor 4P connector. 4. Disconnect the TDC 1/TDC2 sensor 4P connector. 8. Disconnect PCM connector C (31 Pl. 5. Measure resistance between the terminals of the indicated sensor (see table). TDC1/TDC2 SENSOR 4P CONNECTOR

9. Measure resistance between the terminals ofthe indicated sensor on the PCM connector (see table). PCM CONNECTOR C (31 PI

TDC1P

TDC1M

234 TDC2P

567

TDC2M

2627 28 Terminal side of male terminals

SENSOR

DTC

TDC1

P1361 P1362 P1366 P1367

TDC2

SENSOR TERMINAL 1 2 3 4

PCM TERMINAL C20 C21 C29 C30

WIRE COLOR GRN RED VEL


Is there 1,850- 2,450 Q ? YES - Go to step 10.

BlK NO- Repair open in the indicated sensor wires (see table) .•

Is there 1,850- 2,450 Q ? YES- Go to step 6. NO-Replace the TDC 1/TDC 2 sensor (see page 655) .•

BACK

(cont'd)

11-77

PGM-FI System OTe Troubleshooting (cont'd) 10. Check for continuity between body ground and PCM connector terminals C20 and/or C29 individually. PCM CONNECTOR C (31P) TDC1P(GRN)

1 2 3 4 5 6 7 9 10 V 12 13 14 V 16 17 18 19 20 21 V 23 IV 25 29 30 V 26 27 28

fCZPIYEU Q

[~


Is there continuity? VES- Repair short in the indicated sensor wires (see table) .• NO-Substitute a known-good PCM and recheck. Refer to the '98-02 Accord Service Manual (see page 11-5). If the symptom/indication goes away, replace the original PCM .•

11-78

BACK

DTC P1676: FPTDR Signal Line Malfunction 1. Reset the PCM.

6. Check for continuity between ABS/TCS control unit 16P connector terminal No.1 and PCM connector terminal A22. PCM CONNECTOR A (32P)

2. Start the engine and wait 10 seconds.

Is OTC P1676 indicated? YES-Goto step 3.

FPTDR GRN/RED, '98-00 models.

, - - - - - - - - - ' PNK, '01-02 models ABS/TCS CONTROL UNIT 16P CONNECTOR

NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the ABS/TCS control unit and at the PCM .•


3. Turn the ignition switch OFF. 4. Disconnect PCM connector A (32P) and the ABS/TCS control unit 16P connector.

Is there continuity? YES-Goto step 7.

5. Check for continuity between body gound and PCM connector terminal A22.

NO- Repair open in the wire between the ABS/TCS control unit and the PCM (A22) .•


7. Reconnect PCM connector E (32). 11 12 3 4 5 6 7 8 9 10 11 I 1121131415161718192021122 23 24 1 25 26 27 28 29 30 31 ~

@ ~

8. Connect PCM connector terminals A22 and C28 with a jumper wire.

FPTDR GRN/RED, '98-00 models, PNK, '01"()2 models


JUMPER WIRE

Is there continuity? YES-Repair short in the wire between the ABS/ TCS control unit and the PCM (A22) .• NO-Goto step 6.


9. Do the PCM Reset Procedure. 10. Start the engine and wait 60 seconds.

Is OTC P1678 indicated? YES-Substitute a known-good ABS/TCS control unit and recheck. If the symptom/indication goes away, replace the original ABS/TCS control unit.• NO-Substitute a known-good PCM and recheck Refer to the '98-02 Accord Service Manual (see page 11-5). If the symptom/indication goes away, replace the original PCM .•

BACK

11-79

PGM-FI System DTC Troubleshooting (cont'd) DTe P1678: FPTDR Signal Line Malfunction 1. Reset the PCM. 2. Start the engine and wait 60 seconds. Is DTC P1678 indicated? YES-Substitute a known-good ABS/TCS control unit and recheck. Ifthe symptom/indication goes away, replace the original ABS/TCS control unit.• NO-Intermittent failure, system is OK at this time. Check for poor connections or loose wires at the ABS/TCS control unit and at the PCM.

11-80

BACK

Injector Replacement '98-99 models: 1. Relieve fuel pressure (see page 11-89). 2. Remove the intake manifold covers and the intake manifold. 3. Disconnect the connectors from the injectors (A).

4. Disconnect the vacuum hose and fuel return hose from the fuel pressure regulator (B). Place a rag or shop towel over the hoses before disconnecting them. 5. Disconnect the fuel hose (e) from the fuel rail (D). 6. Remove the retainer bolts (E) from the fuel rails and harness holders (F), then replace the O-rings (G). 7. Disconnectthe fuel rails. 8. Remove the injectors from the fuel rails.

(cont'd)

BACK

11-81

PGM-FI System Injector Replacement (cont'd) 9. Slide new cushion rings (A) onto the injectors (B).

c

A

B

E

10. Coat new O-rings (C) with clean engine oil, and put them on the injectors. 11. Insert the injectors into the fuel rails (D). 12. Coat new seal rings (E) with clean engine oil, and press them into the intake manifold. 13. Install the injectors into the intake manifold. 14. Install and tighten the retainer bolts. 15. Connect the fuel hose to the fuel rail with new washers. 16. Connect the vacuum hose and fuel return hose to the fuel pressure regulator. 17. Install the connectors on the injectors and harness holders. 18. Install the intake manifold and the intake manifold covers. 19. Turn the ignition switch ON (II), but do not operate the starter. After the fuel pump runs for approximately 2 seconds, the fuel pressure in the fuel line rises. Repeat this 2 or 3 times, then check for fuel leakage.

11-82

BACK

'00-02 models: 1. Relieve fuel pressure (see page 11-89). 2. Remove the intake manifold covers and the intake manifold. 3. Disconnect the connectors from the injectors (A).

9.8N·m (1.0 kgf·m, 7.2Ibf·ft)

E

4. Remove the retainer bolts (D) from the fuel rails (C) and harness holders (E), then replace the O-rings (F). 5. Disconnect the fuel rails. 6. Remove the injectors from the fuel rails.

(cont'd)

BACK

11-83

PGM-FI System Injector Replacement (cont'd) 7. Slide new cushion rings (A) onto the injectors (8).

c A

B

E

8. Coat new O-rings (C) with clean engine oil, and put them on the injectors. 9. Insert the injectors into the fuel rails (D). 10. Coat new seal rings (E) with clean engine oil, and press them into the intake manifold. 11. Install the fuel injectors into the intake manifold. 12. Install and tighten the bolts. 13. Install the connectors on the injectors. 14. Install the intake manifold and the intake manifold covers. 15. Turn the ignition switch ON (II), but do not operate the starter. After the fuel pump runs for about 2 seconds, the fuel pressure in the fuel line rises. Repeat this 2 or 3 times, then check for fuel leakage.

11-84

BACK

Primary H02S Replacement

Secondary H02S Replacement



Commercially available 02 sensor wrench: Snap-on YA8875, SP Tools 93750, or equivalent

Commercially available 02 sensor wrench: Snap-on YA8875, SP Tools 93750, or equivalent

1. Disconnect the primary H02S 4P connector (A), then remove the primary H02S (B). B

1. Disconnect the secondary H02S 4P connector (A), then remove the secondary H02S (B).


2. Install the primary H02S in the reverse order of removal. 2. Install the secondary H02S in the reverse order of removal.

BACK

11-85

Idle Control System Component Location Index NOTE: The illustration shows '00-02 models.

IDLE AIR CONTROL (lAC) VALVE Troubleshooting, page 11-102 in the '98-02 Accord Service Manual

POWER STEERING PRESSURE (PSP) SWITCH Troubleshooting, page 11-108 in the '98-02 Accord Service Manual

11-86

BACK

Idle Speed Adjustment Adjust idle speed using the Honda PGM Tester procedure, if possible. If not, use the following procedure:

5. Adjust the idle speed, if necessary, by turning the idle adjusting screw (A) 1/4-turn clockwise or counterclockwise.

NOTE: • Leave the lAC valve connected. • Before setting the idle speed, check these items: - The MIL has not been reported on. - Ignition timing - Spark plugs - Air cleaner - PCV system • On Canadian models, pull the parking brake lever up. Start the engine, then check that the headlights are off.

NOTE: Do not turn the idle adjusting screw more than 1/4-turn without checking the idle speed. A

1. Disconnect the EVAP purge control solenoid valve 2P connector. 2. Connect a tachometer, or connect the Honda PGM Tester (A) or an aBO II scan tool to the Data Link Connector (DLC) (B) located under the driver's side of the dashboard. 6. After turning the idle adjusting screw 1/4-turn, check the idle speed again. If it is out of spec, turn the idle adjusting screw 1/4-turn again. 7. Idle the engine for one minute with the heater fan switch at HI, and the air conditioner on, then check the idle speed. Idle speed should be: 680 ± 50 rpm (in Park or neutral)

3. Start the engine. Hold the engine at 3,000 rpm with no load (transmission in Park or neutral position) until the radiator fan comes on, then let it idle. 4. Check the idle speed with no-load conditions: headlights, blower fan, rear defogger, radiator fan, and air conditioner off.

NOTE: • Do not turn the idle adjusting screw when the air conditioner is on . • If the idle speed is not within specification, see the Symptom Troubleshooting Index. 8. Reconnect the EVAP purge control solenoid valve 2P connector.

Idle speed should be: 680±50 rpm (in Park or neutral)

BACK

11-87

Fuel Supply System Component Location Index NOTE: The illustration shows '00-02 models.

FUEL FEED LINE

FUEL PUMP Test, page 11-117 in the '98-02 Accord Service Manual Replacement, page 11-124 in the '98-02 Accord Service Manual

FILTER Replacement, page 11-123 in the '98-02 Accord Service Manual

FUEL GAUGE SENDING UNIT Test, page 11-95 Replacement, page 11-129 in the '98-02 Accord Service Manual

FUEL TANK Replacement, page 11-125 in the '98-02 Accord Service Manual

FUEL TUBE/QUICK-CONNECT FITTINGS Precautions, page 11-120 in the '98-02 Accord Service Manual Removal, page 11-120 in the '98-02 Accord Service Manual Installation, page 11-121 in the '98-02 Accord Service Manual

FUEL PRESSURE REGULATOR Replacement for '98-99 models, page 11-93 Replacement for '00-02 models, page 11-94

PGM-FI MAIN RELAV Troubleshooting, page 11-112 in the '98-02 Accord Service Manual

11-88

BACK

Fuel Pressure Relieving Before disconnecting fuel lines or hoses, release pressure from the system by loosening the fuel pulsation damper on top of the fuel rail. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable. 3. Remove the fuel fill cap. 4. Place a wrench on the fuel pulsation damper (A) at the fuel rail. A 22N·m 12.2 kgf·m, 16 Ibf·ft)

B

5. Place a rag or shop towel (B) over the fuel pulsation damper. 6. Slowly loosen the fuel pulsation damper (A) one complete turn. NOTE: Replace all washers whenever the fuel pulsation damper is loosened or removed.

BACK

11-89

Fuel Supply System Fuel Pressure Test 3. Attach the fuel pressure gauge.


• Fuel pressure gauge 07406-0040001 • Fuel pressure gauge attachment 07VAJ-00401 00

'98-99 models:

1. Relieve the fuel pressure (see page 11-89). 2. Use a wrench to remove the fuel pulsation damper from its fitting, then attach the fuel pressure gauge attachment.

07VAJ-0040100

/ '00-02 models:

4. Disconnect the vacuum hose (A) of the fuel pressure regulator and pinch it closed with a clamp (8).

5. Start the engine and let it idle. • Ifthe engine starts, go to step 7. • If the engine does not start, go to step 6. 6. Check to see if the fuel pump is running: remove the fuel fill cap and listen to the fuel fill port while an assistant turns the ignition switch ON (II). You should hear the pump run for about 2 seconds when the ignition is turned ON (II). • Ifthe pump runs, go to step 7. • If the pump does not run, test it, refer to the '98-02 Accord Service Manual (see page 11117) .•

11-90

BACK

7. Read the pressure gauge (with the fuel pressure regulator vacuum hose disconnected and clamped). The pressure should be: '98-00 models: 280-330 kPa (2.9-3.4 kgf/cm2, 4148 psi). '01-02 models: 320-370 kPa (3.3-3.8 kgf/cm2, 4854 psi). • Ifthe pressure is OK and the engine is running, go to step 8. If the engine is not running, repair the cause, then continue this test. • If the pressure is out of spec, go to step 9. 8. With the engine running, reconnect the vacuum hose, and read the gauge again. The pressure should be: '98-00 models: 220-270 kPa (2.25-:2.75 kgf/cm2, 32-40 psi). '01-02 models: 260-310 kPa (2.7-3.2 kgf/cm2, 3846 psi). • If the fuel pressure is OK, the test is complete. Go to step 10. • If the pressure is out of spec, go to step 9. 9. Disconnect the vacuum hose from the pressure regulator again while you watch the pressure gauge. The pressure should rise when you disconnect the hose. • If the pressure did not rise, replace the fuel pressure regulator for '98-99 models (see page 11-93) orfor '00-02 models (see page 11-94), and recheck the fuel pressure. • If the pressure rose, and all your readings were within spec, go to step 10. • If the pressure rose, but your readings were out of spec, check for these problems: - If the pressure is too low, check for a clogged fuel filter and for leaks in the fuel lines.• - If the pressure is too high, check for a pinched or clogged fuel return hose or line .• 10. Reconnect the vacuum hose, remove the pressure gauge, and reinstall the fuel pulsation damper with a new washer.Tighten the fuel pulsation damper to 22 N·m (2.2kgf·m, 16Ibf·ft). NOTE: Disassemble and clean the fuel pressure gauge attachment thoroughly after use.

BACK

11-91

Fuel Supply System Fuel Line Inspection Check the fuel system lines, hoses, and fuel filter for damage, leaks, or deterioration. Replace any damaged parts. NOTE: The illustration shows '00-02 models.

37N·m

(3.8 kgf·m, 27 Ibf·ftl

11-92

BACK

Fuel Pressure Regulator Replacement '98-99 models:

7. Turn the fuel pressure regulator (A) counterclockwise to set the angle as shown.

/A

1. Remove the intake manifold cover and intake manifold. 2. Place a shop towel under the fuel pressure regulator, then relieve fuel pressure (see page 11-

89).

.~.

3. Disconnect the vacuum hose (A) and fuel return hose (8). E

8. Tighten the locking nut to 29 N·m (3.0 kgf·m, 22 Ibf·ft).

4. Loosen the locking nut (C), and remove the fuel pressure regulator (D).

NOTE: • Replace the O-ring . • When assembling the fuel pressure regulator, apply clean engine oil to the O-ring and assemble it into its proper position, taking care not to damage the O-ring.

5. Apply clean engine oil to a new O-ring (E), and carefully install it into its proper position. 6. Install the fuel pressure regulator in the fuel rail. Turn it by hand until stops.

(cont'd)

BACK

11-93

Fuel Supply System Fuel Pressure Regulator Replacement (cont'd) '00-02 models:

6. Turn the fuel pressure regulator (A) counterclockwise to set the angle as shown.

1. Place a shop towel under the fuel pressure regulator, then relieve fuel pressure (see page 1189). 2. Disconnect the vacuum hose (A) and fuel return hose (B).

A

7. Tighten the locking nut to 29 N·m (3.0 kgf·m, 22 Ibf·ft). NOTE: • Replace the O-ring . • When assembling the fuel pressure regulator, apply clean engine oil to the O-ring and assemble it into its proper position, taking care not to damage the O-ring.

B

3. Loosen the locking nut (e), and remove the fuel pressure regulator (D). 4. Apply clean engine oil to a new O-ring (E), and carefully install it into its proper position. 5. Install the fuel pressure regulator in the fuel joint. Turn it by hand until stops.

11-94

BACK

Fuel Gauge Test NOTE: For the fuel gauge system circuit diagram, refer to the '98-02 Accord Service Manual (see page 22-60). 1. Check the No.9 BACK UP LIGHT INSTRUMENT LIGHT (7.5 A) fuse in the driver's under-dash fuse/ relay box before testing.

6. Turn the ignition switch OFF. 7. Install a 2 Q resistor between the fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II). FUEL PUMP 5P CONNECTOR

2. Remove the spare tire lid. JUMPER WIRE

3. Remove the access panel from the floor.

2Q RESISTOR

(VEL/BLU)

4. Turn the ignition switch OFF, then disconnectthe fuel pump 5P connector. (BlK)

5. Measure voltage between the fuel pump 5P connector terminals No.1 and No.2 with the ignition switch ON (II). There should be between 5 and 8V. Wire side of female terminals

• If the voltage is as specified, go to step 6. • If the voltage is not as specified, check for:

8. Check that the pointer of the fuel gauge starts moving toward the "F" mark.

- an open in the YELjBLU or BLK wire. - poor ground (G552).

• If the pointer of the fuel gauge does not move at all, replace the gauge. • Ifthe gauge is OK, inspect the fuel gauge sending unit, refer to the '98-02 Accord Service Manual (see page 11-129).


NOTE: • Turn the ignition switch OFF before the pointer reaches "F" on the gauge dial. Failure to do so may damage the fuel gauge. • The fuel gauge is a bobbin (cross-coil) type, so the fuel level is continuously indicated even when the ignition switch is OFF. • The fuel gauge pointer moves more slowly than a bimetal type.


BACK

11-95

Intake Air System Component Location Index NOTE: The illustration shows '00-02 models.

INTAKE AIR BYPASS CONTROL VALVE Test, page 11-103

THROTTLE BODY Test, page 11-97 Removal/Installation, page 11-101 Disassembly/Reassembly, page 11-102

11-96

BACK

,.... \

Throttle Body Test 5. Operate the throttle lever by hand to see if the throttle valve and/or shaft are too loose or too tight.


Vacuum Pump/Gauge, 0-30 in.Hg A973X-041-XXXXX

o

'98-99 models: 1. Disconnect the vacuum hose (A) between the top of the throttle body at the intake air bypass control valve, and connect it to a vacuum gauge.

o

If there is excessive play in the throttle valve shaft or if the throttle valve binds at the fully closed position, replace the throttle body. If the throttle valve and shaft are OK, go to step 6.

6. Check for clearance between the throttle stop screw and the throttle lever at the fully closed position. If there is any clearance, replace the throttle body (see page 11-101). Do not adjust the throttle stop screw.

2. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then let it idle. The gauge should not indicate any vacuum. o

o

If the gauge indicates vacuum, check and if necessary adjust the throttle cable (see page 11100), then go to step 3. If the gauge does not indicate vacuum, go to step 3.

3. Open the throttle slightly from idle, and check the gauge again. The gauge should indicate vacuum. o o

If the gauge indicates vacuum, go to step 4. If the gauge does not indicate vacuum, check the throttle body port. If it's clogged, clean it with carburetor cleaner, then go to step 4.

4. With the engine OFF, check the throttle cable operation. The cable should operate without binding or sticking. o o

Ifthe cable is OK, go to step 5. If the cable binds or sticks, check it and its routing. If the cable is faulty, reroute it or replace it, and adjust it (see page 11-100), then go to step 5.

(cont'd)

BACK

11-97

Intake Air System Throttle Body Test (cont'd) '00-02 models: NOTE: • Do not adjust the throttle stopscrew. It is preset at the factory . • Ifthe Malfunction Indicator Lamp (MIL) has been reported on, check for Diagnostic Trouble Codes (DTCs), refer to the '98-02 Accord Service Manual (see page 11-3). 1. With the engine off, check the throttle cable operation. The cable should move without binding or sticking. • If the cable operates OK, go to step 2. • Ifthe cable binds or sticks, check it and its routing. • If the cable is faulty, reroute it or replace it and adjust it (see page 11-100), then go to step 2. 2. Operate the throttle lever by hand to see if the throttle valve and/or shaft are too loose or too tight. • If there is excessive play in the throttle valve shaft, or any binding in the throttle valve at the fully closed position, replace the throttle body. • If the throttle valve and shaft are OK, go to step 3. 3. Connect the scan tool to the Data Link Connector (DLC). 4. Turn the ignition switch ON (II). 5. Check the throttle position with the scan tool. There should be about 10% when the throttle is fully closed and about 90% when the throttle is fully opened. • If the throttle position is correct, the throttle body isOK. • If the throttle position is not correct, replace the throttle body.

11-98

BACK

AirCleanerE~~~~~~~~~~~~~~~~~~~~~~~ r'~ ement RepIacement

AIR CLEANER HOUSING

..#

)

AIR CLEANER ELEMENT

r BACK

11-99

Intake Air System Throttle Cable Adjustment 1. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then let it idle. 2. Hold the throttle link (A) to the throttle lever (8). There should be no clearance.

3. Check cable free play at the throttle linkage. Cable deflection (A) should be 10-12 mm (3/8-1/2 in.)

4. If deflection is not within spec (10-12 mm, 3/81/2 in.) loosen the locknut (8), turn the adjusting nut (C) until the deflection is as specified, then retighten the locknut. 5. With the cable properly adjusted, check the throttle valve to be sure it opens fully when you push the accelerator pedal to the floor. Also check the throttle valve to be sure it returns to the idle position whenever you release the accelerator pedal.

11-100

BACK

Throttle Body Removal/Installation NOTE: • Do not adjust the throttle stop screw. • After reassembly, adjust the cruise control cable (see page 4-54) and the throttle cable (see page 11-100). • The TP sensor is not removable. '98-99 models: MAP SENSOR THROTILE CABLE

/ CRUISE CONTROL CABLE ~22N.m

~

12.2 kgf.m, 16Ibf.ft)

TPSENSOR lAC VALVE

'00-02 models: SENSOR THROTTLE CABLE

/ CRUISE CONTROL CABLE

N·m

12.2 kgf·m, 16 Ibf·ft)

TPSENSOR

r

lAC VALVE

BACK

11-101

Intake Air System Throttle Body DisassemblyIReassembly '98-99 models: ~2.1N.m ~~ (0.21 kgf·m,

1.5 Ibf·ft)

IDLE ADJUSTING SCREW TPSENSOR

O-RING

O-RING Replace.

~3.5 N·m (0.35 kgf·m, 2.5Ibf·ft)

'00-02 models: 2.1N·m (0.21 kgf·m, 1.5 Ibf·ft)

IDLE ADJUSTING SCREW TPSENSOR

O-RING

O-RING Replace.

_ ~3.5 N·m (0.35 kgf·m, 2.5Ibf·ft)

11-102

BACK

Intake Air Bypass Control Valve Test '00-02 models:

Special Tools Required:

Vacuum pump gauge, 0-30 in.Hg A973X-041-XXXXX

1. Start the engine. then let it idle.

'98-99 models:

NOTE: Engine coolant temperature must be below 104°F (40°C).

1. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral position) until the radiator fan comes on, then let it idle.

2. Remove the vacuum hose (A) from the intake duct, and connect a vacuum gauge to the hose.

2. Remove the vacuum hose (A) from the intake duct, and connect a vacuum gauge to the hose. A

A

A973X-041-XXXXX

~"

\

A973X-041XXXXX

!l\

3. Raise and lower the engine speed, and make sure the vacuum gauge reading changes as the rpm changes. 3. Raise and lower the engine speed, and make sure the vacuum gauge reading changes as the rpm changes. If the vacuum reading does not change, check for these problems: • Misrouted, leaking, broken, or clogged intake air bypass control system vacuum lines . • A cracked or damaged intake air bypass control valve.

If the vacuum reading does not change, check for these problems: • Misrouted, leaking, broken, or clogged intake air bypass control system vacuum lines. • A cracked or damage intake air bypass control valve . 4. Hold the engine at 3,000 rpm with no load (in Park or neutral position) until the radiator fan comes on, then let it idle. 5. Raise and lower the engine speed, and make sure the vacuum gauge reading does not change as the rpm changes. If the vacuum reading changes, check for these problems: • Misrouted, leaking, broken, or clogged intake air bypass control system vacuum lines. • A cracked or damage intake air bypass control valve.

BACK

11-103

PCVSystem PCV Valve Inspection and Test 1. Check the PCV valve (A), hoses (B), and connections for leaks and restrictions.

2. At idle, make sure there is a clicking sound from the PCV valve when the hose between the PCV valve and intake manifold is lightly pinched (A) with your fingers or pliers. Ifthere is no clicking sound, check the PCV valve grommet for cracks or damage. If the grommet is OK, replace the PCV valve and recheck.

'98-99 models:

'98-99 models:

'00-02 models: B

A '00-02 models:

B

A

11-104

BACK

Evaporative Emission Control System Component Location Index NOTE: The illustration shows '00-02 models.


FUEL TANK VAPOR CONTROL VALVE Test, page 11-160 in the '98-02 Accord Service Manual Replacement, page 11-162 in the '98-02 Accord Service Manual


EVAPORATIVE EMISSION (EVAP) CANISTER VENT SHUT VALVE EVAPORATIVE EMISSION (EVAP) BYPASS SOLENOID VALVE EVAPORATIVE EMISSION (EVAP) TWO-WAY VALVE Test, page 11-159 in the '98-02 Accord Service Manual

BACK

11-105

BACK

Automatic Transmission Automatic Transmission

Transmission End Cover

Special Tools ................................................... 14-2 General Troubleshooting Information ......... 14-3 DTCTroubleshooting Index ............................ 14-7 Symptom Troubleshooting Index ................. 14-8 System Description •..••........................•.......... 14-18 DTC Troubleshooting ..................................... 14-64 ~ Indicator Circuit Troubleshooting ......................................... 14-93 Interlock System Troubleshooting Shift Lock System Circuit .•............•............ 14-96 Key Interlock System Circuit ...................... 14-99 Road Test .......................................................• 14-101 Stall Speed Test .............................................. 14-103 Pressure Tests ................................................ 14-104 Torque Converter Clutch Solenoid ValveShiftSolenoidValveATest .•...................•• 14-106 Torque Converter Clutch Solenoid ValveShift Solenoid Valve A Replacement ........ 14-106 Shift Solenoid Valves Band C Test ............... 14-107 Sl1ift Solenoid Valves Band C Replacement ............................................... 14-107 AfT Clutch Pressure Control Solenoid Valves A and B Test .................................... 14-108 AfT Clutch Pressure Control Solenoid Valves A and B Replacement ..................... 14-109 Speed Sensor Replacement .........................• 14-110 2nd Clutch Pressure Switch Replacement ............................................... 14-111 3rd Clutch Pressure Switch Replacement ............................................... 14-111 ATF Level Check ............................................. 14-112 ATF Replacement ........................................... 14-113 Transmission Removal .................................. 14-114 Transmission Installation .............................. 14-121 ATF Cooler Flushing ....................................... 14-127 ATF Cooler Hoses Replacement ................... 14-128 Shift Lever Removal ....................................... 14-129 Shift Lever Installation ................................... 14-130 Shift Lever Disassembly/Reassembly .......... 14-132 Shift Cable Replacement ............................... 14-133 Shift Cable Adjustment .................................. 14-136

AfT Gear Position Indicator Component Location Index ........................... Circuit Diagram ............................................... Transmission Range Switch Test ................. Transmission Range Switch Replacement ............................................... Indicator Input Test ........................................ Indicator Bulb Replacement ..........................

14-138 14-139 14-140 14-141 14-143 14-144

AfT Interlock System Component Location Index ........................... Circuit Diagram ............................................... Control Unit Input Test ................................... Key Interlock Solenoid/Switch Test .............. ShiftLockSolenoidTest ................................ Shift Lock Solenoid Replacement ................. Park Pin Switch Test .......................................

End Cover Removal ...................................•.... 14-151 Park Lever Stop Inspection and Adjustment .......... 14-153 End Cover and Idler Gears Instllation ........... :.......... 14-195

Transmission Housing Housing and Shaft Assemblies Removal ................ 14-154 Bearing Replacement ..................................... 14-156 Shaft Assemblies and Housing Installation ............ 14-192

Valve Body Valve Bodies and ATF Strainer Removal ................ Valve Body Repair .......................................... Valve Body Valve Installation ........................ Main Valve Body Disassembly, Inspection and Reassembly ....................... ATF Pump Inspection ..................................... Regulator Valve Body Disassembly, Inspection and Reassembly ...................... Servo Body Disassembly, Inspection and Reassembly .............•......... Accumulator Body Disassembly, Inspection and Reassembly ......................................... Valve Bodies and ATF Strainer Installation ...................................................

14-157 14-159 14-160 14-161 14-163 14-164 14-165 14-166 14-190

Torque Converter Housing Mainshaft Bearing/Oil Seal Replacement ............................................... 14-167 Countershaft Bearing Replacement •••.•........ 14-168 Secondary Shaft Bearing Repacement 14-168

Shafts and Clutches Mainshaft Disassembly, Inspection, and Reassembly ...........•............................. 3rd/4th Clutch Clearance Inspection ............. Mainshaft Sealing Rings Replacement ........ Countershaft Disassembly, Inspection, and Reassembly ...................... Countershaft Reverse Selector Hub, 3rd Gear, and 1st Gear Replacement ........ Countershaft Bearing Hub/Bearing Replacement ............................................... Secondary Shaft Disassembly, Inspection, and Reassembly ......................................... Secondary Shaft Clearance Inspection ........ Secondary Shaft Idler Gear Bearing Replacement ..........•.................................... Clutch Disassembly ........................................ Clutch Inspection ............................................ Clutch Reassembly .........................................

14-169 14-170 14-171 14-172 14-173 14-175 14-176 14-177 14-179 14-180 14-183 14-185

AfT Differential 14-145 14-146 14-147 14-149 14-149 14-150 14-150

Outline of V6 Model Change The B7XA automatic transmission has been added.

Component Location Index ........................... Backlash Inspection ........................................ Final Driven Gear/Carrier Replacement .................. Carrier Bearing Replacement ........................ Oil Seal Replacement ..................................... Carrier Bearing Outer Race Replacement ............... Carrier Bearing Preload Inspection ...............

14-201 14-201 14-202 14-202 14-203 14-204 14-205

Automatic Transmission Special Tools Ref.No.

aty

CD

1 1 1 1 1 1 1 1 2 4 4 1 2 1 1 1 1 1 1 1 1 1 1

Tool Number Description 07GAB-PF50101 or 07GAB-PF50100 Mainshaft Holder 07GAD-PG40101 or 07GAD-PG40100 Seal Driver Attachment ® 07GAE-PG40200 or 07GAE-PG4020A Clutch Spring Compressor Bolt Assembly ® *G) 07 HAC-PK40 102 Housing Puller 07HAJ-PK40201 Preload Inspection Tool ® 07JAD-PH80101 Oil Seal Driver Attachment ® (j) Pilot, 28 x 30 mm 07 JAD-PH80400 Attachment, 40 x 50 mm 07 LAD-PW50601 ® Clutch Spring Compressor Attachment **® 07LAE-PX40100 07MAJ-PY4011A A/T Pressure Hose, 2,210 mm ®> @ 07MAJ-PY40120 A/T Pressure Hose Adapter @ 07 NAD-PX40 100 Attachment, 78 x 80 mm @ 07SAZ-001000A Backprobe Set @ SCS Service Connector (DLC) 07WAZ-002010A @ 07ZAE-PRP0100 Clutch Compressor Attachment @ 07406-0020400 A/T Oil Pressure Gauge Set W/Panel Adjustable Bearing Puller, 25-40 mm ***@ 07736-A01000B or 07736-A01000A @ Attachment, 42 x 47 mm 077 46-00 10300 @ 077 46-0010500 Attachment, 62 x 68 mm @ Attachment, 72 x 75 mm 077 46-00 10600 Driver 40 mm I.D. 077 46-0030100 ® @ 077 49-00 10000 Driver @ Driver Attachment 07947-6340500 * If the top arm is too short, replace It with 07SAC-POZ01001. ** 07HAE-PL501 01 may be used to substitute one of these tools. *** Must be used with commercially available 3/8"-16 slide hammer.

·A

··I~~~

. I .... .. (1)

®

CD

~.\\ ~

-----~

®

®

@

®

@

~ ~f

14-2

BACK

(!) _ ,\

,

(O\' -=--

.._.

/

,

,

r

General Troubleshooting Information How to Check for DTCs with the PGM Tester/Scan Tool When the PCM senses an abnormality in the input or output systems, the ~ indicator in the gauge assembly will blink. When the 16P Data Link Connector (DLC) (located next to the driver's side kick panel) is connected to the OBD II Scan Tool or Honda PGM Tester as shown, the scan tool or tester will indicate the Diagnostic Trouble Code (DTC) when the ignition switch is turned ON (II). HONDA PGM TESTER or OBD II SCAN TOOL

/ DATA LINK CONNECTOR (16P)

If the ~ indicator or the MIL has been reported on, or if a driveability problem is suspected, follow this procedure 1. Connect the OBD II Scan Tool (conforming to SAE J1978) or Honda PGM Tester to the 16P DLC. (See the OBD II Scan Tool or Honda PGM Tester user's manual for specific instructions. If you are using the Honda PGM Tester, make sure it is set to the SAE DTC type.) 2. Turn the ignition switch ON (11), and observe the DTC on the screen. 3. Record all fuel and emission DTCs, AfT DTCs, and freeze data. 4. If there is a fuel and emissions DTC, first check the fuel and emissions system as indicated by the DTC (except for DTC P0700). DTC P0700 means there is one or more AfT DTC, and no problems were detected in the fuel and emissions circuit ofthe PCM. 5. Get the anti-theft code for the radio, then write down the radio station presets. 6. Reset the memory with the PGM Tester or by removing the BACK UP fuse in the passenger's under-dash fuse/ relay box for more than 10 seconds. 7. Drive the vehicle for several minutes under the same conditions as those indicated by the freeze data, and then recheck for DTCs. If the AfT DTC returns, go to the DTC Troubleshooting Index on page 14-7. If the DTC does not return, there was an intermittent problem within the circuit. Make sure all pins and terminals in the circuit are tight, and then go to step 8. 8. Enter the radio code, reset the radio preset stations, and set the clock. (cont'd)

BACK

14-3

Automatic Transmission General Troubleshooting Information (cont'd) How to Check for DTCs When the PCM senses an abnormality in the input or output systems, the ~ indicator in the gauge assembly will usually blink and/or the Malfunction Indicator Lamp (MIL) may come on. When the Data Link Connector (DLC) (located next to the driver's side kick panel) is connected to the Honda PGM Tester, the ~ indicator will blink the Diagnostic Trouble Code (DTC) when the ignition switch is turned ON (II). When the ~ indicator has been reported on, connect the Honda PGM Tester to the DLC. Turn the ignhion switc ON (II), select Honda Systems, and then the SCS mode, then observe the ~ indicator.

~INDICATOR

Codes 1 through 9 are indicated by individual short blinks. Codes 10 and above are indicated by a series of long and short blinks. One long blink equals 10 short blinks. Add the long and short blinks together to determine the code. After determining the code, refer to the DTC Troubleshooting Index.

~

Short blink (once)

OFF---"Jl-·----------------------------~n~------------------------SeeDTc1 OFF~----------------------------rlJl-----------------------SeeDTc2 Long blink

OFF~'

Short blinks (five times)

lfliUlnn

I

~SeeDTC15

If the ~ indicator or the MIL has been reported on, or if a driveability problem, follow this procedure: 1. Record all fuel/emissions DTCs, AfT DTCs, and freeze data. 2. If there is a fuel and emissions DTC, first check the fuel and emissions system as indicated by the DTC (except for DTC P0700), DTC P0700 means there is one or more AfT DTC, and no problems were detected in the fuel and emissions circuit of the PCM. 3. Get the customer's radio anti-theft code, and write down the numbers of the radio station presets. 4. Reset the memory by removing the BACK UP fuse in the passenger's under-dash fuse/relay box for more than 10 seconds. 5. Drive the vehicle for several minutes under the same conditions as those indicated by the freeze data, and then recheck for DTCs. If the DTC returns, refer to the DTC Troubleshooting Index. If the DTC does no return, there was an intermittent problem within the circuit. Make sure all pins and terminals in the circuit are tight, then go to step 6. 6. Enter the radio code, reset the preset stations, and reset the clock.

14-4

BACK

~

How to Troubleshoot Circuits at the PCM Special Tools Required Backprobe set 07SAZ-001000A (Two required) SRS components are located in this area. Review the SRS components locations, precautions, and procedures in the SRS section before performing repairs or service, refer to the '98-02 Accord Service Manual (see page 23-28). 1. Pull back the carpet from the passenger's side of the center console to expose the PCM. 2. Inspect the circuit on the PCM, according to the DTC troubleshooting, with the special tools and a digital multimeter. 3. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a multi meter (C). Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it comes in contact with the terminal end of the wire.

07SAZ-001000A

07SAZ-001000A

(cont'd)

BACK

14-5

Automatic Transmission General Troubleshooting Information (cont'd) How to Reset the PCM 1. Make sure you have the anti-theft code for the radio, then write down the radio station presets. 2. Turn the ignition switch OFF. 3. Use one of these methods to reset the PCM memory: • Use the aBO II Scan Tool or the Honda PGM Tester. • Remove the BACK UP fuse (7.5 A)(A) from the passenger's under-dash fuse/relay box (B) for 10 seconds.

D

How to End a Troubleshooting Session This procedure must be done after any troubleshooting. 1. Turn the ignition switch OFF. 2. Disconnect the aBO II Scan Tool or Honda PGM Tester (C) from the DLC (D). 3. Reset the PCM. 4. Turn the ignition switch ON (II). 5. Enter the radio code, reset the preset stations, and set the clock. 6. To verify that the problem is repaired, test-drive the vehicle for several minuites at speeds over 30 mph (48km/h).

14-6

BACK

OTe Troubleshooting Index NOTE: Record all freeze data before you troubleshoot. DTC*

~ Indicator

MIL

Detection Item

Page

D1 '-~

P0715 (15)

Blinks

ON

Mainshaft speed sensor

(see page 14-77)

P0720 (9)

Blinks

ON

Countershaft speed sensor

(see page 14-76)

P0730 (41)

OFF

ON

Shift control system

(see page 14-90)

P0740 (40)

OFF

ON

Lock-up control system

(see page 14-89)

P0753 (7)

Blinks

ON

Shift solenoid valve A

(see page 14-72)

P0758 (8)

Blinks

ON

Shift solenoid valve B

(see page 14-74)

P0763 (22)

Blinks

ON

Shift solenoid valve C

(see page 14-81)

P0780 (45)

Blinks

ON


(see page 14-91)

P1705 (5)

Blinks

ON

Transmission range switch (short to ground)

(see page 14-66)

P1706 (6)

OFF

ON

Transmission range switch (open)

(see page 14-69)

P1738 (25)

OFF

OFF

2nd clutch pressure switch

(see page 14-85)

P1739 (26)

OFF

OFF

3rd clutch pressure switch

(see page 14-87)

P1750 (46)

Blinks

ON


(see page 14-92)

P1751 (47)

Blinks

ON


(see page 14-92)

P1753 (1)

Blinks

ON

Torque converter clutch solenoid valve

(see page 14-64)

P1768 (16)

Blinks

ON

NT clutch pressure control solenoid valve A

(see page 14-79)

P1773 (23)

Blinks

ON

NT clutch pressure control solenoid valve B

(see page 14-83)

The DTC in the parentheses is the flash code the ~ indicator indicates when the Data Link Connector (DLC) is connected to the Honda PGM Tester. NOTE: Codes P0780 (45), P1750 (46), and P1751 (47) are applied to the '00-02 models.

BACK

14-7

Automatic Transmission Symptom Troubleshooting Index These symptoms DO NOT trigger Diagnostic Trouble Codes (DTCs) or cause the ~ indicator to blink. If the Malfunction Indicator Lamp (MIL) was reported ON orthe ~ indicator has been blinking, check for DTCs. But if the vehicle has one of the symptoms in the following chart, check the probable causes(s) for it, in the sequence listed, until you find the problem.

Symptom

Probable cause(s)

Notes

When you turn the ignition switch ON (II), the ~ indicator comes on and stays on or never comes on at all

A problem in the ~ indicator circuit

Check the ~ indicator circuit (see page 14-93).

Shift lever cannot be moved from the [f] position while you're pushing on the brake pedal

A problem in shift lock system of interlock system

Check interlock system - shift lock system circuit (see page 14-96).

Ignition key cannot be moved from ACC (I) position to LOCK (0) position while you're pushing the ignition key with the shift lever in the [f] position

A problem in key interlock system of interlock system

Check interlock system - key interlock system circuit (see page 14-99).

14-8

BACK

Probable cause(s)

Symptom

Engine runs, but vehicle does not move in any gear

1. 2.

3. 4.

5. 6.

7. 8. 9. 10.

Vehicle moves in [!] and [RJ, but not in~, ~, or III position

1. 2.

3.

Notes

Low ATF level Shift cable broken or out of adjustment Joint in shift cable and transmission or body worn ATF pump worn or binding Regulator valve stuck or spring worn ATF strainer clogged Mainshaft worn or damaged Final gears worn or damaged Transmission-to-engine assembly error Axle disengaged

• Check ATF level and check ATF cooler lines for leakage and loose connections. If necessary, flush ATF cooler lines. • Check for a loose shift cable at the shift lever and the transmission control shaft. • Improper alignment of ATF pump and torque converter housing may cause ATF pump seizure. The symptoms are mostly an rpm-related ticking noise or a high pitched squeak. • Measure line pressure. • Ifthe strainer is clogged, find the damaged components that caused debris. • Inspect the differential pinion gears for wear. If the differential pinion gears are worn, replace the differential assembly, replace the ATF strainer, thoroughly clean the transmission, and flush the torque converter, cooler, and lines. • Be careful not to damage the torque converter housing when replacing the main ball bearing. You may also damage the ATF pump when you torque down the main valve body. This will result in ATF pump seizure if not detected. Use the proper tools. • Install the main seal flush with the torque converter housing. If you push it into the torque converter housing until it bottoms out, it will block the fluid return passage and result in damage.

1st accumulator defective 1st gears worn or damaged 1st clutch defective

• Inspect 1st clutch pressure. • Inspect the secondary shaft and 1st/2nd clutch assembly for wear and damage. • Inspect the clutch piston and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

(cont'd)

BACK

14-9

Automatic Transmission Symptom Troubleshooting Index (co nt'd) Probable cause(s)

Symptom Vehicle moves in ~, ~,/Il, [RJ, but not in 00 position

1. 2. 3. 4.

5.

Vehicle moves in ~, ~, 00, /Il, but not in [RJ position

1. 2. 3. 4.

5. 6.

14-10

Notes

Shift solenoid valve A defective Shift valve A defective 2nd accumulator defective 2nd gears worn or damaged 2nd clutch defective

• Check the 00 indicator indication, and check for loose connectors. Inspect the a-rings, and check the shift solenoid valve for seizure. • Inspect the secondary shaft and 1st/2nd clutch assembly for wear and damage. • Inspect the clutch piston and a-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. Ifthe clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

Shift fork shaft stuck Modulator valve defective Reverse CPC valve defective 4th accumulator defective 4th clutch defective Reverse gears worn or damaged

• Measure line pressure and 4th clutch pressure. • Check for a missing shift fork bolt on the shift fork shaft. • If the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump. If the ATF pump is OK, and no cause for the contamination is found, replace the torque converter. • Inspect the reverse selector gear teeth chamfers, and inspect engagement teeth chamfers of the countershaft 4th gear and reverse gear. Replace the reverse gears and the reverse selector if they are worn or damaged. If the transmission makes clicking, grinding, or whirring noises, also replace the mainshaft 4th gear, reverse idler gear, and countershaft 4th gear. • If the 4th clutch feed pipe guide in the end cover is scored by the mainshaft, inspect the ball bearing for excessive movement in the transmission housing. If the ball bearing is OK, replace the end cover as it is dented. The a-ring under the guide is probably worn. • Replace the mainshaft ifthe bushing for the 3rd and 4th clutch feed pipes are loose or damaged. If the 4th clutch feed pipe is damaged or out of round, replace the end cover. • Inspect the clutch piston, clutch piston check valve, and a-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. Ifthe clearance is out oftolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clearance with the clutch end plate.

BACK

Probable cause(s)

Symptom

Poor acceleration; flares on starting off

1. 2.

in~and~

positions: Stall speed high in ~, ~, [II, and positions

m

3. 4.

5. 6.

Poor acceleration; flares on starting off

1.

in~and~

2.

Low ATF level Shift cable broken or out of adjustment ATF pump worn or binding Regulator valve stuck or spring worn ATF strainer clogged Torque converter check valve defective

• Check ATF level and check ATF cooler lines for leakage and loose connections. If necessary, flush ATF cooler lines. • Check for a loose shift cable at the shift lever and the transmission control shaft. • Check line pressure. • Improper alignment of ATF pump and torque converter housing may cause ATF pump seizure. The symptoms are mostly an rpm-ticking noise or a high pitched squeak. • Be careful not to damage the torque converter housing when replacing the main ball bearing. You may also damage the ATF pump when you torque down the main valve body. This will result in ATF pump seizure if not detected. Use the proper tools.

Shift cable broken or out of adjustment 1st cl utch defective

• Check for a loose shift cable at the shift lever and the transmission control shaft. • Check 1st clutch pressure. • Inspect the clutch piston and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

Shift cable broken or out of adjustment 2nd clutch defective

• Check for a loose shift cable at the shift lever and the transmission control shaft. • Check 2nd clutch pressure. • Inspect the clutch piston and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

positions: Stall speed high in ~, ~, and positions

m

Poor acceleration; flares on starting off in [II position: Stall speed high in [II position

Poor acceleration; flares on starting off in [HJ position: Stall speed is in specification in ~, ~, [II, and positions, but high in [HJ position

1. 2.

Notes

4th clutch defective

• Check 4th clutch pressure. • Inspect the clutch piston, clutch piston check valve, and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out oftolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

m

(cont'd)

BACK

14-11

Automatic Transmission Symptom Troubleshooting Index (cont'd) Symptom Poor acceleration; Stall speed low

Engine idle vibration

Probable cause(s)

Notes

1. Torque converter clutch solenoid valve defective 2. Torque converter one-way clutch defective 3. Engine output low 4. Lock-up clutch piston defective 5. Lock-up shift valve defective 6. Restricted cooler

Check ATF cooling system for restriction.

1.

• Set idle rpm in gear to the specified idle speed. If still no good, adjust the engine mounts as outlined in the engine section of this service manual. • Check ATF level and check ATF cooler lines for leakage and loose connections. If necessary, flush ATF cooler lines. • Check ATF cooling system for restriction.

Low ATF level

2. Torque converter clutch 3. 4.

5. 6.

7. 8. Vehicle moves in [HJ position

1. 2. 3. 4.

5. 6.

7. 8.

9.

14-12

solenoid valve defective Drive plate defective or transmission misassembed Engine output low Lock-up clutch piston defective ATF pump worn or binding Lock-up shift valve defective Restricted cooler Excessive ATF Foreign material in separator plate orifice 1st clutch defective 2nd clutch defective 3rd clutch defective 4th clutch defective Clutch clearance incorrect Needle bearing seized up, worn, or damaged Thrust washer seized up, worn, or damaged

• Check ATF level, and drain ATF if necessary. • Inspect the clutch piston, clutch piston check valve, and O-rings. Check the spring retainer for wear and damage. Inspectthe clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance. • Check for clutch pressure in neutral.

BACK

Probable cause(s)

Notes

Shift solenoid valve C defective 2. AfT clutch pressure control solenoid valves A and B defective 3. Shift cable broken or out of adjustment 4. Joint in shift cable and transmission or body worn 5. Shift fork shaft stuck 6. CPC valve A stuck 7. Foreign material in separator plate orifice 8. Shift valve C defective 9. Servo control valve defective 10. 1st accumulator defective 11. 1st check ball stuck 12. 1st clutch defective

• Check the ~ indicator indication, and check for loose connectors. Inspect the O-ring, and check the shift solenoid valve for seizure. • Inspect the AfT clutch pressure control solenoid valve body gasket and ATF feed pipes for wear and damage. If the AfT clutch pressure control solenoid valve is stuck, inspect the CPC valves. • Check for a loose shift cable at the shift lever and the transmission control shaft. • If the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump. Ifthe ATF pump is OK, and no cause for the contamination is found, replace the torque converter. • Check 1st clutch pressure. • Inspect the clutch piston, clutch piston check valve, and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

Symptom

Late shift from IHl position to ~ and ~ positions

Late shift from position to lBJ position

IHl

1.

1. 2.

3. 4.

5. 6.

7. 8. 9.

Shift solenoid valve C defective AfT clutch pressure control solenoid valves A and B defective Shift cable broken or out of adjustment Joint in shift cable and transmission or body worn Shift fork shaft stuck Foreign material in separator plate orifice Reverse CPC valve defective 4th accumulator defective 4th clutch defective

• Check the ~ indicator indication, and check for loose connectors. Inspect the O-ring, and check the shift solenoid valve for seizure. • Inspect the AfT clutch pressure control solenoid valve body gasket and ATF feed pipes for wear and damage. If the AfT clutch pressure control solenoid valve is stuck, inspect the CPC valves. • Check for a loose shift cable at the shift lever and the transmission control shaft. • Ifthe ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump. If the ATF pump is OK, and no cause for the contamination is found, replace the torque converter. • Check 4th clutch pressure. • Inspect the clutch piston, clutch piston check valve, and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

(cont'd)

BACK

14-13


No shift Erratic shifting gears: Fails to shift in ~ position; does not upshift to 4th

Probable cause(s)

Modulator valve defective 1.

• Inspect the O-ring, and check the shift solenoid valve for seizure. • Check the ~ indicator indication, and check for loose connectors. Inspect the transmission range switch. If the transmission range switch is faulty, replace it. If the transmission range switch is out of adjustment, adjust it and the shift cable.

Shift solenoid valve B defective Shift fork shaft stuck Shift valve B defective Servo control valve defective

• Check the ~ indicator indication, and check for loose connectors. Inspect the O-ring, and check the shift solenoid valve for seizure. • Check for a missing shift fork bolt on the shift fork shaft.

2. 3.

Shift solenoid valve B defective Shift valve B defective Shift valve E defective

Check the ~ indicator indication, and check for loose connectors. Inspect the O-ring, and check the shift solenoid valve for seizure.

1.

A(f clutch pressure control

• Check the ~ indicator indication, and check for loose connectors. Inspect the A(f clutch pressure control solenoid valve body gasket and ATF feed pipes for wear and damage. If the A(f clutch pressure control solenoid valve is stuck, inspect the CPC valves. • Ifthe ATF strainer is clogged with particles of steel or aluminum, inspectthe ATF pump. Ifthe ATF pump is OK, and no cause for the contamination is found, replace the torque converter.

2.

4.

5.

Erratic shifting gears: Fails to shift in ~, ~ and [I] positions; starts off in 3rd Excessive shock, or flares on all upshifts and downshifts

1. 2. 3. 4.

1.

2. 3. 4.

Excessive shock or flares on 1-2 upshift or 2-1 downshift

14-14

Measure line pressure.

Shift solenoid valve A defective Mainshaft speed sensor defective Countershaft speed sensor defective Shift valve A defective Shift valve D defective

3.

Erratic shifting gears: Fails to shift in ~ and ~ positions; does not upshift to 3rd and 4th

Notes

solenoid valves A and B defective CPC valve A defective CPC valve B defective Foreign material in separator plate orifice

Shift solenoid valve C defective 2. 2nd clutch pressure switch defective 3. Foreign material in separator plate orifice 4. Shift valve C defective 5. 1st accumulator defective 6. 2nd accumulator defective 7. 1st check ball stuck 8. 2nd check ball stuck 9. 1st clutch defective 10. 2nd clutch defective 1.

• Check the ~ indicator indication, and check for loose connectors. Inspect the O-rings, and check the shift solenoid valve for seizure. • Check the ~ indicator indication, and check for loose connectors. Check that the outlet is not clogged inside of the connector. • Check 1st and 2nd clutch pressures. • Inspect the clutch piston and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

BACK

Symptom

Excessive shock, or flares on 2-3 upshift or 3-2 downshift

Probable cause(s)

1. 2. 3. 4. 5.

6.

7. 8. 9. Excessive shock, or flares on 3-4 upshift or 4-3 downshift

1. 2.

3. 4. 5.

6.

7.

Noise from transmission in all shift lever positions

Vehicle does not accelerate more than 31 mph (50 km/h)

1. 2.

Notes

Shift solenoid valve C defective 3rd clutch pressure switch defective Foreign material in separator plate orifice Shift valve C defective 2nd accumulator defective 3rd accumulator defective 2nd check ball stuck 2nd clutch defective 3rd clutch defective

• Check the ~ indicator indication, and check for loose connectors. Inspect the O-rings, and check the shift solenoid valve for seizure. • Check 2nd and 3rd clutch pressures. • Inspect the clutch piston, clutch piston check valve, and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out of tolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

Shift solenoid valve C defective Foreign material in separator plate orifice Shift valve C defective 3rd accumulator defective 4th accumulator defective 3rd clutch defective 4th clutch defective

• Check the ~ indicator indication, and check for loose connectors. Inspect the O-rings, and check the shift solenoid valve for seizure. • Check 3rd and 4th clutch pressures. • If the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump.lfthe ATF pump is OK, and no cause for the contamination is found, replace the torque converter, and check the stall speed. • Inspect the clutch piston, clutch piston check valve, and O-rings. Check the spring retainer for wear and damage. Inspect the clutch end plate-to-top disc clearance. If the clearance is out oftolerance, inspect the clutch discs and plates for wear and damage. If the discs and plates are worn or damaged, replace them as a set. If they are OK, adjust the clutch end plate clearance.

ATF pump worn or binding Torque converter housing or transmission housing bearing worn or damaged

• Improper alignment of ATF pump and torque converter housing may cause ATF pump seizure. The symptoms are mostly an rpm-ticking noise or a high pitched squeak. • Inspect the contact of the countershaft and secondary shaft with the bearings. Check the ATF guide plates for damage and wear. Inspect the 1st clutch feed pipe for damage and out of round. If the 1st clutch feed pipe is damaged or out of round, replace it. Replace the secondary shaft if the bushing for the 1st clutch feed pipe is damaged or out of round.

Torque converter one-way clutch defective

Replace torque converter.

(cont'd)

BACK

14-15


Symptom Vibration in all shift lever positions

Shift lever does not operate smoothly

Drive plate defective or transmission misassembled

3.

Lock-up clutch does not disengage

14-16

• Set idle rpm in gear to the specified idle speed. If still no good, adjust the engine mounts as outlined in the engine section of the service manual. • Check the stall speed.

1. A/T gear position switch

2.

Transmission does not shift into [f] position

Notes

defective or out of adjustment Shift cable broken or out of adjustment Joint in shift cable and transmission or body worn

1. Shift cable broken or out of adjustment 2. Joint in shift cable and transmission or body worn 3. Park mechanism defective

1. Torque converter clutch solenoid valve defective 2. A/T clutch pressure control solenoid valves A and B defective 3. Lock-up clutch piston defective 4. Lock-up shift valve defective 5. Lock-up control valve defective 6. Lock-up timing valve defective 7. Restricted cooler

• Check the ~ indicator indication, and check for loose connectors. Inspect the transmission range switch. If the transmission range switch is faulty, replace it. If the transmission range switch is out of adjustment, adjust it and the shift cable. • Check for a loose shift cable at the shift lever and the transmission control shaft. • Check for a loose shift cable at the shift lever and the transmission control shaft. • Check the park pawl spring installation and the park lever spring installation. If installation is incorrect, install the spring correctly. Make sure that the park lever stop is not installed upside down. Check the distance between the park pawl and the park lever roller pin. If the distance is out of tolerance, adjust the distance with the park lever stop. • Check the ~ indicator indication, and check for loose connectors. Inspect the A/T clutch pressure control solenoid valve body gasket and ATF feed pipes for wear and damage. If the A/T clutch pressure control solenoid valve is stuck, inspect the CPC valves. • Check ATF cooling system for restriction.

BACK

Probable cause(s)

Symptom

Lock-up clutch does not operate smoothly

1. Torque converter clutch

2. 3. 4.

5.

6. 7. Lock-up clutch does not engage

solenoid valve defective AfT clutch pressure control solenoid valves A and B defective Lock-up clutch piston defective Torque converter check valve defective Lock-up shift valve defective Lock-up control valve defective Lock-up timing valve defective

1. Torque converter clutch

2. 3. 4.

5.

6. 7.

S.

solenoid valve defective AfT clutch pressure control solenoid valves A and B defective Mainshaft speed sensor defective Countershaft speed sensor defective Lock-up clutch piston defective Torque converter check valve defective Lock-up shift valve defective Lock-up control valve defective

AfT gear position

1. Transmission range switch

indicator does not indicate shift lever positions

defective or out of adjustment 2. Shift cable broken or out of adjustment 3. Joint in shift cable and transmission or body worn

Speedometer does not operate

Countershaft speed sensor defective

BACK

Notes

• Check the ~ indicator indication, and check for loose connectors. Inspect the AfT clutch pressure control solenoid valve body gasket and ATF feed pipes for wear and damage. If the AfT clutch pressure control solenoid valve is stuck, inspect the CPC valves. • Center all engine mounts.

Check the ~ indicator indication, and check for loose connectors. Inspect the AfT clutch pressure control solenoid valve body gasket and ATF feed pipes for wear and damage. If the AfT clutch pressure control solenoid valve is stuck, inspect the CPC valves.

• Check the ~ indicator indication, and check for loose connectors. Inspect the transmission range switch. If the transmission range switch is faulty, replace it. If the transmission range switch is out of adjustment, adjust it and the shift cable. • Check for a loose shift cable at the shift lever and the transmission control shaft. Check the ~ indicator indication, and check for loose connectors.

14-17

Automatic Transmission System Description General Operation The automatic transmission is a combination of a 3-element torque converter and triple-shaft electronically controlled automatic transmission which provides 4 speeds forward and 1 reverse. The entire unit is positioned in line with the engine. Torque Converter, Gears, and Clutches The torque converter consists of a pump, turbine, and stator assembly in a single unit. They are connected to the engine crankshaft so they turn together as a unit as the engine turns. Around the outside of the torque converter is a ring gear which meshes with the starter pinion when the engine is being started. The entire torque converter assembly serves as a flywheel transmitting power to the transmission mainshaft. The transmission has three parallel shafts: the mainshaft, the countershaft, and the secondary shaft. The mainshaft is in line with the engine crankshaft. The mainshaft includes the 3rd and 4th clutches, and gears for 3rd, 4th, reverse, and idler (reverse gear is integral with the 4th gear). The countershaft includes the final drive, 1st, 3rd, 4th, reverse, 2nd, park, and idler gears (the final drive gear is integral with the countershaft). The secondary shaft includes the 1st and 2nd clutches, and gears for 1st, 2nd and idler. The countershaft 4th gear and the countershaft reverse gear can be locked to the countershaft at its center, providing 4th gear or reverse, depending with which way the selector moved. The gears on the mainshaft and the secondary shaft are in constant mesh with those on the countershaft. When certain combinations of gears in the transmission are engaged by the clutches, power is transmitted from the mainshaft and the secondary shaft to the countershaft to provide ~, ~, 00, [I] and [RJ positions. Electronic Control The electronic control system consists of the Powertrain Control Module (PCM), sensors, and six solenoid valves. Shifting and lock-up are electronically controlled for comfortable driving under all conditions. The PCM is located below the dashboard, under the front lower panel behind the center console. Hydraulic Control The valve bodies include the main valve body, the regulator valve body, the servo body, and the accumulator body. They are bolted to the torque converter housing. The main valve body contains the manual valve, the modulator valve, the shift valve C, the shift valve D, the shift valve E, the servo control valve, the torque converter check valve, the reverse CPC valve, the lock-up shift valve, the relief valve, the cooler check valve, and the ATF pump gears. The regulator valve body contains the regulator valve, the lock-up timing valve, and the lock-up control valve. The servo body contains the servo valve, the shift valve A, the shift valve B, the CPC valves A and B, and 3rd and 4th accumulators. The accumulator body contains the 1st and 2nd accumulators and lubrication check valve. Fluid from the regulator passes through the manual valve to the various control valves. The 1st, 3rd, and 4th clutches receive fluid from their respective feed pipes, and the 2nd clutch receives fluid from the internal hydraulic circuit. Shift Control Mechanism The PCM controls shift solenoid valves A, B, and C, and AfT clutch pressure control solenoid valves A and B while receiving input signal from various sensors located throughout the vehicle. The shift solenoid valves shift the positions of the shift valves to switch the port leading hydraulic pressure to the clutch. The AfT clutch pressure control solenoid valves A and B control the CPC valves A and B to shift smoothly between lower gear and higher gear. This pressurizes a line to one of the clutches, engaging the clutch and its corresponding gear. Lock-up Mechanism In ~ position (3rd and 4th), and ~ position (3rd), pressurized fluid is drained from the back of the torque converter through a fluid passage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the mainshaft rotates at the same speed as the engine crankshaft. Together with hydraulic control, the PCM optimizes the timing ofthe lock-up mechanism. When the torque converter clutch solenoid valve activates, modulator pressure changes to switch lock-up on and off. The lock-up control valve and the lock-up timing valve control the range of lock-up according to AfT clutch pressure control solenoid valves A and B. The torque converter clutch solenoid valve is mounted on the torque converter housing, and AfT clutch pressure control solenoid valves A and B are mounted on the transmission housing. They are all controlled by the PCM.

14-18

BACK

Gear Selection

The shift lever has seven positions: [f] PARK, [HJ REVERSE, [NJ NEUTRAL, ~ 1st through 4th gear ranges, ~ 1st through 3rd gear ranges, [II 2nd gear, and [j] 1st gear.

Description

Position

[f] PARK

Front wheels locked; park pawl engaged with park gear on countershaft. All clutches released.

[HJ REVERSE

Reverse; reverse selector engaged with countershaft reverse gear and 4th clutch locked.

[NJ NEUTRAL

All clutches released.

~DRIVE

General driving; starts off in 1st, shifts automatically to 2nd, 3rd, then 4th, depending on vehicle speed and throttle position. Downshift through 3rd, 2nd, and 1st on deceleration to stop. The lock-up mechanism operates in 3rd and 4th gears.

(1stthrough 4th)

~DRIVE

(1st through 3rd)

Used for rapid acceleration at highway speeds and general driving; up-hill and down-hill driving; starts off in 1st, shifts automatically to 2nd, then 3rd, depending on vehicle speed and throttle position. Downshifts through 2nd to 1st on deceleration to stop. The lock-up mechanism operates in 3rd gear.

[II SECOND

Used for engine braking or better traction starting off on loose or slippery surfaces; stays in 2nd gear; does not shift up or down.

[I] FIRST

Used for engine braking; stays in 1st gear; does not shift up.

Starting is possible only in [f] and [NJ positions through the use of a slide-type, neutral-safety switch. Automatic Transaxle (AfT) Gear Position Indicator The AIT gear position indicator in the instrument panel shows which gear has been selected without having to look down at the console.

(cont'd)

BACK

14-19

Automatic Transmission System Description (cont'd) Clutches The four-speed automatic transmission uses hydraulically-actuated clutches to engage or disengage the transmission gears. When hydraulic pressure is introduced into the clutch drum, the clutch piston moves. This presses the friction discs and steel plates together, locking them so they don't slip. Power is then transmitted through the engaged clutch pack to its hub-mounted gear. Likewise, when the hydraulic pressure is bled from the clutch pack, the piston releases the friction discs and the steel plates, and they are free to slide past each other. This allows the gear to spin independently on its shaft, transmitting no power. 1st Clutch The 1st clutch engages/disengages 1st gear, and is located at the middle ofthe secondary shaft. The 1st clutch is joined back-to-back to the 2nd clutch. The 1st clutch is supplied hydraulic pressure by its ATF feed pipe within the secondary shaft. 2nd Clutch The 2nd clutch engages/disengages 2nd gear, and is located at the middle of the secondary shaft. The 2nd clutch is joined back-to-back to the 1st clutch. The 2nd clutch is supplied hydraulic pressure through the secondary shaft by a circuit connected to the internal hydraulic circuit. 3rdClutch The 3rd clutch engages/disengages 3rd gear, and is located at the middle of the mainshaft. The 3rd clutch is joined back-to-back to the 4th clutch. The 3rd clutch is supplied hydraulic pressure by its ATF feed pipe within the mainshaft. 4th Clutch The 4th clutch engages/disengages 4th gear, as well as reverse gear, and is located at the middle of the mainshaft. The 4th clutch is joined back-to-back to the 3rd clutch. The 4th clutch is supplied hydraulic pressure by its ATF feed pipe within the mainshaft.

14-20

BACK

Transmission Sectional View

PITOT FLANGE ('00-02 models)

MAINSHAFT 4TH GEAR

4TH CLUTCH

LUBRICATION PITOTPIPE ('00-02 models)

ATF PUMP DRIVEN GEAR

TORQUE CONVERTER

LOCK-UP CLUTCH PISTON

COUNTERSHAFT 2ND GEAR

~---

COUNTERSHAFT

COUNTERSHAFT IDLER GEAR

111 .....- - - _ DRIVE PLATE

FINAL DRIVE GEAR REVERSE SELECTOR NTERSHAFT 3RDGEAR

COUNTERSHAFT 1ST GEAR

2ND CLUTCH

FINAL DRIVEN GEAR


(cont'd)

BACK

14-21

Automatic Transmission System Description (cont'd) Power Flow POSITION TORQUE CONVERTER

1ST GEAR 1ST CLUTCH

2ND GEAR 2ND CLUTCH

PART 3RDGEAR 3RD CLUTCH

0 0 0 0 0 0 0 0 0 0 0 0

x x x 0 x x x 0 x x x 0

x x x x 0 x x x 0 x 0 x

x x x x x 0 x x x 0 x x

(f] [RJ

IHl ~

~

1ST 2ND 3RD 4TH 1ST 2ND 3RD

II] [I] O:Operates X :Doesn't operate

GEAR

4TH CLUTCH

x x x x x x 0 x x x x x

x 0 x x x x 0 x x x x x

REVERSE GEAR

PARK GEAR

x 0 x x x x x x x x x x

0 x x x x x x x x x x x

Gear Operation Gears on the mainshaft: • • • •

The 3rd gear is engaged/disengaged with the mainshaft by the 3rd clutch. The 4th gear is engaged/disengaged with the mainshaft by the 4th clutch. The reverse gear is engaged/disengaged with the mainshaft by the 4th clutch. The idler gear is splined with the mainshaft and rotates with the mainshaft.

Gears on the countershaft • The final drive gear is integral with the countershaft. • The 1st gear, 3rd gear, 2nd gear, and park gear are splined with the countershaft and rotate with the countershaft. • The 4th gear and reverse gear rotate freely from the countershaft. The reverse selector engages the 4th gear or the reverse gear with the reverse selector hub. The reverse selector hub is splined with the countershaft so that the 4th gear or reverse gear engage with the countershaft. • The idler gear rotates freely from the countershaft. Gears on the secondary shaft • The 1st gear is engaged/disengaged with the secondary shaft by the 1st clutch. • The 2nd gear is engaged/disengaged with the secondary shaft by the 2nd clutch. • The idler gear is splined with the secondary shaft and rotates with the secondary shaft.

14-22

BACK

[f] Position Hydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft. The countershaft is locked by the park pawl interlocking the park gear. [N] Position Engine power transmitted from the torque converter drives the mainshaft idler gear, the countershaft idler gear, and the secondary shaft idler gear, but hydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft. The countershaft 4th gear is engaged with the reverse selector hub and the countershaft by the reverse selector, when the shift lever is shifted in [N] position from ~ position. The countershaft reverse gear is engaged when shifted from [RJ position.

TORQUE CONVERTER

~

MAINS HAFT IDLER GEAR

M~~

F=1J---'------=-----'

/

COUNTERSHAFT

~

SECONDARY SHAFT

/

SECONDARY SHAFT

IDLER GEAR

(cont'd)

BACK

14-23

Automatic Transmission System Description (cont'd) Power Flow (cont'd) In ~ or ~ position, the optimum gear is automatically selected from the 1st, 2nd, 3rd and 4th gears, according to conditions such as the balance between the throttle opening (engine loading) and vehicle speed. ~ or ~ Position in 1st gear and II] Position

• Hydraulic pressure is applied to the 1st clutch, then the 1st clutch engages the secondary shaft 1st gear with the secondary shaft. • The mainshaft idler gear drives the secondary shaft via the countershaft idler gear and secondary shaft idler gear. • The secondary shaft 1st gear drives the countershaft 1st gear and the countershaft. • Power is transmitted to the final drive gear, which in turn drives the final driven gear.

COUNTERSHAFT

1ST GEAR

MAINSHAFT

~ COUNTERSHAFT

~ COUNTERSHAFT

IDLER GEAR

SECONDARY SHAFT

1ST CLUTCH

IDLER GEAR FINAL DRIVEN GEAR

14-24

BACK

~ or ~ Position in 2nd gear and [g] Position o

o o o

Hydraulic pressure is applied to the 2nd clutch, then the 2nd clutch engages the secondary shaft 2nd gear with the secondary shaft. The mainshaft idler gear drives the secondary shaft via the countershaft idler gear and secondary shaft idler gear. The secondary shaft 2nd gear drives the countershaft 2nd gear and the countershaft. Power is transmitted to the final drive gear, which in turn drives the final driven gear.

MAINS HAFT IDLER GEAR

MAINSHAFT

~ COUNTERSHAFT

~

SECONDARY SHAFT

SECONDARY SHAFT

IDLER GEAR

~ FINAL DRIVEN GEAR (cont'd)

BACK

14-25

Automatic Transmission System Description (cont'd) Power Flow (cont'd) ~ or ~ Position in 3rd gear

• Hydraulic pressure is applied to the 3rd clutch, then the 3rd clutch engages the mainshaft 3rd gear with the mainshaft. • The mainshaft 3rd gear drives the countershaft 3rd gear and the countershaft. • Power is transmitted to the final drive gear, which in turn drives the final driven gear. TORQUE CONVERTER MAINSHAFT

3RD CLUTCH

3~G~R

\

,...--,"'i:t.r.r.'i"I

/

MAINSHAFT

~ COUNTERSHAFT

~

/

SECONDARY SHAFT

FINAL DRIVEN GEAR

14-26

BACK

~ Position in 4th gear

• Hydraulic pressure is applied to the servo valve to engage the reverse selector with the countershaft 4th gear while the shift lever is in the forward range (~, ~, 00 and [II position). • Hydraulic pressure is also applied to the 4th clutch, then the 4th clutch engages the mainshaft 4th gear with the mainshaft. • The mainshaft 4th gear drives the countershaft 4th gear, which drives the reverse selector hub and the countershaft. • Power is transmitted to the final drive gear, which in turn drives the final driven gear. TORQUE CONVERTER MAINSHAFT 4TH GEAR

4TH CLUTCH

/

MAINSHAFT

--------COU~

FINAL DRIVE GEAR

- - - - - - FINAL DRIVEN GEAR

(cont'd)

BACK

14-27

Automatic Transmission System Description (cont'd) Power Flow (cont'd) [RJ Position • Hydraulic pressure is applied to the servo valve to engage the reverse selector with the countershaft (reverse gear while the shift lever is in the [RJ position). • Hydraulic pressure is also applied to the 4th clutch, then the 4th clutch engages the mainshaft reverse gear with the mainshaft. • The mainshaft reverse gear drives the countershaft reverse gear via the reverse idler gear. • The rotation direction of the countershaft reverse gear is changed via the reverse idler gear. • The countershaft reverse gear drives the countershaft via the reverse selector which drives the reverse selector hub. • Power is transmitted to the final drive gear, which in turn drives the final driven gear. TORQUE CONVERTER

4TH CLUTCH

/ SERVO VALVE

~

REVERSE SELECTOR

~ REVERSE IDLER GEAR FINAL DRIVEN GEAR

14-28

BACK

Electronic Control System Functional Diagram The electronic control system consists ofthe Powertrain Control Model (PCM), sensors, and six solenoid valves. Shifting and lock-up are electronically controlled for comfortable driving under all conditions. The PCM is located below the dashboard, under the front lower panel behind the center console. PCM

Throttle Position Sensor Signal

1-+-----11

1 1

Data Link Connector

PGM-FI Control System

'1-__

-+1

Engine Coolant Temperature Sensor Signal ,

AfT Control System

-

INTERLOCK CONTROL UNIT

1+1----1:

Shift Solenoid Valve A

1

Shift Solenoid Valve B

lJ:-l LJI--~l~--lH

I

1

1-+-1----...,1

8-J

1

Shift Control

1+1---.--1

1

D4

,

1+1--.----7-1,

I I

Shift Solenoid Valve C

Automatic Transaxle Clutch Pressure Control Solenoid Valve A

I

Automatic Transaxle Clutch Pressure Control Solenoid ValveB

D3 1


1

2

~

Lock-up Control

rl U

Self-Diagnosis Signal I

I-+-I----...,Jl

Torque Converter Clutch Solenoid Valve

-1',

Mainshaft Speed Sensor Signal

~ Indicator

'------------'

r------...,

If-----il+i 1

'-----------'

3rd Clutch Pressure IL--Sw_itc_h_ _ _----'

1

/

Self-Diagnosis Function

L _ _ _ _ _- - '

I I

1-+_ _

I I

'-------------'

-1'

1-+_ _

,

Countershaft Speed Sensor Signal

JI (cont'd)

BACK

14-29

Automatic Transmission System Description (cont'd) Electronic Control System (cont'd) Electronic Controls Location KEY INTERLOCK SOLENOID

\ 1 n

EflU


POWERTRAIN CONTROL MODULE IPCMI

PARKING PIN SWITCH

SHIFT LOCK SOLENOID 2ND CLUTCH PRESSURE SWITCH

A!T CLUTCH PRESSURE CONTROL SOLENOID VALVES A and B

MAINS HAFT SPEED SENSOR

TORQUE CONVERTER CLUTCH SOLENOID VALVE! SHIFT SOLENOID VALVE A

TRANSMISSION RANGE SWITCH 3RD CLUTCH PRESSURE SWITCH SHIFT SOLENOID VALVE C

14-30

BACK

Shift Control Shifting is related to engine torque through the solenoid valves, which are controlled by the PCM. The PCM instantly determines which gear should be selected by various signals sent from sensors, and actuates the shift solenoid valves A, B, and C to control shifting. Also, a Grade Logic Control System to controls shifting in ~ and ~ positions while the vehicle is ascending or descending a slope, or reducing speed. The combination of driving signals to shift solenoid valves A, B, and C is shown in the table below.

Position

Gear position

~,~

Shifting from [f!] position Stays in 1st Shifting gears between 1st and 2nd Stays in 2nd Shifting gears between 2nd and 3rd Stays in 3rd Shifting gears between 3rd and 4th ~ Stays in 4th [I] 2nd [II 1st [ID Shifting from [f] and [f!] position Stays in reverse Reverse inhibit [f] Park [f!] Neutral NOTE: For a description ofthe reverse Inhibit mode, refer to page 14-56.

A ON OFF ON ON ON ON OFF OFF ON OFF OFF OFF OFF OFF OFF

Shift solenoid valves B ON ON ON ON OFF OFF OFF OFF ON ON ON ON ON ON ON

C ON ON ON OFF OFF ON ON OFF OFF ON ON OFF ON OFF OFF

Lock-up Control The torque converter clutch solenoid valve controls modulator pressure to switch the lock-up shift valve and lock-up ON and OFF. The PCM controls the torque converter clutch solenoid valve and the AfT clutch pressure control solenoid valves A and B. When the torque converter clutch solenoid valve is turned ON, the condition of lock-up starts. The AfT clutch pressure control solenoid valves A and B regulate AfT clutch pressure control solenoid pressure, and apply the pressure to the lock-up control valve and the lock-up timing valve. The lock-up control mechanism operates in 3rd, and 4th gear in ~ and in 3rd gear in ~ positions.

(cont'd)

BACK

14-31

Automatic Transmission System Description (cont'd) Electronic Control System (cont'd) Grade Logic Control System How it works: The PCM compares actual driving conditions with memorized driving conditions, based on the input from the countershaft speed sensor, the throttle position sensor, the engine coolant temperature sensor, the brake pedal position switch signal, and the shift level position signal, to control shifting while the vehicle is ascending or descending a slope, or reducing speed.

SIGNALS DETECTED

SENSORS/SWITCHES

PCM

H

-

Countershaft Speed \ Sensor

1/1

I:

H

0

-Throttle Position Sensor

!!

\-

Driving Resistance

e-

Judgement of Controlling Area

--

I

I

Calculation of actual acceleration

Detection of standard acceleration (in Memory)

I

I

"CI

I:

0

CJ a! I:

:~

Q

H H

i---

Engine Coolant Temperature Sensor

Transmission Range Switch

Coolant Temperature

~ or ~ Position

~

r-

Calculation of gradient

I

I

I

Calculation of deceleration

I

I

Selection of Shifting Mode • Normal Mode (Flat road mode) • Ascending Mode • Fuzzy Logic • Descending Mode • Gradual Descendin~ Mode • Steep Descending ode • Deceleration Mode

I

I Automatic 4 Speeds

14-32

BACK

Ascending Control

When the PCM determines that the vehicle is climbing a hill in ~ and ~ positions, the system extends the engagement area of 2nd gear and 3rd gear to prevent the transmission from 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 schedules stored in the PCM between 2nd and 3rd gears, and between 3rd and 4th gears, enable the PCM's fuzzy logic to automatically select the most suitable gear according to the magnitude of a gradient. • Fuzzy logic is a form of artificial intelligence that lets computers respond to changing conditions much like a human mind would. 100%

'c'" II c

ASCENDING MODE: Upshift Schedule

gIl

~

- - : FLAT ROAD MODE • - - - - _. : GRADUAL ASCENDING MODE _ .. _ .. - : STEEP ASCENDING MODE

~

_

: 3RD·4TH SHIFTING CHARACTERISTICS CONTROL AREA

o L......J'--L_ _ 62 mph (100 km/h,

Vehicle speed

Descending Control

When the PCM determines that the vehicle is going down a hill in ~ and ~ positions, the shift-up speed from 3rd to 4th gear and from 2nd to 3rd (when the throttle is closed) becomes faster than the set speed for flat road driving to widen the 3rd gear and 2nd gear driving areas. This, in combination with engine braking from the deceleration lock-up, achieves smooth driving when the vehicle is descending. There are two descending modes with different 3rd gear driving areas and 2nd gear driving areas according to the magnitude of a gradient stored in the PCM. When the vehicle is in 4th gear, and you are decelerating when you are applying the brakes on a steep hill, the transmission will downshift to 3rd gear. When you accelerate, the transmission will then return to higher gear. 100%

'c'" II c

CI. 0

~

DESCENDING MODE: Downshift Schedule 50 - - : FLAT ROAD MODE

2

• - - - - - - : GRADUAL DESCENDING MODE

~

- .. - .. -

: STEEP DESCENDING MODE

0 62 mph (100km/h,

Vehicle speed

Deceleration Control

When the vehicle goes around a corner and needs to decelerate first and then accelerate, the PCM sets the data for deceleration control to reduce the number of times the transmission shifts. When the vehicle is decelerating from speeds above 27 mph (43 km/h), the PCM shifts the transmission from 4th to 2nd earlier than normal to cope with upcoming acceleration.

(cont'd)

BACK

14-33

Automatic Transmission System Description (cont'd) Electronic Control System (cont'd) PCM Electrical Connections Electronic Control System (cont'd) PCM Electrical Connections

+

PGM·FI MAIN RELAY

IGNITION SWITCH IGI

ATTERY

-V--J'

~~

PCM

-

B2

~ BI

-

-v

~ B21

l

C28 C27 18


I

ENGINE COOLANT TEMPERATURE SENSOR

I

DATAUNK CONNECTOR

I--

I-

C26

AID

PGI PG2

IGPI IGP2 VBU

LSA LSB+

LSB

? ?

VCC2 TPS SG2

ECT

LSA+

I I I I I I I I I I I

SHA

BRAKE UGH;

--=-----..J B20

1

*

GAUGE ASSEMBLY

B22

I

I

AUTOMATIC TRANSAXLE CONTROL SYSTEM

6

Ir

~

SHB

02

~

SHIFT SOLENOID J-VALVEB

03

~

SHIFT SOLENOID J-VALVEC

LC

LGI

01

~

TORQUE CONVERTER CLUTCH SOLENOID J-VALVE

LG2 05

I

VB SOL NM

NC

®00

NCSG ILU

os

011

_~ '"'-' MAINSHAFT SPEED SENSOR

VSSOUT

NMSG

R

07

STOPSW

A9

I

P

B18

I

PGM·FI CONTROL SYSTEM

Aff GEAR POSITION INDICATOR


Aff CLUTCH PRESSUR CONTROL SOLENOID VALVE B

SCS

IGNITION SWITCH IGI

~~0

B25

SHIFT SOLENOID J-VALVEA

SHC A32

Aff CLUTCH PRESSUR CONTROL SOLENOID VALVE A

B8

I

BRAKE PEDAL POSITION SWITCH +B --------0

B17

012 010

~ '"'-'

II MULTIPLEX CONTROL UNIT (DRIVER'S)

A28

ATPR

09

0,

08

2

014

I

015

g:~f:~!

ATPD.

OP2SW

1

@I

AI.

B14

ATPD, ATP2

AlP1 OP3SW

g~~I:~~~!


NP

CRS D. INDICATOR

I


N D.


016

D41ND

ATSFTP

A5

II

CRUISE CONTROL UNIT

Al1

I I

BSUUNIT

I I

(01 model)

PCM Connactor Terminal Locations

A (32P)

14-34

B(25P)

C(31P)

BACK

o(16P)

PCM Inputs and Outputs The PCM terminal voltage and measuring conditions are shown for the connector terminals related to the AfT control system. The other PCM terminal voltage and measuring conditions are described in section 11.


~

-r--

V

345 6 7 8"1 5 6 891OVI12 V/2 3 4 1415 16 17 18 1920 21/ 23 24J 9 10 1112 13 1415 17 18J ~ 112113 2526 27

2829 30

V

32

'---

A (32P)

L20

'--'---

/

2122

-'--

23 24 25

2V / 567 8 9 10 / kt" / 1/ 16 17 1819 20 21/ VV 25 26 27 28 29 30 /

C (31P)

B (25P)

r-

f5l

1 2 3/ 6 7 8 9 10 111121

13 1415

16

'--

D (16P)

PCM CONNECTOR A (32P) Terminal Number A5

Wire

Signal

Description

BLU/GRN

CRS

A9

BLU/WHT

VSSOUT

A10

BRN

SCS

Downshift signal input from cruise control unit Vehicle speed signal detected from countershaft speed sensor Timing and adjustment service check signal

A14

GRN/BLK

D41ND

A28

WHT/RED

ILU

A32

WHT/BLK

BKSW

D4 indicator light control

Interlock control

Brake pedal position switch signal output

Measuring Conditions/Terminal Voltage When cruise control is used: Pulsing signal Depending on vehicle speed: Pulsing signal

With ignition switch ON (II) and data link connector open: 5 V With ignition switch ON (II) and data link connector connected with Honda PGM tester: 0 V When ignition switch is first turned ON (II): Battery voltage for two seconds In ~ position: Battery voltage When ignition switch ON (II), brake pedal pressed, and accelerator pedal released: Battery voltage Brake pedal pressed: Battery voltage Brake pedal released: 0 V

(cont'd)

BACK

14-35



~

-;--

alll 2VV

3 4 345 5 6 m 8 9 10 11111 1 2 6 7 112113 14 1516 17 1819 20 21f2.2 23 241 9 10 1112 13 1415 17 181V 25 26 27 2E 29 30 (31 32 2122 23 24 25 /

Iml2

'--

A (32P)

L20

'--'--

V

VVVV

'--'--

V 25

C(31P)

B(25P)

r--

Isl

567 8 9 10 1 23/ 16 17 18 19 20 6 7 8 9 10 111121 26 27 28 2930 l( 1314 15 16

21V

--

D(16P)

PCM CONNECTOR B (25P) Terminal Number B1

Wire

Signal

Description

VEL/BlK

IGP1

B2 B8

BlK WHT

PG1 lSA-

B9

VEL/BlK

IGP2

B10 B14 ('98-99) B14 ('00-02)

BlK BlU/BlK

PG2 OP2SW

BlU/BlK

ATPNP

Power supply circuit from main relay Ground AfT clutch pressure control solenoid valve A power supply negative electrode Power supply circuit from main relay Ground AfT 2nd clutch pressure switch signal input Transmission range switch [f] and IHI positions input

B17

RED

lSA+

B18

GRN

lSB-

B20 B21 B22

BRN/BlK WHT/YEl BlK ('98-99) BRN/BlK ('00-02) BlU/WHT

lG1 VBU lG2

B24 B25

14-36

ORN

OP3SW lSB+

AfT clutch pressure control solenoid valve A power suppl'[Qositive electrode AfT clutch pressure control solenoid valve B power supply negative electrode Ground Back-up power supply Ground

AfT 3rd clutch pressure switch signal input AfT clutch pressure control solenoid valve B power supply positive electrode

BACK

Measuring Conditions/Terminal Voltage With ignition switch ON (II): Battery voltage With ignition switch OFF: 0 V

With ignition switch ON (II): Battery voltage With ignition switch OFF: 0 V With ignition switch ON (II): Battery voltage (No 2nd clutch pressure) In [f] and IHI positions: 0 V In other than [f] and IHI position: Battery voltage With ignition switch ON (II): Pulsing signal

Always battery voltage

With ignition switch ON (II): Battery voltage (No 3rd clutch pressure) With ignition switch ON (II): Pulsing signal

PCM CONNECTOR D (16P) Terminal Number

Wire

Signal

Description

01

VEL

LC

02

GRN/WHT

SHB

Torque converter clutch solenoid valve control Shift solenoid valve B control

03

GRN

SHC

Shift solenoid valve C control

04 05

--

--

BLK/YEL

VBSOL

06

WHT

ATPR

07

BLU/YEL

SHA

Not used Power supply for solenoid valves (Fuse No.6 in driver's under-dash fuse/relay box) Transmission range switch [R] position input Shift solenoid valve A control

Measuring Conditions/Terminal Voltage

During lock-up conditions: Battery voltage During no lock-up condition: 0 V Battery voltage in following positions: • ill, [!] positions. • ~, and ~ positions in 1st and 2nd gear • ~, IBJ, and [f!) positions oV in following positions: • ~, and ~ positions in 3rd gear • ~ position in 4th gear Battery voltage in following positions: • ill position • ~, and ~ positions in 1st and 3rd gear oV in following positions: • [!] position • ~, and ~ positions in 2nd gear • ~ position in 4th gear • ~, IBJ, and [f!) positions With ignition switch ON (II): Battery voltage With ignition switch OFF: 0 V In [R] position: 0 V In other than [R] position: Battery voltage Battery voltage in following positions: • [!] position • ~, and ~ positions in 2nd and 3rd gear oV in following positions: • ill position • ~, and ~ positions in 1st gear • ~ position in 4th gear • ~, IBJ, and [f!) positions

(cont'd)

BACK

14-37



,(

-;--

2'1V VV /

5 6 m 8 9 10 <1111 1 2 345 6 7 811 1 1(1) 234 ~2 13 14 1516 17 18 19 20 21i22 23 241 9 10 1112 13 1415 17 181V I 25 26 27 2829 30(3 32 2122 23 24 25 I "'""-

A (32P)

L20 '--"'""-

V

'--'--

'I 25

C(31P)

B(25P)

~

23'1 f5l

567 8 9 10 1 16 17 1819 20 6 7 8 9 10111121 26 27 28 2930'I 13 14 15 16

21V

-

D(16P)


Wire

Signal

Description

PNK

ATPD3

D9

VEL

ATPD4

D10

BLU

NC

D11

RED

NM

Transmission range switch ~ position input Transmission range switch ~ _position inJ!ut Countershaft speed sensor input Mainshaft speed sensor input

D12

WHT

NMSG

D13 ('98-99)

BLU/WHT

ATPNP

D13 ('00-02) D14

BLU/BLK

OP2SW

BLU

ATP2

D15

BRN

ATP1

D16

GRN

NCSG

Mainshaft speed sensor ground Transmission range switch ~ and IN] positions input

AfT 2nd clutch pressure switch signal input Transmission range switch 00 position input Transmission range switch [II position input Countershaft speed sensor ~ound

14-38

BACK

Measuring Conditions/Terminal Voltage In ~ position: 0 V In other than ~ position: Battery voltage In ~ position: 0 V In other than ~ p_osition: Battery voltage Depending on vehicle speed: Pulsing signal When vehicle is stopped: Approx. 0 V Depending on vehicle speed: Pulsing signal When engine is stopped: Approx. 0 V

In ~ and IN] positions: 0 V In other than ~ and IN] position: Battery voltage With ignition switch ON (II): Battery voltage (No 2nd clutch pressure) In 00 position: 0 V In other than 00 position: Battery voltage In [II position: 0 V In other than [II position: Battery voltage

Hydraulic Controls The valve body includes the main valve body, the regulator valve body, the servo body and the accumulator body. The ATF pump is driven by splines on the left end of the torque converter which is attached to the engine. Fluid flows through the regulator valve to maintain specified pressure through the main valve body to the manual valve directing pressure to each of the clutches. The shift solenoid valves Band C are mounted on the outside of the torque converter housing. The shift solenoid valve A and the torque converter clutch solenoid valve are mounted on the torque converter housing as an assembly. The AfT clutch pressure control solenoid valves A and B are mounted on the transmission housing. ~3RDCLUTCH

~.............-

mtf

PRESSURE SWITCH

~A/T

CLUTCH PRESSURE CONTROL SOLENOID VALVES A and B

SERVO BODY

~

TORQUE CONVERTER CLUTCH SOLENOID VALVE/ SHIFT SOLENOID VALVE A 2ND CLUTCH PRESSURE SWITCH

ACCUMULATOR BODY

(cont'd)

BACK

14-39

Automatic Transmission System Description (cont'd) Hydraulic Controls (cont'd) Main Valve Body

The main valve body contains the manual valve, the modulator valve, the shift valve C, the shift valve D, the shift valve E, the servo control valve, the cooler check valve, the torque converter check valve, the reverse CPC valve, the lock-up shift valve, the relief valve, and the ATF pump gears. The primary function of the main valve body are to switch fluid pressure on and off and to control hydraulic pressure going to the hydraulic control system. MODULATOR VALVE

SHIFT VALVE D

SHIFT VALVE E

SHIFTVALVEC

RELIEF VALVE

LOCK-UP SHIFT VALVE

COOLER CHECK VALVE SERVO CONTROL VALVE

TORQUE CONVERTER CHECK VALVE

Regulator Valve Body

The regulator valve body is located on the main valve body. The regulator valve body contains the regulator valve, the lock-up timing valve and the lock-up control valve.

REGULATOR VALVE

LOCK-UP CONTROL VALVE

LOCK-UP TIMING VALVE

14-40

BACK

Regulator Valve The regulator valve maintains constant hydraulic pressure from the ATF pump to the hydraulic control system, while also furnishing fluid to the lubricating system and torque converter. Fluid from the ATF pump flows through Band B'. Fluid entering from B flows through the valve orifice to the A cavity. This pressure of the A cavity pushes the regulator valve to the right side, and this movement of the regulator valve uncovers the fluid port to the torque converter and the relief valve. The fluid flows out to the torque converter and the relief valve, and the regulator valve moves to the left side. According to the level of the hydraulic pressure through B, the position of the regulator valve changes, and the amount of fluid from B' through torque converter changes. This operation is continued, maintaining the line pressure.

NOTE: When used, "left" or "right" indicates direction on the illustration below. From ATF PUMP

jt

To LUBRICATION

REGULATOR VALVE

Increases in hydraulic pressure according to torque are performed by the regulator valve using stator torque reaction. The stator shaft is splined to the stator in the torque converter, and its arm end contacts the regulator spring cap. When the vehicle is accelerating or climbing (Torque Converter Range), stator torque reaction acts on the stator shaft, and the stator arm pushes the regulator spring cap in the direction ofthe arrow in proportion to the reaction. The stator reaction spring compresses, and the regulator valve moves to increase the line pressure which is regulated by the regulator valve. The line pressure reaches its maximum when the stator torque reaction reaches its maximum. REGULATOR VALVE BODY STATOR

REGULATOR VAL

TORQUE CONVERTER STATOR SHAFT ARM

(cont'd)

BACK

14-41

Automatic Transmission System Description (cont'd) Hydraulic Controls (cont'd) Servo Body The servo body is on the main valve body. It contains the servo valve, shift valve A, shift valve B, CPC valves A and B, and the 3rd and 4th accumulators.

SHIFT VALVE A

SHIFT VALVE B

ACCUMULATOR PISTON

Accumulator Body The accumulator body is on the torque converter housing, next to the main valve body. It contains the 1st and 2nd accumulators and the lubrication check valve.

LUBRICATION CHECK VALVE

2ND ACCUMULATOR PISTON

1ST ACCUMULATOR PISTON

ACCUMULATOR BODY

14-42

BACK

Hydraulic Flow Distribution of Hydraulic Pressure

As the engine turns, the ATF pump starts to operate. Automatic transmission fluid (ATF) is drawn through the ATF strainer (filter) and discharged into the hydraulic circuit. Then, ATF flowing from the ATF pump becomes line pressure that's regulated by the regulator valve. Torque converter pressure from the regulator valve enters the torque converter through the lock-up shift valve and it is discharged from the torque converter. The torque converter check valve prevents torque converter pressure from rising. The PCM controls the shift solenoid valves ON and OFF, and the shift solenoid valves control shift solenoid pressure to the shift valves. Applying shift solenoid pressure to the shift valves moves the position of the shift valve, and switches the port of hydraulic pressure. The PCM also controls AfT clutch pressure control solenoid valves A and B. The AfT clutch pressure control solenoid valves regulated the AfT clutch pressure control solenoid pressure and apply the AfT clutch pressure control solenoid pressure to CPC valves A and B. When shifting between upper gear and lower gear, the clutch is engaged by pressure from the CPC pressure mode. The PCM controls one of the shift solenoid valves to move the position of the shift valve. This movement switches the port of the CPC and line pressure. Line pressure is then applied to the clutch, and the CPC pressure is intercepted. Engaging the clutch with line pressure happens when shifting is completed. Hydraulic pressure atthe parts is as follows: PORT NO. 1 3 3' 3" 4 4' 4" 4A 4B 5A 5D 5B 5E 5F 5F' 5C 5G

DESCRIPTION OF PRESSURE LINE LINE LINE LINE LINE LINE LINE CPCA CPCB CPCA CPCB CPCAor LINE CPCAor LINE CPCAor LINE CPCAor LINE CPC B or LINE CPC B or LINE

PORT NO. 5H 5J 5K 5K' 6 SA SB SC LA 9 10 20 25 30 40 41 56

DESCRIPTION OF PRESSURE CPC B or LINE CPC B or LINE CPC B or LINE CPC B or LINE MODULATE SHA SH B SHC LC LINE 1ST CLUTCH 2ND CLUTCH LINE 3RDCLUTCH 4TH CLUTCH 4TH CLUTCH LSA

PORT NO. 57 58 90 90' 91 91' 92 93 94 95 95' 96 97 99 X HX AX

DESCRIPTION OF PRESSURE LS B LS Aor LS B TORQUE CONVERTER TORQUE CONVERTER TORQUE CONVERTER TORQUE CONVERTER TORQUE CONVERTER ATF COOLER TORQUE CONVERTER LUBRICATION LUBRICATION TORQUE CONVERTER TORQUE CONVERTER SUCTION DRAIN HIGH POSITION DRAIN AIR DRAIN

NOTE: • CPC: Clutch Pressure Control pressure • SH: Shift Solenoid pressure • LS: AfT Clutch Pressure Control Solenoid pressure • LC: Torque Converter Clutch Solenoid pressure

(cont'd)

BACK

14-43


!Nl Position The PCM controls the shift solenoid valves. The conditions of the shift solenoid valve and positions of the shift valve are as follows: • The shift solenoid valve A is turned OFF, and the shift valve A is moved to the left side. • The shift solenoid valve B is turned ON, and the shift valve B remains in the right side. • The shift solenoid valve C is turned OFF, and the shift valve C remains in the left side. Line pressure (1) passes through the manual valve and stops at shift valve D. Line pressure (1) also flows to the modulator valve, and becomes modulator pressure (6). Modulator pressure (6) flows to the shift solenoid valves and the NT clutch pressure control solenoid valves. Under this condition, hydraulic pressure is not applied to the clutches. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

14-44

BACK

r ~ Position; 1st gear shifting from

IHI position

The PCM turns the shift solenoid valves A and C ON when shifting to ~ position from IHI. Shift solenoid valve B remains ON. Shift solenoid valve C is turned ON, and SH C pressure (SC) in the right side of the shift valve Cis released, then the shift valve C is moved to the right side. Shift solenoid valve A is turned ON, and SH A pressure (SA) in the left side of the shift valve A is released, then shift valve A is moved to the right side. The AfT clutch pressure control solenoid valve A regulates LS A pressure (56) and applies it to CPC valve A. Line pressure (1) becomes line pressure (4) at the manual valve, and flows to shift valve C and CPC valve A. Line pressure (4) becomes CPC A pressure (4A) and passes through shift valve C, A, and B, then CPC A pressure (4A) becomes 1st clutch pressure (10) at shift valve B. 1st clutch pressure (10) is applied to the 1st clutch, then the 1st clutch is engaged with pressure of the CPC pressure mode. Line pressure (4) passes through shift valve A and B, then stops at shift valve B. NOTE: • When used, "Ieft" or "right" indicates direction on the hydraulic circuit . • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

AlT ClUtcH MESSUM CONTIIOL SDUNOID VALVE.

ATlCOO&.U ' - - - - - - '

(cont'd)

BACK

14-45

Automatic Transmission System Description (cont'd) Hydraulic Flow (cont'd) ~ Position: Driving in 1st gear

The PCM turns shift solenoid valve A OFF, but shift solenoid valves Band C remain ON. SH A pressure (SA) is applied to the left side of shift valve A, then shift valve A is moved to the left side. This movement switches the port of line pressure and CPC pressure on shift valve A. The 1st clutch pressure is changed to line pressure mode, and the 1st clutch is engaged securely. CPC A pressure (5E) stops at shift valve B. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar. 'NO

Ancoou" ' -_ _ _J

14-46

BACK

~ Position: Shifting between 1st gear and 2nd gear

As the speed of the vehicle reaches the prescribed value, the PCM turns shift solenoid valve A OFF. Shift solenoid valves 8 and C remain ON. Then shift solenoid valve A is turned ON, and SH A pressure (SA) in the left side of the shift valve A is released. Shift valve A is moved to the right side to switch the port of line pressure and CPC pressure. The PCM also controls the AfT clutch pressure control solenoid valves. The AfT clutch pressure control solenoid valves A and 8 apply their pressure to the CPC valves A and 8. Line pressure (4) becomes CPC 8 pressure (48) at the CPC valve 8, and CPC 8 pressure passes through shift valves C, 8, and A, to become 2nd clutch pressure. The 1st and 2nd clutches are engaged with the CPC pressure mode. NOTE: • When used, "Ieft" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar. '00

AlT ClUTC" ","HUM. CONTaOL SOLENOID

(cont'd)

BACK

14-47

Automatic Transmission System Description (cont'd) Hydraulic Flow (cont'd) ~ Position: Driving in 2nd gear

The PCM turns shift solenoid valve C OFF, and controls AfT clutch pressure control solenoid valve A to release LS A pressure (56). Shift solenoid valves A and B remain ON. Releasing LS A pressure in the CPC valve A releases CPC A pressure in the 1st clutch pressure circuit. Shift solenoid valve C is turnd OFF, and SH C pressure (SC) is applied to the right side of shift valve C. Then shift valve C is moved to the left side to switch the port of line pressure and CPC pressure. The 2nd clutch pressure is changed to line pressure mode, and the 2nd clutch is engaged securely. The CPC B pressure (50) stops at shift valve B. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit . • Hydraulic circuit shows the '98-99 models; the '00·02 models are similar.

14-48

BACK

~ Position: Shifting between 2nd gear and 3rd gear

As the speed of the vehicle reaches the prescribed value, the PCM turns shift solenoid valve B OFF. The PCM also control AfT clutch pressure control solenoid valve A to apply LS A pressure (56) to CPC valve A. Shift solenoid valve A remains ON, and C remains OFF. Shift solenoid valve B is turned OFF, and SH B pressure (SB) is applied to the right side of shift valve B. Then shift valve B is moved to the left side to switch the port of line pressure and CPC pressure. Line pressure (4) becomes CPC A pressure (4A) at the CPC valve A. The CPC A pressure (4A) becomes 3rd clutch pressure (30) at shift valve B, and flows to the 3rd clutch. The 2nd clutch pressure is changed to CPC pressure mode by switching the position of shift valve B. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

TOAQlE CONYIATER

...

~~~

II I

_liB

rT Juo I

.................. ;,;!I

I

"

(cant' d)

BACK

14-49

Automatic Transmission System Description (cont'd) Hydraulic Flow (cont'd) [Q;I Position: Driving in 3rd gear The PCM turns the shift solenoid valve C ON, and controls AfT clutch pressure control solenoid valve B to release LS B pressure (57). Shift solenoid valve A remains ON, and B remains OFF. Releasing LS B pressure in the CPC valve B releases CPC B pressure in the 2nd clutch pressure circuit. Shift solenoid valve C is turned ON, and SH C pressure (SC) in the right side of shift valve C is released. Then shift valve C is moved to the right side to switch the port of line pressure and CPC pressure. The 3rd clutch pressure is changed to line pressure mode, and the 3rd clutch is engaged securely. The CPC A pressure (4A) stops at shift valve E. NOTE: • When used, "Ieft" or "right" indicates direction on the hydraulic circuit . • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

AfT ClUTCH I'I'lIS5U1'lf CONTIIiOlIOllNOID

14-50

BACK

~ Position: Shifting between 3rd gear and 4th gear

As the speed of the vehicle reaches the prescribed value, the PCM turns shift solenoid valve A OFF. The PCM also controls AfT clutch pressure control solenoid valve B to apply LS B pressure (57) to CPC valve B. Shift solenoid valve B remains OFF, and C remains ON. Shift solenoid valve A is turned OFF, and SH A pressure (SA) is applied to the left side of shift valve A. Then shift valve A is moved to the left side to switch line pressure and CPC pressure. Line pressure (4) becomes CPC B pressure (4B) at CPC valve B. The CPC B pressure (4B) becomes 4th clutch pressure (41) at shift valve D, and flows to the 4th clutch via the manual valve. The 3rd clutch pressure is changed to CPC pressure mode by switching the position of shift valve A. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

(cont'd)

BACK

14-51

Automatic Transmission System Description (cont'd) Hydraulic Flow (cont'd) ~ Position: Driving in 4th gear

The PCM turns shift solenoid valve C OFF, and controls A{f clutch pressure control solenoid valve A to release LS A pressure (56). Shift solenoid valves A and 8 remain OFF. Releasing LS A pressure (56) releases CPC A pressure in the 3 rd clutch pressure circuit. Shift solenoid valve C is turned OFF, and SH C pressure (SC) is applied to the right side of shift valve C. Then shift valve C is moved to the left side to switch the port of line pressure and CPC pressure. The CPC 8 pressure (58) changes to line pressure (58) at shift valve C, and flows to the 4th clutch via shift valve 8, shift valve C, shift valve D, and the manual valve. The 4th clutch pressure is changed to line pressure mode by switching the position of shift valve C, and 4th clutch is engaged securely. The CPC 8 pressure (5D) stops at shift valve A. NOTE:

• When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar. ... ACCUMULATO"

14-52

BACK

.RO ACCUMULATOIt

00 Position The PCM controls the shift solenoid valves and the AfT clutch pressure control solenoid valves. The conditions of the shift solenoid valves and the positions of the shift valve are as follows: • Shift solenoid valve A is turned ON, and the shift valve A is in the right side. • Shift solenoid valve B is turned ON, and the shift valve B is in the right side. • Shift solenoid valve C is turned OFF, and the shift valve C is moved to the left side. The PCM also controls AfT clutch pressure control solenoid valve B to apply LS B pressure (57) to CPC valve B. Line pressure (4) from the manual valve becomes line pressure (5C) at shift valve C. Line pressure (5C) flows to shift valve A via shift valve B, and becomes 2nd clutch pressure (20). The 2nd clutch pressure is applied to the 2nd clutch, and 2nd clutch is engaged. NOTE: • When used, "Ieft" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

(cont'd)

BACK

14-53


rn Position The PCM the shift solenoid valves and the AfT clutch pressure control solenoid valves. The conditions of the shift solenoid valves and the positions of the shift valve are as follows: • Shift solenoid valve A is turned OFF, and shift valve A is moved to the left side. • Shift solenoid valve 8 is turned ON, and shift valve 8 is in the right side. • Shift solenoid valve C is turned ON, and shift valve C is in the right side. Line pressure (4) becomes line pressure (58) at shift valve C. Line pressure (5C) flows to shift valve 8 via shift valve A, and becomes 1st clutch pressure (10). 1st clutch pressure (10) is applied to the 1st clutch, then 1st clutch is engaged. NOTE: • When used, "Ieft" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

14-54

BACK

[R) Position: Shifting to [R) position from ~ or

lID position

Line pressure (1) becomes line pressure (3) at the manual valve, and flows to the reverse CPC valve. Line pressure (3) is regulated by the reverse CPC valve and becomes line pressure (3'). Line pressure (3') pushes the servo valve to the reverse position, passes through the servo valve, and flows to the manual valve. Line pressure (3') becomes 4th clutch pressure (40). The 4th clutch pressure (40) is applied to the 4th clutch, and 4th clutch is engaged with the reverse CPC pressure mode. NOTE:

• When used, "left" or "right" indicates direction on the hydraulic circuit . • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

AlT CLUTCH 'I'tlS5URt CONTIIIOl SOUNOIO

(cont'd)

BACK

14-55

Automatic Transmission System Description (cont'd) Hydraulic Flow (cont'd) [RJ Position: Driving in reverse gear The PCM turns shift solenoid valve C OFF. Shift solenoid valve A remains OFF, and 8 remains ON. Shift solenoid valve C is turned OFF, and SH C pressure (SC) is applied to the right side of the reverse CPC valve. Then the reverse CPC valve moves to the left side, creating full line pressure. Line pressure to the 4th clutch is same as shifting to [RJ position, and 4th clutch pressure increases. The 4th clutch is engaged with line pressure mode. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

AIT CLUTCH ""fSSUM: CON'Tl'lOL SOLENOID

14-56

BACK

[tI Position Shift solenoid valve C is turned OFF by the PCM, and SH C pressure (SC) is applied to the right side of the reverse CPC valve. Then the reverse CPC valve is moved to the left side to uncover the port leading line pressure (3) to the servo valve. Line pressure (3') passes through the servo valve and flows to the manual valve. Line pressure (3') is intercepted at the manual valve, and is not applied to the clutches.

NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit . • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

...

1ST ACCUMULAlOlt

ACCUMULA TCM

..." CLUTCN rN.5UIlt

cornaoa. IOUHOID V"'-VlI

(cont'd)

BACK

14-57

Automatic Transmission System Description (cont'd) Lock-up System In ~ position (3rd and 4th), and ~ position (3rd), pressurized fluid is drained from the back ofthe torque converter through a fluid passage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the mainshaft rotates at the same speed as the engine crankshaft. Together with hydraulic control, the PCM optimizes the timing of the lock-up mechanism. When the torque converter clutch solenoid valve activates, modulator pressure changes to switch lock-up ON and OFF. The lock-up control valve and the lock-up timing valve control the range of lock-up according to AfT clutch pressure control solenoid valves A and B. The torque converter clutch solenoid valve is mounted on the torque converter housing, and AfT clutch pressure control solenoid valves A and B are mounted on the transmission housing. They are controlled by the PCM. General Operation

1. Operation (clutch on) With the lock-up clutch on, fluid in the chamber between the torque converter cover and the lock-up piston is drained off, and the converter fluid exerts pressure through the piston against the torque converter cover. As a result, the converter turbine is locked to the converter cover. The effect is to bypass the converter, placing the vehicle in direct drive.

IPower flow I

LOCK·UP PISTON

DAMPER SPRING

The power flows by way of:

E'lgin. D~ive

plate

Tlrque converter cover

LIck-UP piston

/

TORQUE CONVERTER COVER

To ATF cooler

DTmper spring Turbine

I

Mainshaft

MAINSHAFT

2. Operation (clutch off) With the lock-up clutch off, fluid flows in the reverse of CLUTCH ON. As a result, the lock-up piston moves away from the converter cover, and torque converter lock-up is released.

IPower flow I E'lgine D~ive

plate

Torque converter cover

TURBINE TORQUE CONVERTER

PUMP

CO~~:::::::~=:i'\-.

I

p~mp Turbine

I

Mainshaft

To ATF cooler

MAINS HAFT

14-58

BACK

No Lock-up

The torque converter clutch solenoid valve is turned OFF by the PCM. The lock-up shift valve receives LC pressure (LA) on the left side, and modulator pressure (6) on the right side. The lock-up shift valve is in the right side to uncover the port leading torque converter pressure (92) to the left side of the torque converter. Torque converter pressure (92) becomes torque converter pressure (94), and enters into the left side of the torque converter to disengage the lock-up clutch. The lock-up clutch is OFF. NOTE:

• When used, "left" or "right" indicates direction on the hydraulic circuit . • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

rr]J[~~=~~~:-

MODULATORPRIESSURE

LOCK·UP SHIFT VALVE

COOLER CHECK VALVE

ATfCOOLER

(cont'd)

BACK

14-59

Automatic Transmission System Description (cont'd) Lock-up System (cont'd) Partial Lock-up As the speed of the vehicle reaches the prescribed value, the torque converter clutch solenoid valve is turned ON by the PCM to release LC pressure (LA) in the left side of the lock-up shift valve. The lock-up shift valve is moved to the left side to switch the port leading torque converter pressure to the left side and right side ofthe torque converter. Torque converter pressure (92) flows to the right side of the torque converter to engage the lock-up clutch. The PCM also controls AfT clutch pressure control solenoid valves A and B, and LS A or LS B pressure is applied to the lock-up control valve and the lock-up timing valve. The position of the lock-up control valve depends on torque converter pressure and LS A or LS B pressure. When LS A or LS B pressure (58) is lower, torque converter pressure (91) from the lock-up timing valve is lower. The lock-up clutch is engaged partially. LS A or LS B (58) increases, and the lock-up timing valve is moved to the left side to uncover the port leading torque converter pressure to high. The lock-up clutch is then engaged securely. Under this condition, the lock-up clutch is engaged by pressure from the right side of the torque converter; this condition is partial lock-up. NOTE: • When used, "left" or "right" indicates direction on the hydraulic circuit . • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

14-60

BACK

Full Lock-up When the vehicle speed further increases, the PCM controls AfT clutch pressure control solenoid valves A and B to increase LS A or LS B pressure (58). The LS A or LS B pressure (58) is applied to the lock-up control valve and the lock-up timing valve, and moves them to the left side. Under this condition, torque converter back pressure is released fully, causing the lock-up clutch to be fully engaged. NOTE:

• When used, "left" or "right" indicates direction on the hydraulic circuit. • Hydraulic circuit shows the '98-99 models; the '00-02 models are similar.

rl:[fi:~~~=~L~ -

LOCK·UP SHIFT VALVE

MODULATOR PRESSURE LSAOlLS8PRESSURE •

COOLER CHECK VALVE

ATFCOOLER

(cont'd)

BACK

14-61

Automatic Transmission System Description (cont'd) Circuit Diagram Circuit Diagram UNDER·HOOD FUSEIRElAYBOX

BATIERY

No.47 (2OA)

WHTNEL - - - - - - - - - - - - - No.41 (100A)

No.<12 (50A)

No.6 (lSA)

IGl

No.9 (7.SA)

IGNITION SWITCH

No.1 (15A)

No.54 (4OA)

1

No.~ (15A)

PGM-F1

MAIN

RELAY


~

SOLENOID

SHIFT LOCK SOLENOID 22 BLKlYEL

2

GRN

VEUBLK

WHTNEL B21 V8U

MULTIPLEX CONTROl UNIT, DRIVER'

~' -~

DRIVER'S UNDER'[)ASH FUSEIRELAY BOX

ToSV

VEUBLK

Bl

B9

IGPl

IGP2

BLK

Tol2V

TRANSMISSION RANGE SWITCH PPOSITION

-:-

82

Bl0

PGl

PG2

G1Dl

05 ILU

VB SOL Tol2V

5V REGULATOR

POWERTRAIN CONTROl MODULE (PCM)

VSP OUT AS

ILlIIWHT

DRIVER'S UNDER·DASH FUSEIRELAY BOX No.9 (7.5A)

Y

GAUGE ASSEMBLY

B2

STARTER CUT RELAY

VEL

811

LTBLU

8181-_ _- - - '

ILK

1 G501

14-62

BACK

-t>

CRUISE CONTROL UNIT

- - - WHTIYEL

---4r---, WHTIYEL

r

NGINE ~~~TURE SENSOR

DATA LINK CONNECTOR WHTlREO

STEERING LOCK ASSEM8LY

PARK PIN SWITCH

J, CfD

8RAKE PEDAL

POSITION

SWITCH

8LK

l.

I

II

I


Y

r

REDlBLK

8RN

8LUIGRN

RED

WHT

BLU

GRN

REOIWHT

YEUBLU

GRNlBLK

G501 All

011

012

010

016

C26

C28

C27

C18

ATSFTP

NM

NMSG

NC

NCSG

ECT

VCC2

TPS

SG2

.,.

?

.,. LSAM

LSAP

LS8M

88

817

B18

WHT

RED

GRN

LS8P

B25

PDWERTRAIN CONTROL MODULE (PCM)

LC

SHA

SH8

SHC

LGI

LG2

01

07

02

D3

820

B22

GRf>W/HT

ORN

BLUIBLK

GRN

BlUJWHT

2ND CLUTCH PRESSURE SWITCH TORQUE CONVERTER CLUTCH SOLENOID VALVE

3ROCLUTCH PRESSURE

SWITCH

SHIFT SOLENOID VALVE A

Gl0l

Gl0l

Gl0l


A (32P)

B (25P)

C(31P)

BACK

o (16P)

14-63

Automatic Transmission OTe Troubleshooting DTC P1753: Problem in Torque Converter Clutch Solenoid Valve Circuit

5. Turn the ignition switch OFF. 6. Measure the resistance between the D1 and 820 or 822 terminals.

NOTE: Record all freeze data before you troubleshoot.

PCM CONNECTORS LC (VEL)


Q

2. Disconnectthe 8 (25P) and D (16P) connectors from the PCM.

4. Measure the voltage between the D1 and 820 or 822 terminals. PCM CONNECTORS LC (VEL)

L

23V J5l

3 4 5

1

2122

6 7 8 9 10 111121 1314 15 16

-

2324 25

'--

LG2(BLK: '98-99) (BRN/BLK: '00-02)

';i

LG1 (BRN/BLK)

2

"'--

3 4 5

6 7 81

20

1

/

1718 1 23 24 25

2122 '--

23V J5l

6 7 8 9 10 111121 1314 15

16

'--

LG2 (BLK: '98-99) (BRN/BLK: '00-02)

Q Wire side of female terminals

D (16P)

6 7 81 9 10 11 121 314 15/ 17 181

/20

1

LG1 (BRN/BLK)

';i

B(25P)

'--

;---

9 10 11 121 314 15


-1 2

D (16P)

B(25P)

/s the resistance 12- 25Q ?

VES- Go to step 11. NO-Go to step 7. 7. Check for continuity between the 820 and 822 terminals and body ground.

Wire side of female terminals PCM CONNECTOR B (25P)

/s there voltage? 1

VES- Repair short to power in the wire between the D1 terminal and the torque converter clutch solenoid valve .•

2

3 4 5

9 10 1112131415 20

21 22

LG1 (BRN/BLK)

NO-Go to step 5.

23 24 25 LG2(BLK: '98-99) (BRN/BLK: '00-02)


/s there continuity? VES- Go to step 8. NO- Repair open in the wires between the 820 and 822 terminals and ground (G101) .•

14-64

BACK

8. Disconnect the torque converter clutch solenoid valve/shift solenoid valve A 3P connector. 9. Check for continuity between the D1 and 820 or 822 terminals.

11. Turn the ignition switch ON (II). 12. Measure the voltage between the D5 and 820 or 822 terminals. PCM CONNECTORS

PCM CONNECTORS lC (YEll

'Y

Q

~~ 1

B(25P)

D (16P) 1

""""';-r--

f5l

3 4 5

6 7 81

9 10 11121 314

1511 17181

6 7 8 9 10 111121

2324 25

1314 15

V

"--

2

20

2122 '--

23V 16

1

r--

0"6.1

I

3 4 5

6 7 81

9 10 11121 314

15V 17181

6 7 8 9 10111121

2324 25

1314 15

IL "--

2

20

2122

.....

1

2 3/

5

16 '--

lG2 (BlK: '98-99) (BRN/BlK: '00-02)

'--

lG2(BlK: '98-99) (BRN/BlK: '00-02)

'Y

lG1 (BRN/BlK)

Q

lG1 (BRN/BlK)

VB SOL (BlK/YEl)


Is there battery voltage? Is there continuity? YES-Repair short to ground in the wire between the D1 terminal and the torque converter clutch solenoid valve .• NO-Go to step 10. 10. Measure the resistance between the No.3 terminal ofthe lock-up control solenoid valve/shift solenoid valve A connector and body ground.

YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .• NO-Check for blown No.6 (15A) fuse in the driver's under-dash fuse/relay box. Ifthe fuse is OK, repair open in the wire between the D5 terminal and the driver's under-dash fuse/relay box.•

TORQUE CONVERTER CLUTCH SOLENOID VALVE/ SHIFT SOLENOID VALVE A CONNECTOR (3P)


Is the resistance 12-25Q? YES-Check for open in the wire between the D1 terminal and the torque converter clutch solenoid valve .• NO- Replace the torque converter clutch solenoid valve/shift solenoid valve A.•

BACK

14-65

Automatic Transmission DTe Troubleshooting (cont'd) OTC P1705: Short in Transmission Range Switch Circuit

8. Shift to all positions other than [f] or INJ. 9. Measure ATP NP voltage between these terminals:

NOTE: Record all freeze data before you troubleshoot. 1. Turn the ignition switch ON (II). 2. Observe the AfT gear position indicator, and shift each position separately.

• '98-99 models: Between terminals D13 and B20 or B22 . • '00-02 models: Between terminals B14 and B20 or B22. '98-99 models:

Do any indicators stay on when the shift lever is not in that position?


YES-Go to step 3. NO-The system is OK at this time. Check the wire harness for damage.•

1

D(16j::::P)::;::::::::;::::::;!

2

9

3. Disconnect the transmission range switch connector.

Do all gear position indicators go out?

'------J

':i. ~_---l

LG1 (BRN/BLK)

YES- Replace the transmission range switch .• NO - Go to step 4. 4. Turn the ignition switch OFF, and connect the transmission range switch connector.


'00-02 models: PCM CONNECTOR B (25P)


2

6. Shift to all positions other than [RI.

3 4 5

9

7. Measure the voltage between the D6 and B20 or B22 terminals.

LG1 (BRN/BLK)

ATP NP (BLU/WHT)

PCM CONNECTORS

1415

16


ATPRIWHTI

Is there about 5 V? Wire side of female terminals

YES-Gotostep 10.

Is there battery voltage? YES-Go to step 8. NO-Check for short in the wire between the D6 terminal and the transmission range switch or AfT gear position indicator, and check for an open in the wires between the B20 and B22 terminals and body ground (G101). If wires are OK, check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .•

14-66

NO-Check for short in the wire between the D13 terminal and the transmission range switch, and in the [f] and INJ position signal wires between the AfT gear position indicator and the transmission range switch. If wires are OK, check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .• 10. Shift to all positions other than ~.

BACK



PCM CONNECTORS D (16P) roo-

B(25P)

--

6 7 al 1 2 3 4 5 9 10 11121 314 15 / 17 lal 2122 23 2425 20

L

'--

f5l

1 23/ 6 7 a 9 10 111121 1314 15 16

L....

LG2 (BLK: '98-99) (BRN/BLK: '00-02) LG1 (BRN/BLK)

12. Shift to all positions other than ~.

-

ATPD4( VEL)

PCM CONNECTORS B(25P) ;--;--

1 2 6 7 al 3 4 5 9 10 11121 314 15 17 lal ~20 2122 23 24 25

V

L....

D (16P) roo-

LG2(BLK: '98-99) (BRN/BLK: '00-02)

':i. ':i.

LG1 (BRN/BLK)


J5]

1 2 3lL 6 7 a 9 10 111121 13141 16 L....

ATPD3 (PN K)

':i. ':i.


Is there about 5 V? YES- Go to step 12.


NO - Check for short in the wire between the 09 terminal and the transmission range switch. If wire is OK, check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck.•

YES - Go to step 14. NO-Check for short in the wire between the 08 terminal and the transmission range switch or AfT gear position indicator. If wires are OK, check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck.•

(cont'd)

BACK

14-67

Automatic Transmission DTC Troubleshooting (cont'd) 14. Shift to all positions other than

00.




--

PCM CONNECTORS B(25P) r--r--

1

3 4 5

2

6 7 81

9 10 11121 314 15

~20

1

D (16P)

/

17181 23 24 25

2122

L.-

-1 23V /sl 6 7 8 9 10 11 112 1 131 415 16

lG2 (BlK: '98-99) (BRN/BlK: '00-02) lG1 (BRN/BlK)

/20

'-

2122

/

17181 24 23 25

-1

'--

'--

lG1 (BRN/BlK)

'::i.

3V [5

2

6 7 8 9 1011112 131415 16

lG2 (BlK: '98-99) (BRN/BlK: '00-02)

L.-

ATP1 (BRN)

'::i. '::i.


'::i.


6 7 81

3 4 5

9 10 11121 314 15

ATP2(BLU)


2

D (16P)


YES-Go to step 16.




16. Shift to all positions other than [II.

14-68

BACK

DTC P1706: Open in Transmission Range Switch Circuit (no gear position inputs)

5. Shift to ~ position.

6. Measure the voltage between the 09 and 820 or NOTE: Record all freeze data before you troubleshoot.

1. Test the transmission range switch (see page 14140).

822 terminals. PCM CONNECTORS D(16P)

B(25P)

-1 -2 L '--

YES - Go to step 2.

/

r-

'--


ATPD4( YEll

~ ~



2

-

LG2 (BLK: '98-99) (BRN/BLK: '00-02)

LG1 (BRN/BLK)


f5l

1 2 3/ 6 7 8 9 10 111121 1314 15 16

3 4 5

NO- Replace the transmission range switch .•

1

-

6 7 81 9 10 11 121 314 15 17 181 2122 23 24 25 20

Is the switch OK?

Is there voltage? YES- Repair open in the wire between the 09 terminal and the transmission range switch .•

345

NO-Go to step 7. LG2 (BLK: '98-99) (BRN/BLK: '00-02)

7. Shift to [RJ position. 8. Measure the voltage between the 06 and 820 or 822 terminals. PCM CONNECTORS

Wire side of female terminals B(25P)

D (16P)


1 2

YES-Go to step 4.

9 10 11121 314 15 17 1aJ 2122 23 24 25 /20

3 4 5

6 7 81

V

<--

NO-Repair open in the wires between the 820 and 822 terminals and ground (G101), or repair poor ground (G101) .•

-



-1

23V

f5l

6 7 8 9 10111 12 1 14 15 16 '--

ATPR(WHT)

~

~


Is there voltage? YES- Repair open in the wire between the 06 terminal and the transmission range switch .• NO-Goto step 9. 9. Shift to [f] or [H] position.

(cont'd)

BACK

14-69

Automatic Transmission OTC Troubleshooting (cont'd) 10. Measure ATP NP voltage between these terminals: • '98-99 models: Between terminals 013 and B20 or B22 . • '00-02 models: Between terminals B14 and B20 or B22.

11. Shift to ~ position. 12. Measure the voltage between the 08 and B20 or B22 terminals. PCM CONNECTORS D(16P)

B(25P) r--r--

'98-99 models:

1 2

678 3 4 5 9 10 11121 314 15 17 18 2122 23 24 25 20 L-


2

3 4 5

D(16P) ~rl

-1

f5l

2 3/ 6 7 8 9 10111 12 1 13141 16 LlG2(BlK: '98-99) ATPD3(PN K)

/

li:

"--

(BRN/BlK: '00-02)

9

lG1 (BRN/BlK)

20 lG1 (BRN/BlK)

'Y. 'Y.


Is there voltage? Wire side of female terminals

YES-Repair open in the wire between the 08 terminal and the transmission range switch .•

'00-02 models: PCM CONNECTOR B (25P)

NO-Gotostep 13. 13. Shift to 00 position. 14. Measure the voltage betweet1 the 014 and B20 or B22 terminals.

lG1 (BRN/BlK)

PCM CONNECTORS D (16P)

B(25P)

-1 -2

6 7 8J 3 4 5 9 10 11121 314 15 17 181 2122 23 24 25 20


L <--

L-

lG2 (BlK: '98-99) (BRN/BlK: '00-02)

Is there voltage?

lG1 (BRN/BlK)

YES-Repair open in the wire between the 013 ('98-99) or B14 ('00-02) terminal and the transmission range switch .• NO-Go to step 11.

/

r-

I5l

1

2 3lL 6 7 8 9 10 111121 131 415 16 L-

ATP2 (BLU)

'Y. 'Y.


Is there voltage? YES- Repair open in the wire between the 014 terminal and the transmission range switch .• NO-Go to step 15.

14-70

BACK

15. Shift to

rn position.

16. Measure the voltage between the D15 and 820 or 822 terminals. PCM CONNECTORS D(16PI

B(25PI -,--

1

2

3 4 5

6 7 81

9 10 11 12 1314 15/ 17 181 , / 20 "--

2122

2324 25

L-

-

1

f5l

6 7 8 9 10111 12 1 131415 16

LG2(BLK: '98-991 (BRN/BLK: '00-021 LG1 (BRN/BLKI

2 3'/

--

ATP 1 (BRNI

':/.. ':/..


Is there voltage? YES-Repair open in the wire between the D15 terminal and the transmission range switch .• NO-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .•

BACK

14-71

Automatic Transmission DTC Troubleshooting (cont'd) DTC P0753: Problem in Shift Solenoid Valve


A Circuit NOTE: Record all freeze data before you troubleshoot.

6. Measure the resistance between the D7 and 820 or 822 terminals. PCM CONNECTORS SH A (BLU/VEL)


Q

2. Disconnect PCM connectors 8 (25P) and D (16P). 3. Turn the ignition switch ON (II).

9

4. Measure the voltage between the D7 and 820 or 822 terminals. PCM CONNECTORS SH A (BLU/VEL)

Q

B (25P) r--r-1 2

9

3 4 5

6 7 81

10 11121 314 15V 17181

lL 20

2122

2324 25

-

1

LG2 (BLK: '98-99) (BRN/BLK: '00-02)

Q

LG1 (BRN/BLK)

2122 L.-

6 7 81

1

23V ["5]

15V 17 181

6 7 8 9 10 111121

2324 25

131 415

16

L.-

LG2(BLK: '98-99) (BRN/BLK: '00-02)

Q Wire side of female terminals

/s the resistance 12- 25 Q ?

16 '-

L.-

10 11 121 314

lL 20

lil

6 7 8 9 10 111121 13 1415

3 4 5

-

LG1 (BRN/BLK)

D (16P) 23/

D (16P)

B(25P) r--r-1 2


YES-Gotostep 11. NO-Go to step 7. 7. Check for continuity between the 820 and 822 terminals and body ground. PCM CONNECTOR B (25P)

/s there voltage? YES- Repair short to power in the wire between the D7 terminal and the shift solenoid valve A..

1

2

9

10 1112131415 20

NO - Go to step 5.

3 4 5 21 22

23 24 25

LG2(BLK: '98-99) (BRN/BLK: '00-02)


/s there continuity? YES-Go to step 8. NO-Repair open in the wires between the 820 and 822 terminals and ground (G101) .•

14-72

BACK

~,

8. Disconnect the torque converter clutch solenoid valve/shift solenoid valve A 3P connector. 9. Check for continuity between the D7 and 820 or 822 terminals.

11. Turn the ignition switch ON (II). 12. Measure the voltage between the D5 and 820 or 822 terminals. PCM CONNECTORS

PCM CONNECTORS SH A (BLU/VEL)

Q

B (25P)

1

2

r-

3 4 5

6 7 al

9 10 11 121 314 15

lL 20 "--

;--;--

D (16P)

B(25P) r--r---"

2122

.......

/

17 1al

23 24 25

1

2

3V f5l

6 7 a 9 10 111121 131 415 16

1

2

3 4 5

6 7 aJ

9 10 11 121 314 15

lL 20 "--

2122

.......

/

17 181 23 24 25

OI16P)

23/

~ 5

6 7 a 9 10111 12 1 16 13 1415

-

':i

LG1 (BRN/BLK)

Q

r1

LG2 (BLK: '98-99) (BRN/BLK: '00-02)

.......


VB SOL (BLK/VEL)

':i


Is there battery voltage? Is there continuity? YES-Repair short to ground in the wire between the D7 terminal and shift solenoid valve A.. NO-Go to step 10. 10. Measure the resistance between the No.1 terminal of the torque converter clutch solenoid valve/shift solenoid valve A connector and body ground.

YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .• NO-Check for blown No.6 (15A) fuse in the driver's under-dash fuse/relay box. If the fuse is OK, repair open in the wire between the D5 terminal and the driver'S under-dash fuse/relay box .•

TORQUE CONVERTER CLUTCH SOLENOID VALVE/ SHIFT SOLENOID VALVE A CONNECTOR (3P)


Is the resistance 12- 25 Q ? YES-Check for open in the wire between the D7 terminal and shift solenoid valve A.. NO- Replace the torque converter clutch solenoid valve/shift solenoid valve A..

BACK

14-73

Automatic Transmission DTe Troubleshooting (cont'd) OTe P0758: Problem in Shift Solenoid Valve


B Circuit NOTE: Record all freeze data before you troubleshoot.

6. Measure the resistance between the D2 and 820 or 822 terminals. PCM CONNECTORS


SH B (GRN/WHT)

Q 2. Disconnect PCM connectors 8 (25P) and D (16P).

liD (16P)

B (25P)

-;--

r-

6 7 81 1 2 3 4 5 9 10 11121 314 151/ 171eJ 2122 2324 25 ~20

3. Turn the ignition switch ON (II). 4. Measure the voltage between the D2 and 820 or 822 terminals.

<--

-

II D (16P)

B (25P)

1

2

r-

6 7 81

3 4 5

9 10 11121 314 15/ 171eJ /20

'--

2122

1314 15

2324 25

1

2

LG1 (BRN/BLK)

/s the resistance 12- 25 Q ?

16 '--

'--

16

-


3V f5l

6 7 8 9 10 111121 1314 15

f5l

Q

SH B (GRN/WHT)

)L

23/

6 7 8 9 10 111121

LG2 (BLK: '98-99) (BRN/BLK: '00-02)

PCM CONNECTORS

.---

1

LG2(BLK: '98-99) (BRN/BLK: '00-02)

)L LG1 (BRN/BLK)


YES-Go to step 11. NO-Go to step 7. 7. Check for continuity between the 820 and 822 terminals and body ground individually.

/s there voltage?


YES - Repair short to power in the wire between the D2 terminal and the shift solenoid valve 8 .•

1

2

3 4 5

9 10 1112131415 232425

NO-Go to step 5.

LG2 (BLK: '98-99) (BRN/BLK: '00-02)



YES-Go to step 8. NO-Repair open in the wires between the 820 and 822 terminals and ground (G101) .•

14-74

BACK

8. Disconnect the shift solenoid valve B 2P connector.


9. Check for continuity between the 02 and B20 or B22 terminals.

12. Measure the voltage between the 05 and B20 or B22 terminals.

PCM CONNECTORS

B125P)

,.....

~,.........;.

1

3V /sl

6 7 81

9 10 11121 314

15V 17181

6 7 8 9 10111 121

2324 25

1314 15

II'--

20

2122

'-

1

IIDI16P)

3 4 5

V

2

PCM CONNECTORS SH B IGRN/WHT)

Q

2

B125P) -,....... 1

2

II'--

L-.

3 4 5

6 7 8J

9 10 11121 314 15

lL' 20

16

VB SOL IBLK/YEL)

')L

LG2IBLK: '98-99) IBRN/BLK: '00-02)

2122

'-

V 17181

2324 25

-

1

0)'6P) 2

3V

6 7 8 9 10 1314 15

I

5

1~ 121

16

L-.

LG2IBLK: '98-99) IBRN/BLK: '00-02)

LG1 IBRN/BLK)

LG1 IBRN/BLK)


')L Wire side of female terminals


Is there approx. battery voltage?

YES-Repair short to ground in the wire between the 02 terminal and the shift solenoid valve B.•


NO-Gotostep 10. 10. Measure shift solenoid valve B resistance at the solenoid valve connector. SHIFT SOLENOID VALVE BCONNECTOR

NO-Check for blown No.6 (15A) fuse in the driver's under-dash fuse/relay box. If the fuse is OK, repair open in the wire between the 05 terminal and the driver's under-dash fuse/relay box.•


Is the resistance 12- 25 Q? YES-Check for open in the wires between the 02 terminal and the shift solenoid valve Band between the No.1 terminal of the shift solenoid valve B connector and ground (G101) .• NO- Replace the shift solenoid valve B.•

BACK

14-75

Automatic Transmission DTC Troubleshooting (cont'd) DTC P0720: Problem in Countershaft Speed Sensor Circuit


NOTE: Record all freeze data before you troubleshoot. 1. Check the countershaft speed sensor installation.

NC(BLU)

Is the countershaft speed sensor installed properly? YES-Go to step 2. NO-Reinstall and recheck.•

=

2. Disconnect the countershaft speed sensor 2P connector. 3. Measure countershaft speed sensor resistance at the sensor connector. COUNTERSHAFT SPEED SENSOR CONNECTOR


Is there continuity? YES- Repair short to ground in the wires between the D10 and D16 terminals and the countershaft speed sensor.• NO-Go to step 6. 6. Connect the countershaft speed sensor connector. 7. Measure the resistance between the D10 and D16 terminals. PCM CONNECTOR D (16P)

Terminal side of male terminals NC(BLU)


2 3

6 7 8 9

YES - Go to step 4.

13 14 15

NO - Replace the countershaft speed sensor.• 4. Disconnect PCM connector D (16P). Wire side of female terminals

Is the resistance 400- 600 Q ? YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .• NO- Repair loose terminal or open in the wires between the D10 and D16 terminals and the countershaft speed sensor.•

14-76

BACK

DTC P0715: Problem in Mainshaft Speed Sensor Circuit

4. Disconnect PCM connector D (16P).

NOTE: • Record all freeze data before you troubleshoot. • Code P0715 (15) on the PCM doesn't always mean there's an electrical problem in the mainshaft or countershaft speed sensor circuit; code P0715 (15) may also indicate a mechanical problem in the transmission. Any problem causing irregular countershaft to mainshaft speed difference can cause this code.


2 3

5

6 7 8 9 10 11 13 1415

16

NM(RED)

1. Check the mainshaft and countershaft speed sensor installation.

Are the mainshaft and countershaft speed sensor installed properly?


YES-Go to step 2.


NO- Reinstall and recheck .•

YES- Repair short to ground in the wires between the D11 and D12 terminals and the mainshaft speed sensor.•

2. Disconnect the mainshaft speed sensor 2P connector.

NO-Goto step 6. 3. Measure mainshaft speed sensor resistance at the sensor connector. MAINSHAFT SPEED SENSOR CONNECTOR

6. Connect the mainshaft speed sensor connector. 7. Measure the resistance between the D11 and D12 terminals. PCM CONNECTOR D (16P)

2 3

5

6 7 8 9 10 11 12 131415

16

NM(RED)


Is the resistance 400- 600 Q ? Wire side of female terminals

YES-Go to step 4.

Is the resistance 400- 600 Q ? NO - Replace the mainshaft speed sensor.. YES-Run the Electrical Troubleshooting Flowchart for code P0720 (code 9). Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .• NO - Go to step 8. (cont'd)

BACK

14-77

Automatic Transmission OTe Troubleshooting (cont'd) 8. Disconnect the mainshaft speed sensor 2P connector. 9. Check for continuity between the D11 terminal and the No.1 terminal ofthe mainshaft speed sensor connector. PCM CONNECTOR D (16P)

MAINSHAFT SPEED SENSOR CONNECTOR


Is there continuity? YES-Gotostep 10. NO- Repair open in the wire between the D11 terminal and the mainshaft speed sensor.. 10. Check for continuity between the D12 terminal and the No.2 terminal of the mainshaft speed sensor connector. PCM CONNECTOR D (16P)

2 3 6 7 131415

MAINSHAFT SPEED SENSOR CONNECTOR WHT


Is there continuity? YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck.• NO- Repair open in the wire between the D12 terminal and the mainshaft speed sensor.•

14-78

BACK

OTC P1768: Problem in AfT Clutch Pressure Control Solenoid Valve A Circuit NOTE: Record all freeze data before you troubleshoot.

5. Connect the AfT clutch pressure control solenoid valve A connector. 6. Measure the resistance between the B8 and B17 terminals.

1. Disconnect the AfT clutch pressure control solenoid valve A 2P connector.

PCM CONNECTOR B (25P) lSA- (WHT)

2. Measure AfT clutch pressure control solenoid resistance at the solenoid valve connector. A/T CLUTCH PRESSURE CONTROL SOLENOID VALVE A CONNECTOR

345

2

9 10 20

lSA+ (RED) Wire side of female terminals

Is the resistance about 5 Q? YES-Go to step 7. NO- Repair loose terminal or open in the wires between the B8 and B17 terminals and AfT clutch pressure control solenoid valve A..


Is the resistance about 5 Q? YES - Go to step 3. NO- Replace the AfT clutch pressure control solenoid valve A..

7. Disconnect PCM connector D (16P). 8. Turn the ignition switch ON (II).

3. Disconnect PCM connector B (25P).

9. Measure the voltage between the D5 and B20 or B22 terminals.

4. Check for continuity between body ground and the B8 terminal and the B17 terminal individually. B (25P)

lSA- (WHT)

9

-r--

3 4 5

2

9

10 11 121 314 15

L

2122

"--

10 20

6 7 81

1

20

3 4 5

-

/

17

18 1

23 24 25

-

1

!

VB SOL (BlK/VEl)

'Y.


2

PCM CONNECTORS

DI16P)

2

3V

5

6 7 8 9 10111 12 1 1314 15 16 L-.

lG2(BlK: '98-99) (BRN/BlK: '00-02)

'Y.

lG1 (BRN/BlK)




Is there continuity? YES - Repair short to ground in the wires between the B8 and B17 terminals and AfT clutch pressure control solenoid valve A.. NO-Go to step 5.

BACK

YES - Go to step 10. NO-Check for blown No.6 (15A) fuse in the driver'S under-dash fuse/relay box. If the fuse is OK, repair open in the wire between the D5 terminal and the driver's under-dash fuse/relay box .• (cont'd)

14-79

Automatic Transmission DTC Troubleshooting (cont'd) 10. Turn the ignition switch OFF. 11. Check for continuity between the 820 and 822 terminals and body ground. PCM CONNECTOR B (25P) 1

2

3 4 5

LG2 (BLK: '98-99) (BRN/BLK: '00-02)


Is there continuity? YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck.• NO-Repair open in the wire between the 82, 810, 820 and 822 terminals and ground (G 101). Repair poor ground (G 101) .•

~I

14-80

BACK

DTC P0763: Problem in Shift Solenoid Valve C Circuit NOTE: Record all freeze data before you troubleshoot.



SHC(GRN)

2. Disconnect PCM connectors 8 (25P) and D (16P). 3. Turn the ignition switch ON (II).

B(25P) ,........;-,....-' 1 2

D (16P) 3 4 5

6 7 81

9 10 11 121 314 15V 17181


IL 20 """-

2122

D (16P) r-

3 4 5

6 7 81

9 10 11121 314 15V 17181

IL' 20

"--

2122 l...-

2324 25

1

Jl

231i

m

6 7 8 9 10111 12 1 1314 15

151

2317

16

'--

lG2(BlK: '98·99) (BRN/BlK: '00·02)

Q

lG1 (BRN/BlK)


/s the resistance 12- 25 Q?

16 I...-

YES-Go to step 11.

lG2 (BlK: '98-99) (BRN/BlK: '00-02)

NO-Goto step 7.

':i.

lG1 (BRN/BlK)

II

6 7 8 9 10111121 1314 15

SHC(GRN)

':i.

1

'"-

PCM CONNECTORS

B(25P) ,........;-,....-' 1 2

2324 25

r-




/s there voltage?

YES - Repair short to power in the wire between the D3 terminal and the shift solenoid valve C.•

1

2

345

9

NO-Go to step 5. lG2 (BlK: '98-99) (BRN/BlK: '00-02)


/s there continuity? YES - Go to step 8. NO- Repair open in the wires between the 820 and 822 terminals and ground (G101) .•

(cont'd)

BACK

14-81

Automatic Transmission DTC Troubleshooting (cont'd) 8. Disconnect the shift solenoid valve 8 2P connector.


9. Check for continuity between the D3 and 820 or 822 terminals.


PCM CONNECTORS

PCM CONNECTORS

SH C (GRN) B(25P)

r---r--

D (16P) ,1 2

II 311 [5]

1

2

3 4 5

6 7 81

9

10 11121 314

15V 17181

6 7 8 9 10111121

2324 25

1314 15

V

---

20

2122

'--

16

'--

'Y. B(25P) ,.......;. r---' 1 2 9

Q

6 7 81

10 11121 314 15/ 17181

12': 20

2122

L-

2324 25

1

2

3V

5

6 7 8 9 10 111121 1314 15

16 '--

lG2 (BlK: '98-99) (BRN/BlK: '00-02)

lG2 (BlK: '98-99) (BRN/BlK: '00-02)

lG1 (BRN/BlK)

0118PI r-

3 4 5

!

VB SOL (BlK/YEl)

'Y.

lG1 (BRN/BlK)





YES-Repair short to ground in the wire between the D3 terminal and the shift solenoid valve C.•


NO-Goto step 10. 10. Measure shift solenoid valve C resistance at the solenoid valve connector.

NO-Check for blown No.6 (15A) fuse in the driver's under-dash fuse/relay box. Ifthe fuse is OK, repair open in the wire between the D5 terminal and the driver's under-dash fuse/relay box.•

SHIFT SOLENOID VALVE CCONNECTOR


Is the resistance 12-25 Q ? YES-Check for open in the wires between the D3 terminal and the shift solenoid valve C and between the No.1 terminal of the shift solenoid valve C connector and ground (G101) .• NO-Replace shift solenoid valve C.•

14-82

BACK

DTe P1773: Problem in AfT Clutch Pressure Control Solenoid Valve B Circuit NOTE: Record all freeze data before you troubleshoot. 1. Disconnect the AfT clutch pressure control solenoid valve 8 2P connector.

3. Disconnect PCM connector 8 (25P). 4. Check for continuity between body ground and the 818 terminal and the 825 terminal individually. PCM CONNECTOR B (25P)

2

2. Measure AfT clutch pressure control solenoid resistance atthe solenoid valve connector.

3 4 5

9 10 20

2122

AfT CLUTCH PRESSURE CONTROL SOLENOID VALVE B CONNECTOR


Is there continuity? YES- Repair short to ground in the wires between the 818 and 825 terminals and AfT clutch pressure control solenoid valve 8 .•


Is the resistance about 5 Q?

NO-Go to step 5. 5. Connect the AfT clutch pressure control solenoid valve 8 2P connector.

YES - Go to step 3. NO- Replace the AfT clutch pressure control solenoid valve 8 .•

6. Measure the resistance between the 818 and 825 terminals. PCM CONNECTOR B (25P)


Is the resistance about 5 Q? YES-Go to step 7. NO- Repair loose terminal or open in the wires between the 818 and 825 terminals and AfT clutch pressure control solenoid valve 8 .• (cont'd)

BACK

14-83

Automatic Transmission DTC Troubleshooting (cont'd) 7. Disconnect PCM connector 0 (16P).



11. Check for continuity between the 820 and 822 terminals and body ground individually.

9. Measure the voltage between the 05 and 820 or 822 terminals. PCM CONNECTORS

1

2

0116P) r--

3 4 5

6 7 81

9 10 11121 314 15/ 17181

~ 20

"--

2122

.......

23 2425

1

!

VB SOL (BLK/VELI

':::L B(25PI ,.......:-......-'

PCM CONNECTOR B (25PI

2

3V

6 7 8 9 10 1314 15

2

5

345

LG2 (BLK: '98-991 (BRN/BLK: '00-021

1~121

16

.......

LG2 (BLK: '98-991 (BRN/BLK: '00-021

':::L

LG1 (BRN/BLKI



Is there continuity? YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck.•

Is there battery voltage? YES-Go to step 10. NO-Check for blown No.6 (15A) fuse in the driver's under-dash fuse/relay box. lfthe fuse is OK, repair open inthe wire between the 05 terminal and the driver's under-dash fuse/relay box.•

14-84

NO-Repair open in the wire between the 82,810, 820 and 822 terminals and ground (G 101). Repair poor ground (G101) .•

BACK

OTC P1738: Problem in 2nd Clutch Pressure Switch Circuit NOTE: Record all freeze data before you troubleshoot. 1. Turn the ignition switch ON (II).

3. Turn the ignition switch OFF. 4. Disconnect PCM connector B (25P) ('98-99) or D (16P) ('00-02). 5. Disconnect the 2nd clutch pressure switch connector.

2. Measure OP2SW voltage between these terminals. 6. Check OP2SW for continuity to ground: • '98-99 models: Terminals B14 and B20 or B22. • '00-02 models: Terminals D13 and B20 or B22. '98-99 models: PCM CONNECTOR B (25P)

2 9

10 1112131415 20

21 22

~.........,.--'

'98-99 models:

678

345

• '98-99 models: Between B14 termi nal and body ground . • '00-02 models: Between D13 terminal and body ground.

1718


23 24 25 1

OP2SW (BlU/BlK)

2

3 4 5

9 10 11 12131415 20

21 22

23 24 25 OP2SW (BLU/BLK)

lG1 (BRN/BlK)



'00-02 models: PCM CONNECTORS B(25P)

'00-02 models:

D (16P)

-1 2

345

6 7 81

9 10 11 12 13 1415 2122

/20

V 171~

2324 25

'--

-

1

J5J 2 3

6 7 8 9 10111 12 1 1314 15

w--J

l:T (BRN/BlK)

PCM CONNECTOR D (16P)

23/ 16

5

6 7 8 9 10 11 12

'--

OP2SW (BlU/Bl K)

13 14 15

16

OP2SW (BLU/BLK)

'::L

l G1 (BRN/BlK)

=



Is there battery voltage? Is there continuity? YES-Go to step 7. YES- Repair short to ground in the wire between the B 14 ('98-99) or D13 ('00-02) terminal and the 2nd clutch pressure switch .•

NO-Go to step 3.

NO-Check for loose terminal fit in the PCM connectors. )f necessary, substitute a known-good PCM and recheck .• (cont'd)

BACK

14-85

Automatic Transmission DTC Troubleshooting (cont'd) 7. Raise the front of the vehicle, and make sure it is securely supported.




9. Start the engine, then shift to 00 position and drive for more than five seconds.

14. Measure the voltage between the 2nd clutch pressure switch connector terminal and body ground. 2ND CLUTCH PRESSURE SWITCH CONNECTOR

10. Measure OP2SW voltage between these terminals: • '98-99 models: Terminals 814 and 820 or 822 . • '00-02 models: Terminals 013 and 820 or 822. '98-99 models: PCM CONNECTOR B (25P)

Wire side of female terminal

/s there battery voltage? YES - Go to step 15.


'00-02 models: PCM CONNECTORS B(25P)

lG1

(BRN/BlK)

NO- Repair open in the wire between the 2nd clutch pressure switch and the PCM .• 15. Measure the resistance between the 2nd clutch pressure switch connector terminal and body ground.

D (16¢P):;:::;::::;!


':::/..1--------' =



/s there about 0 V? YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck.• NO-Gotostep 11. 11. Turn the ignition switch OFF.

14-86

/s the resistance 10 MQ or more? YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck.• NO- Replace the 2nd clutch pressure switch .•

BACK

OTe P1739: Problem in 3rd Clutch Pressure Switch Circuit

3. Turn the ignition switch OFF. 4. Disconnect PCM connector 8 (25P).

NOTE: Record all freeze data before you troubleshoot. 1. Turn the ignition switch ON (II).



6. Check for continuity between the 824 terminal and body ground.



2

3 4 5

1

9 10 20 LG1 (BRN/BLK)

2

345

9 10 20

2122

OP3SW (BLU/WHT)

LG2 (BLK: '98-99) (BRN/BLK:

'00-02)

__....,'Y.".--__ Wire side of female terminals




YES-Go to step 7.

YES- Repair short to ground in the wire between the 824 terminal and the 3rd clutch pressure switch .•

NO-Go to step 3.


(cont'd)

BACK

14-87

Automatic Transmission DTC Troubleshooting (cont'd) 7. Raise the front of the vehicle, and make sure it is securely supported.

14. Measure the voltage between the 3rd clutch pressure switch connector terminal and body ground.



9. Start the engine, then shift to ~ position and drive in 3rd gear for more than five seconds. 10. Measure the voltage between the 824 and 820 or 822 terminals. PCM CONNECTOR B (25P)

= 2

3 4 5 Wire side of female terminal

LG1 (BRN/BLK)

OP3SW (BLU/WHT) LG2 (BLK: '98-99) (BRN/BLK:


'00-02)

':i.

NO- Repair open in the wire between the 3rd clutch pressure switch and the PCM .•


Is there about 0 V?

15. Measure the resistance between the 3rd clutch pressure switch connector terminal and body ground.



NO-Gotostep 11. 11. Turn the ignition switch OFF. 12. Disconnect the 3rd clutch pressure switch connector.

=


Terminal side of male terminal

Is the resistance 10 MQ or more? YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck .• NO- Replace the 3rd clutch pressure switch .•

14-88

BACK

DTe P0740: Problem in Lock-up Control


System Does the OBO /I scan tool indicate code P0740? NOTE: • Record all freeze data before you troubleshoot . • Keep replacement solenoid valves on hand: - Torque converter clutch solenoid valve/shift solenoid valve A - AfT clutch pressure control solenoid valves A and B

YES- Replace the transmission and torque converter .• NO-The system is OK at this time.•


Does the OBO /I scan tool indicate another code? YES - Perform the Troubleshooting Flowchart for the indicated Code(s). Recheck for code P0740 after troubleshooting .• NO - Go to step 2. NOTE: Do not continue with this troubleshooting until the causes of any other DTCs have been corrected. 2. Measure the line pressure.

Is the line pressure within the service limit? YES-Go to step 3. NO- Repair the hydraulic system as necessary (see page 14-104) .• 3. Replace the torque converter clutch solenoid valve/ shift solenoid valve A (see page 14-106). 4. Replace the AfT clutch pressure control solenoid valves A and B (see page 14-109). 5. Turn the ignition switch OFF and reset the PCM memory by removing the BACK UP fuse in the passenger's under-dash fuse/relay box for more than 10 seconds. 6. Using the scan tool, check to be sure that the engine coolant temperature is in 176°F (80°C) and above. 7. Drive the vehicle at 55 mph (88 km/h) constantly for more than one minute.

BACK

14-89

Automatic Transmission OTC Troubleshooting (cont'd) DTC P0730: Problem in Shift Control System


NOTE: • Record all freeze data before you troubleshoot. • Keep replacement solenoid valves on hand: - Torque converter clutch solenoid valve/shift solenoid valve A - Shift solenoid valves Band C - AfT clutch pressure control solenoid valves A and B

Does the OBO /I scan tool indicate code P0730?

YES- Replace the transmission .• NO- The system is OK at this time .•


Does the OBO /I scan tool indicate another code?

YES- Perform the Troubleshooting Flowchart for the indicated Code(s). Recheck for code P0730 after troubleshooting .• NO - Go to step 2. NOTE: Do not continue with this troubleshooting until the causes of any other DTCs have been corrected. 2. Measure the 1st, 2nd, 3rd, and 4th clutch pressure (see page 14-104).

Is each clutch pressure within the service limit?

YES - Go to step 3. NO- Repair the hydraulic system as necessary.• 3. Replace the torque converter clutch solenoid valve/ shift solenoid valve A (see page 14-106). 4. Replace the shift solenoid valves Band C (see page 14-107). 5. Replace the AfT clutch pressure control solenoid valves A and B (see page 14-109). 6. Turn the ignition switch OFF and reset the PCM memory by removing the BACK UP fuse in the passenger's under-dash fuse/relay box for more than 10 seconds. 7. Drive the vehicle at a speed over 12 mph (20 km/h) in 1st, 2nd, 3rd, 4th gear in ~ position for more than 30 seconds.

14-90

BACK

DTC P0780: Mechanical Problem in Hydraulic Control System for Shift Solenoid Valve A and AfT Clutch Pressure Control Solenoid Valves A and B, or Problem in Hydraulic Control System NOTE: • Record all freeze data before you troubleshoot . • Keep replacement solenoid valves on hand: - Torque converter clutch solenoid valve/shift solenoid valve A - AfT clutch pressure control solenoid valves A and B 1. Check whether the OBD II scan tool indicates another code.

Does the OBO /I scan tool indicate another code? YES- Perform the Troubleshooting Flowchart for the indicated Code(s). Recheck for code P0780 after troubleshooting .• NO-Go to step 2. 2. Turn the ignition switch OFF. 3. Replace the torque converter clutch solenoid valve/ shift solenoid valve A (see page 14-106), and the AI T clutch pressure control solenoid valves A and B (see page 14-109). 4. Reset the PCM memory by removing the BACK UP fuse in the passenger's under-dash fuse relay box for more than 10 seconds. 5. Drive the vehicle for several minutes in 1st, 2nd, 3rd, and 4th gears in ~ position. 6. Recheck for code P0780.

Does the OBO /I scan tool indicate code P0780? YES-Replace the transmission .• NO-The problem has been corrected .•

BACK

14-91

Automatic Transmission OTe Troubleshooting (cont'd) DTC P1750: Mechanical Problem in Hydraulic Control System for AfT Clutch Pressure Control Solenoid Valves A and Bf or Problem in Hydraulic Control System

DTC P1751: Mechanical Problem in Hydraulic Control System for Shift Solenoid Valve B and AfT Clutch Pressure Control Solenoid Valves A and Bf or Problem in Hydraulic Control System

NOTE: Record all freeze data before you troubleshoot. NOTE: • Record all freeze data before you troubleshoot. • Keep replacement solenoid valves on hand: - Shift solenoid valve B - AfT clutch pressure control solenoid valves A and B


Does the OBO /I scan tool indicate another code? YES- Perform the Troubleshooting Flowchart for the indicated Code(s). Recheck for code P1750 after troubleshooting .•


Does the OBO " scan tool indicate another code? NO-Go to step 2. 2. Turn the ignition switch OFF. 3. Replace the AfT clutch pressure control solenoid valvesAand B (see page 14-109). 4. Reset the PCM memory by removing the BACK UP fuse in the passenger's under-dash fuse relay box for more than 10 seconds. 5. Drive the vehicle for several minutes in 1st, 2nd,

YES- Perform the Troubleshooting Flowchart for the indicated Code(s). Recheck for code P1751 after troubleshooting .•

NO - Go to step 2. 2. Turn the ignition switch OFF. 3. Replace the shift solenoid valve B (see page 14107), and the AfT clutch pressure control solenoid valves A and B (see page 14-109).

3rd, and 4th gears in ~ position. 4. Drive the vehicle for several minutes in 1st, 2nd,


Does the OBO" scan tool indicate code P1750?

3rd, and 4th gears in ~ position. 5. Recheck for code P1751.

YES - Replace the transmission .•

Does the OBO /I scan tool indicate code P1751?

NO- The problem has been corrected .•

YES - Replace the transmission .• NO- The problem has been corrected .•

14-92

BACK

[Q;ilndicator Circuit Troubleshooting 1. Turn the ignition switch ON (II), and watch the ~ indicator light.

10. Measure the voltage between the D9 terminal and body ground. PCM CONNECTOR D (16P)

Does the ~ indicator come on and stay on?

r-

YES-Go to step 2.

1

2

3V

-

5

6 7 8 9 10 11 12

NO-If the light comes on for about two seconds and then goes off, it's OK. If it doesn't come on at all, go to step 11.

13 14 15

16 L..-

ATPD4(VE L)


'::l.

3. Disconnect PCM connector A (32P).


4. Turn the ignition switch ON (II). 5. Measure the voltage between the A 14 terminal and body ground.

Is there about 5 V? YES-Faulty PCM or the gauge assembly .•


NO-Check for short to ground in the wire between the D9 terminal and the transmission range switch. If wire is OK, check the transmission range switch .• 2627

28 29 30

11. Make sure the Honda PGM Tester is not connected to the DLC.

D4 IND (GRN/BLK)

12. Shift to ~ position.

=

Does the ~ indicator come on?


YES- Repair short to power in the wire between the A 14 terminal and the gauge assembly.•

YES-Check for loose terminal fit in the PCM connectors and recheck the ~ indicator several times. Ifthe problem is intermittent, substitute a known-good PCM and recheck. If the light then works OK every time, replace the original PCM .•

NO - Go to step 6.

NO-Go to step 13.

Is there voltage?



7. Reconnect PCM connector A (32P). 8. Turn the ignition switch ON (II). 9. Shift to any position other than ~.

(cont'd)

BACK

14-93

Automatic Transmission ~ Indicator Light Circuit Troubleshooting (cont'd) 14. Disconnect PCM connector 8 (25P).


15. Check for continuity between body ground and 820 and 822 terminals.

19. Reconnect PCM connector 8 (25P). 20. Connect the digital multimeter between the A 14 and 820 or 822 terminals.


1

2


345

PCM CONNECTORS A (32P)

B(25P)

LG2(BLK: '98-99) (BRN/BLK: '00-02)


'-------I'Y.. ~-----' LG2 (BLK: '98-99) (BRN/BLK: '00-02)

Is there continuity between ground and each terminal?



Is there voltage for at least 2 seconds? NO-Repair open in the wire(s) between the 820 or 822 terminal and ground (G101 ).• 16. Turn the ignition switch ON (II). 17. Measure the voltage between terminals 81 and 822, and between terminals 89 and 820.

YES - Check for open in the wi re between the A 14 terminal and the gauge assembly. If wire is OK, check for a faulty Ip;J indicator bulb or a faulty printed circuit board in the gauge assembly .• NO- Go to step 22.


LG1 (BRN/BLK)

LG2 (BLK: '98-99) (BRN/BLK: '00-02)


Is there battery voltage? YES - Go to step 18. NO- Repair open or short in the wire between the 81 or 89 terminal and the PGM-FI main relay and from fuse No. 46 in the under-hood fuse/relay box to the PGM-FI main relay .•

14-94

BACK

22. Turn the ignition switch OFF. 23. Disconnect PCM connector A (32P). 24. Check for continuity between the A 14 terminal and No. 12 terminal of the gauge assembly C (16P) connector. PCM CONNECTOR A (32P)

GAUGE ASSEMBLV C (16P)

CONNECTOR


Is there continuity? YES-Check for loose terminal fit in the PCM connectors. Check the transmission range switch. If necessary, substitute a known-good PCM and recheck .• NO-Repair open in the wire between the A14 terminal and the gauge assembly.•

BACK

14-95

Automatic Transmission Interlock System - Shift Lock System Circuit Troubleshooting 1. Press the brake pedal.

5. Measure the voltage between the 812 terminal of the multiplex control unit, driver's 8 (22P) connector and body ground with the throttle released and the brake pedal pressed.

Are the brake lights ON? YES - Go to step 2.

MULTIPLEX CONTROL UNIT, DRIVER'S B (22P) CONNECTOR

NO- Repair faulty brake light circuit, refer to the '98-02 Accord Service Manual (see page 19-8).• 2. Turn the ignition switch ON (II), and shift to [f] position. 3. Press the brake pedal, and release the accelerator pedal.

=

4. Measure the voltage between the A28 terminal and body ground. PCM CONNECTOR A (32P)


Is there battery voltage? YES-Go to step 6. NO-Repair open in the wire between the A28 terminal of the PCM and 812 terminal of the driver's multiplex control unit..

=

6. Measure the voltage between the 822, terminal of the multiplex control unit, driver's 8 (22P) connector and body ground.

Wire side of female terminals MULTIPLEX CONTROL UNIT, DRIVER'S B (22P) CONNECTOR

Is there battery voltage? YES-Go to step 5. NO-Go to step 8.


Is there battery voltage? YES-Go to step 7. NO-Repair open in the wire between the 822 terminal ofthe driver's multiplex control unit and the driver's under-dash fuse No.9 (via the shift lock solenoid) .•

14-96

BACK

7. Turn the ignition switch ON (II), and move the shift lever to [l] position.

8. Turn the ignition switch OFF. 9. Disconnect PCM connectors A (32P) and 8 (25P).

Dose the [l] indicator in the gauge assembly illuminate?

10. Measure the voltage between the A32 and 820 or 822 terminals while pressing the brake pedal.

YES- Check for loose terminal fit to the driver's multiplex control unit 812 and 822 terminal wires. If necessary, substitute a known-good driver's multiplex control unit.•

PCM CONNECTORS B(25PI

A (32PI

NO- Repair open in the [l] position switch circuit from the driver's under-dash fuse/relay box K10 (8LK/8LU) wire to ground (G101) .•

lG2 (BlK: '98-991 (BRN/BlK: '00-021 Wire side offemale terminals

Is there battery voltage? YES-Go to step 11. NO- Repair open in the wire between the A32 terminal and the brake pedal position switch (brake switch) .•

(cont'd)

BACK

14-97

Automatic Transmission Interlock System - Shift Lock System Circuit Troubleshooting (cont'd) 11. Reconnect PCM connectors A (32P) and 8 (25P).

16. Check for continuity between the No.1 terminal of the throttle position sensor and the 820 or 822 terminal of the PCM.


PCM CONNECTOR B (25PI

13. Measure the voltage between the C27 and 820 or 822 terminals. PCM CONNECTORS B(25PI

C(31PI

r---

2V / 5 6 7 8 9 10 VVV / V 161 718 19 20 21V VV 25 262728 2930 V

6 7 811 1 1 2 3 4 5 9 10 11121 314 15 / 17 181 2122 23 24 25 20 L-

IL

LG2(BLK: '98-991 (BRN/BLK: '00-021 LG1 (BRN/BLKI

TPS (RED/BLKI

Y.


Y.



YES-Replace the throttle body.•

Is there approx. 0.5 V (throttle fully closed)? NO-Go to step 17. YES-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck.•

17. Check for continuity between the C18 and 820 or 822 terminals. PCM CONNECTORS

NO-Go to step 14. B(25PI

14. Turn the ignition switch OFF. 15. Disconnect the throttle position sensor connector.

C(31PI

r--r--

V 567 8 9 10 15V 17181 V VVV V 16 171 819 20 2111 / kt" 26 27 29 30 /

1 2 3 4 5 6 J 811 1 2lJ" 9 10 11121 314 25 2122 23 24 25 20

IL

--

~

LG2(BLK: '98-991 (BRN/BLK: '00-021

LG1 (BRN/BLKI

SG2 (GRN/BLKI

.Q .Q


Is there continuity? YES-Repair open in the wire between the C18 terminal and the throttle position sensor.• NO-Check for loose terminal fit in the PCM connectors. If necessary, substitute a known-good PCM and recheck.•

14-98

BACK

~

Interlock System - Key Interlock System Circuit Troubleshooting 1. Check the AfT shift cable adjustment (see page 14136). 2. Disconnect the key switch 7P connector from the steering lock assembly.

6. Measure the voltage between the No.7 terminal and body ground. KEY SWITCH CONNECTOR (7P)

3. Connect the No.7 terminal of the key switch connector to the battery positive terminal, and connect the No.5 terminal to the battery negative terminal. KEY SWITCH CONNECTOR (7P)




4. Turn the ignition switch to ACC (I), then push the ignition key.

'0.

'\.'rl~'«. the

key interlock solenoid operation. A clicking sound should be heard while pushing the ignition key, and no sound should be heard when releasing the key.

Does the key interlock solenoid operate properly? YES-Go to step 6.

NO-Check for blown No. 47 (20A) fuse in the under-hood fuse/relay box. If the fuse is OK, repair open or short in the wire between the No.7 terminal ofthe key switch connector and underhood fuse/relay box .• 7. Disconnect the park pin switch 4P connector on the front side ofthe shift lever. 8. With the shift lever in Park, check for continuity between the No.3 and No.4 terminals of the park pin switch 4P connector. PARK PIN SWITCH 4P CONNECTOR

NO- Faulty key interlock solenoid/switch. Replace the ignition key cylinder/steering lock assembly.• NOTE: Do not re-key the new ignition switch. Re-key the other lock cylinder to match the new switch.


Is there continuity? YES - Go to step 9. NO- Repair open in the wires between the park pin switch and the 4P connector. If wires are OK, replace the park pin switch .• (cont'd)

BACK

14-99

Automatic Transmission Interlock System - Key Interlock System Circuit Troubleshooting (cont'd) 9. Check for continuity between the No.4 terminal of the park pin switch 4P connector and the No.5 terminal of the key switch connector. KEY SWITCH CONNECTOR (7P)



NO-Repair open in the wire between No.4 terminal ofthe park pin switch 4P connector and the No.5 terminal of the key switch connector.• 10. Check for continuity between the No.3 terminal of the 4P connector and body ground. PARK PIN SWITCH 4P CONNECTOR


Is there continuity? YES-Check for loose key switch connector and park pin switch connector. If necessary, substitute a known-good steering lock assembly.• NO- Repair open in the wire between the No.3 terminal of the 4P connector and ground (G1 01) .•

14-100

BACK

Road Test Special Tools Required 8ackprobe set 07SAZ-001000A (Two required) 1. Warm up the engine to normal operating temperature (the radiator fan comes on). 2. Apply the parking brake, and block rear wheels. Start the engine, then shift to ~ position while pressing the brake pedal. Press the accelerator pedal, and release it suddenly. The engine should not stall. 3. Repeat the same test in ~ position. 4. Connect the Honda PGM Tester (A), and go to the PGM-FI Data List; then go to step 1. If you don't have a PGM Tester, go to step 5.

5. Pull back the carpet from the passenger's side of the center console to expose the PCM (A). 6. Connect the digital multimeter (8) and the special tools (C) to check voltage between the C27 (+) terminal and 820 (-) or 822 (-)terminal of the PCM.

C 07SAZ·001000A PCM CONNECTORS A (32P)

B(25P)

F=

8 9 10/1 6 6/ VI2 3 4 112113 1416 1617 1819 2021 ~23

Z4J

262627

1---1-

2829

aoV

31

'--

r--' r 1

2

9 10 L20 .....

lG1 (BRN/BlK)

o (16P)

C(31P) F;=;= -,.... r- ~ r-r-[8l 346 6 6 7 8 9 10 1 678112// 23V 161 11 1213 1416 V17 181V / / / / 161 718 1920 21V 6 7 8 9 10 111121 2122 18 14 16 16 //26 28 2728 29 _aoV .... 1-1~~~ 'F;=;=

'Y

lG;'r (BlK: '98·99) (BRN/BlK: '00·02)

--

I-

TPS (RED/BlK)

'Y

,"'"


(cont'd)

BACK

14-101

Automatic Transmission Road Test (cont'd) 7. Test-drive the vehicle on a flat road in the ~ position. Check for abnormal noise and clutch slippage. While driving, check that the shift points occur at the proper speeds by monitoring the throttle position sensor voltage and comparing your shift point speeds and voltage to those in the table. (The throttle position sensor voltage represents the throttle opening.) Upshift-~ position

Throttle Opening Throttle position sensor voltage: 0.7 V Throttle position sensor voltage: 2.25 V Fully-opened throttle. Throttle position sensor voltage: 4.5 V


1st --+ 2nd 9-10 14-16 24-27 39-43 35-39 57-63

2nd --+ 3rd 21-23 33-37 45-48 72-78 65-68 104-110

3rd --+ 4th 30-34 48-54 65-68 104-110 98-101 157-163

Lock-upON 45-48 73-77 77-81 124-130 99-103 160-166


Lock-up OFF 44-47 71-75 68-71 109-115 90-94 145-151

4th --+ 3rd 17-19 27-31

3rd --+ 2nd

2nd --+ 1st 6-8 (3rd --+ 1st) 9-13 (3rd --+ 1st)

--

--

--

89-92 142-148

54-58 87-93

27-31 44-50

Downshift-~ position

Throttle Opening Throttle position sensor voltage: 0.8 V Throttle position sensor voltage: 2.25 V Fully-opened throttle. Throttle position sensor voltage: 4.5 V

--

----

--

8. Accelerate to about 35 mph (57 km/h) so the transmission is in 4th, then shift from ~ position to [!] position. The vehicle should immediately begin slowing down from engine braking. 9. Check for abnormal noise and clutch slippage in the following positions. [j] (1st Gear) Position Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage. Upshifts should not occur with the shift lever in this position.

[!] (2nd Gear) Position Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage. Upshifts and downshifts should not occur with the shift lever in this position.

IRl (Reverse) Position Accelerate from a stop at full throttle, and check that there is no abnormal noise or clutch slippage. 10. Test in [f] (Park) Position. Park the vehicle on a slope (approx. 16°), apply the parking brake, and shift into [f] position. Release the brake; the vehicle should not move.

14-102

BACK

r

Stall Speed Test 1. Set the parking brake, and block the front wheels. 2. Connect a tachometer to the engine, and start the engine. 3. Make sure the NC switch is OFF. 4. After the engine has warmed up to normal operating temperature (the radiator fan comes on), shift to 00 position. 5. Fully press the brake pedal and accelerator for 6 to 8 seconds, and note engine speed. Do not move the shift lever while raising engine speed. 6. Allow two minutes for cooling, then repeat the test in ~, [1], and IRI positions. NOTE: • Do not test stall speed for more than 10 seconds at a time. • Stall speed tests should be used for diagnostic purposes only. • Stall speed should be the same in ~, 00, [1], and IRI positions. • Do not test stall speed with the NT pressure gauges installed. Stall Speed rpm: Specification: 2,400 rpm Service Limit: 2,250-2,550 rpm

PROBABLE CAUSE

TROUBLE Stall rpm high in ~,

00, [1], and IRI positions

• • • •

Low fluid level or ATF pump output Clogged ATF strainer Pressure regulator valve stuck closed Slipping clutch

Stall rpm high in [1] position

Slippage of 1st clutch

Stall rpm high in 00 position

Slippage of 2nd clutch

Stall rpm high in IRI position

Slippage of 4th clutch

Stall rpm low in ~,

00, [1], and IRI positions

• Engine output low • Torque converter one-way clutch slipping

BACK

14-103

Automatic Transmission Pressure Tests Special Tools Required • AfT oil pressure gauge set 07406-0020400 • AfT pressure hose, 2210 mm 07MAJ-PY4011A • AfT pressure hose adapter 07MAJ-PY40120 1. Before testing, be sure the transmission fluid is filled to the proper level. 2. Raise the front ofthe vehicle, and make sure it is securely supported. 3. Set the parking brake, and block rear wheels securely. 4. Allow the front wheels to rotate freely. 5. Warm up the engine (the radiator fan comes on), then stop it and connect the tachometer. 6. Connect the oil pressure gauges to each inspection hole securely, and do not allow dust or other foreign particles to enter the holes. TORQUE:

18 N·m p.8 kgf·m, 13Ibf·ft)

AfT OIL PRESSURE GAUGE SETWfPANEL 07406-0020400

AfT PRESSURE HOSE, 2210 07MAJ-PY4011A

mm

AfT PRESSURE HOSE ADAPTER 07MAJ-PY 40120

(4 Required)

(4 Required)

3RD=>~ PRES~~;~_~ _~ .. INSPECTION HOLE

LINE PRESSURE INSPECTION HOLE

14-104

4TH CLUTCH PRESSURE INSPECTION HOLE

BACK

2ND CLUTCH PRESSURE INSPECTION HOLE

7. Start the engine, and run it at 1,500 rpm. 8. Shift to [ID or [fl position, and measure line pressure at line pressure inspection hole (A). NOTE: Higher pressure may be indicated if measurements are made in shift lever positions other than [ID or [fl. 9. Shift to 10. Shift to

rn position, and measure 1st clutch pressure at the 1st clutch pressure inspection hole (8). IZl position, and measure 2nd clutch pressure at the 2nd clutch pressure inspection hole (C).

11. Shift to [fl position, then press the brake pedal and hold it. 12. Shift to ~ position, and release the brake pedal (the transmission is in 1st gear). 13. Accelerate the engine to 2,500 rpm (the transmission will be shifted to 2nd gear). 14. Release the accelerator for more than 5 seconds after the transmission is shifted to 2nd gear, the engine speed will decrease to about 1,000 rpm. 15. Press the accelerator very slowly (so it takes at least 5 seconds to raise the engine speed to 2,000rpm), then hold the engine speed at 2,000 rpm. 16. Measure 3rd and 4th clutch pressure atthe 3rd clutch pressure inspection hole (D), and the 4th clutch pressure inspection hole (E), as the transmission will shifted 2nd gear to 3rd gear, then to 4th gear.

PRESSURE

Line (A)

1st clutch

SHIFT LEVER POSITION

[ID or [fl

FLUID PRESSURE Standard

Service Limit

Torque converter, ATF pump, pressure regulator valve, torque converter check valve

800-860 kPa (8.2-8.8 kgf/cm2, 120-130 psi)

760 kPa (7.7 kgf/cm2, 110 psi)

No or low 1st pressure

1st clutch

790-870 kPa (8.1-8.9 kgf/cm2, 120-130 psi)

750 kPa (7.6 kgf/cm2, 110 psi)

IZl

No or low 2nd pressure

2nd clutch

~

No or low 3rd pressure

3rd clutch

No or low 4th pressure

4th clutch

rn

(C)

3rd clutch (D)

PROBABLE CAUSE

No (or low) line pressure

(8)

2nd clutch

SYMPTOM

4th clutch (E) [RJ

Servo valve or 4th clutch

17. Install the inspection hole bolts with new sealing washers, and tighten the bolts to the specified torque. TORQUE: 18 N·m (1.8 kgf.m,13Ibf.ft) NOTE: Do not reuse old sealing washers.

BACK

14-105

Automatic Transmission Torque Converter Clutch Solenoid Valve - Shift Solenoid Valve A Test

Torque Converter Clutch Solenoid Valve - Shift Solenoid Valve A Replacement

1. Disconnect the torque converter clutch solenoid valve 3P connector/shift solenoid valve A.

NOTE: Torque converter clutch solenoid valve/shift solenoid valve A assembly must be removed/replaced as an assembly. 1. Remove the bolts securing the ignition coil bracket ('98-99 models), then remove the harness cover from the transmission hanger. 2. Remove the mounting bolts and torque converter clutch solenoid valve/shift solenoid valve A.

2. Measure the resistance of the torque converter clutch solenoid valve between the No.3 terminal of the 3P connector and body ground.

STANDARD:

12-25Q 6x 1.0 mm 12 N·m (1.2 kgf·m,

3. Measure the resistance of the shift solenoid valve A between the No.1 terminal of the 3P connector and body ground.

STANDARD:

8.7Ibf·ft)

12-25Q

4. Replace the torque converter clutch solenoid valve/ shift solenoid valve A if either resistance is out of specification. 5. If the resistance is within the standard, connect the No.1 terminal of the 3P connector to the battery positive terminal. A clicking sound should be heard. Connect the No.3 terminal to the battery positive terminal. A clicking sound should be heard. Replace the torque converter clutch solenoid valve/ shift solenoid valve A if no sound is heard when connecting either terminal to the battery positive terminal.

3. Clean the mounting surface and fluid passage of the torque converter clutch solenoid valve/shift solenoid valve A, and install a new torque converter clutch solenoid valve/shift solenoid valve A with a new filter/gasket (8). 4. Install the harness cover on the transmission hanger, and install the ignition coil bracket bolts ('98-99 models). 5. Install the male terminal connector (C) of the solenoid connector on the harness cover. 6. Check the connector for rust, dirt, or oil, then reconnect the connector securely.

14-106

BACK

Shift Solenoid Valves Band C Test

Shift Solenoid Valves Band C Replacement

1. Remove the starter. NOTE: If the shift solenoid valve Band C are replaced or removed at the same time, be sure to reinstall them correctly. The connector color of shift solenoid valve B is black, and the connector color of shift solenoid valve C is brown.

2. Disconnect the shift solenoid valve B or C connector.

1. Remove the starter. NOTE: If you are only replacing shift solenoid valve C, starter removal is not needed.

c

2. Remove the mounting bolt and the shift solenoid valve B.

3. Measure the resistance between the No.1 and No.2 terminals of the shift solenoid valve B or C.

STANDARD:

12-25 Q

4. Replace the shift solenoid valve B or C if the resistance is out of standard. 5. If the resistance is within the standard, connect the No.2 terminal of the shift solenoid valve B or C connector to the battery positive terminal, and connect the No.1 terminal to the battery negative terminal. A clicking sound should be heard. Replace the shift solenoid valve B or C if no sound is heard.

6x1.0mm 12 N·m (1.2 kgf·m, 8.7 Ibf·tt)

3. Remove the mounting bolt and the shift solenoid valve C. 4. Install a new shift control solenoid valve B or C with new O-rings (A). While installing the valves, do not allow dust or other foreign particles to enter the transmission. 5. Check the connector for rust, dirt or oil, then reconnect the connector securely. 6. Install the starter.

BACK

14-107

Automatic Transmission A/T Clutch Pressure Control Solenoid Valves A and B Test 1. Disconnect the AIT clutch pressure control solenoid valves A and B 2P connectors. A

7. Connectthe No.1 terminal ofthe AIT clutch pressure control solenoid valves A and B to the battery positive terminal, and connect the No.2 terminal to the battery negative terminal. Make sure the AIT clutch pressure control solenoid valve Aand B move.

c

~/ B

2. Measure the resistance of the AIT clutch pressure control solenoid valves A and B between the No.1 and No.2 terminals of each connector.

STANDARD:

B

8. Disconnect one of the battery terminals and check valve movement.

About 5.0 Q

3. If the resistance of either AIT clutch pressure control solenoid is out of standard, replace the AIT clutch pressure control solenoid valves A and B. 4. Connect the No.1 terminal ofthe AIT clutch pressure control solenoid valve A (and B) to the battery positive terminal, and connect the No.2 terminal to the battery negative terminal. A clicking sound should be heard.

NOTE: You can see the valve movement through the fluid passage in the mounting surface of the AIT clutch pressure control solenoid valves A and B body (C). 9. If either valve binds, or moves sluggishly, or if the AIT clutch pressure control solenoid does not operate, replace the AIT clutch pressure control solenoid valves A and B.

5. If not, remove the AIT clutch pressure control solenoid valves A and B. 6. Check the fluid passage of the AIT clutch pressure control solenoid valve for dust and dirt.

14-108

A

BACK

~I

AIT Clutch Pressure Control Solenoid Valves A and B Replacement 1. Remove the ATF cooler hose (outlet line) at the ATF cooler line. Turn the end of the cooler hose up to prevent ATF from flowing out, then plug the line and hose. 2. Remove the ATF cooler line (outlet line) from the transmission housing. 3. Remove the mounting bolts and the AfT clutch pressure control solenoid valves A and B (A).

4. Clean the mounting surface and fluid passage of the AfT clutch pressure control solenoid valves A and B and the transmission housing. 5. Place the new gasket (B) on the transmission housing, then install the 8 x 18 mm ATF feed pipe (C), 8 x 26 mm pipe (D) and 8 x 36 mm pipe (E) with their filter side into the transmission housing. 6. Install the new O-rings (F) over the feed pipes, and install the 8 x 40 mm ATF feed pipe (G). 7. Install the new AfT clutch pressure control solenoid valves A and B and harness clamp bracket (H). 8. Check the AfT clutch pressure control solenoid valve connectors for rust, dirt, or oil, then connect them securely.

D

9. Install the ATF cooler line (outlet line), and connect the ATF cooler hose to the cooler line.

B

BACK

14-109

Automatic Transmission Speed Sensor Replacement 1. Disconnect the connectors from the mainshaft and countershaft speed sensors. 2. Remove the bolt securing the mainshaft speed sensor, then remove the mainshaft speed sensor from the end cover.

6x1.0mm 12 N·m (1.2 kgf.m, 8.7Ibf·ft)

3. Remove the bolt securing the countershaft speed sensor, then remove the countershaft speed sensor from the transmission housing. 6x1.0mm 12 N·m (1.2 kgf·m, 8.7Ibf·ft)

4. Replace the O-rings with new ones before installing the sensors. 5. Install the mainshaft and countershaft speed sensors, then connect the connectors.

14-110

BACK

3rd Clutch Pressure Switch Replacement

2nd Clutch Pressure Switch Replacement





2. Replace the 2nd clutch pressure switch, then install a new one with a new sealing washer. Tighten the switch on the metal part, not the plastic part. 3. Reconnect the connector, making sure there is no water, oil, dust, or other foreign particles inside it.

BACK

2. Replace the 3rd clutch pressure switch, then install a new one with a new sealing washer. Tighten the switch on the metal part, not the plastic part. 3. Reconnect the connector, making sure there is no water, oil, dust, or other foreign particles inside it.

14-111

Automatic Transmission ATF Level Check NOTE: Keep all foreign particles out ofthe transmission. 1. Warm up the engine to normal operating temperature (the radiator fan comes on). 2. Park the vehicle on the level ground. Turn off the engine.

6. If the level is below the lower mark, pour the recommended fluid into the filler hole (A) to bring it to the upper mark. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a nonHonda ATF can affect shift quality. B 24x 1.5mm 44 N·m (4.5 kgf·m, 33 Ibf·ft)

3. Remove the dipstick (yellow loop) (A) from the transmission, and wipe it with a clean cloth.

\ A

7. Install the ATF filler bolt (8) with a new sealing washer (C). 4. Insert the dipstick into the transmission. 8. Insert the dipstick back into the transmission. 5. Remove the dipstick and check the fluid level. It should be between the upper mark (8) and lower mark (C).

14-112

BACK

ATF Replacement NOTE: Keep all foreign particles out of the transmission. 1. Bring the transmission up to operating temperature (the radiator fan comes on) by driving the vehicle. 2. Park the vehicle on the level ground, and turn the engine off. 3. Remove the ATF filler bolt and drain plug, and drain the automatic transmission fluid (ATF). NOTE: If a cooler flusher is to be used, refer to ATF Cooler Flushing (see page 14-127).

18x 1.5 mm 49 N·m (5.0 kgf·m, 36 Ibf·ft)

5. Refill the transmission with the recommended fluid into the filler hole (A) to the upper mark on the dipstick. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality. Automatic Transmission Fluid Capacity: 2.9 4 (3.1 US qt, 2.6 Imp qt) at changing 7.2 4 (7.6 US qt, 6.3 Imp qt) at overhaul B 24x 1.5 mm 44 N·m (4.5 kgf·m, 33 Ibf·ft)

A 6. Install the ATF filler bolt (B) with a new sealing washer (C).

4. Reinstall the drain plug with a new sealing washer.

BACK

14-113

Automatic Transmission Transmission Removal 8. Remove the ATF cooler hose (A) from the clamp (B) on the starter.

1. Before disconnecting power, make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset stations. 2. Disconnect the battery negative terminal, then remove the positive terminal. 3. Remove the battery hold-down bracket, then remove the battery and battery tray.

\

4. Remove the battery cable clamps from the battery base. 5. Loosen the mounting bolts securing the battery base bracket, then remove the battery base bracket and battery base. 6. Remove the intake air duct and air cleaner housing assembly. 7. Raise the vehicle, and make sure it is securely supported. Remove the drain plug, and drain the automatic transmission fluid (ATF). Reinstall the drain plug with a new sealing washer.

B

c

A

9. Remove the ATF cooler hoses (A) from the ATF cooler lines (C). Turn the ends of the ATF cooler hoses up to prevent ATF from flowing out, then plug the ATF cooler hoses and lines. NOTE: Check for any signs of leakage at the hose joints. 10. Remove the starter cables (A) from the starter (B) and clamp bracket (C), then remove the starter.

B~ E

D

C

11. Remove the transmission ground terminal (D). 12. Disconnect the shift solenoid valve B connector (E), and C connector (F), then remove the harness clamp from the clamp bracket.

14-114

BACK

13. Disconnect the connectors from the 3rd clutch pressure switch (A), mainshaft speed sensor (8), and AfT clutch pressure control solenoid valves A and 8 (e), then remove the harness clamps from the clamp brackets.

17. Disconnect the connectors from the countershaft speed sensor (A), and 2nd clutch pressure switch (8).

A

18. Remove the transmission range switch connector (e) from the connector bracket (D), then disconnect it. 14. Disconnect the connector from the torque converter clutch solenoid valve/shift solenoid valve A assembly (A), then remove the connector from harness cover (8). B

A

19. Remove the nut from the front mount.

D

15. Remove the two bolts securing the harness cover and the ignition coil bracket, and remove the ignition coil (e). ('98-99 models) 16. Push the harness cover rearward to remove from the transmission hanger (D).

(cont'd)

BACK

14-115

Automatic Transmission Transmission Removal (cont'd) 20. Lift and support the engine/transmission assembly with an engine hanger (P/N AAR-T-1256, available through the American Honda Tool and Equipment program, or equivalent).

22. Remove the cotter pins (A) and castle nuts (hex nuts) (8), and remove the damper forks (e), then separate the ball joints from the lower arms (D), refer to the '98-02 Accord Service Manual (see page 18-17).

E


23. Remove the bolts securing the radius rods (E), then separate the radius rods from the lower arms (D). 24. Pry the driveshafts out of the differential and the intermediate shaft, refer to the '98-02 Accord Service Manual (see step 10 on page 16-4).

14-116

BACK

25. Make reference marks (A) across both the front beam (B) and the rear beam (C).

26. Disconnect the vacuum tube (A) on the front beam (B), and unclamp the power steering fluid pipe (C) from the clamps on the front beam.

28. Remove the transmission lower rear mount (A) from the transmission.

A

29. Pull on the inboard joints to remove the left driveshaft from the differential and to remove the right driveshaft from the intermediate shaft. 30. Move the left driveshaft to the front side. Coat all precision finished surfaces with clean engine oil, then tie the plastic bags (B) over the driveshaft ends. 31. Remove the intermediate shaft.

A

27. Remove the nuts securing the transmission lower mounts, then remove the front beam (B). 32. Coat all precision finished surfaces with clean engine oil, then tie the plastic bags over the both ends of intermediate shaft.

(cont'd)

BACK

14-117

Automatic Transmission Transmission Removal (cont'd) 33. Remove the bolts securing shift cable holder (A), then remove shift cable cover (8).

36. Remove the torque converter cover (A), then remove the eight drive plate bolts (8) one at a time while rotating the crankshaft pulley.

NOTE: To prevent damage to the control lever joint, remove the bolts securing the holder before removing the bolts securing the cover.

B

D

c

/

A

37. Remove the engine stiffener bolts (e). 38. Remove the front mount bracket. 34. Remove the lock bolt (e) securing the control lever (D), then remove the shift cable (E) with the control lever. Do not bend the shift cable excessively. 35. Install a 6 x 1.0 x 14 mm bolt (A) and nut (8) on the shift cable cover (e), then reinstall the shift cable cover to the torque converter housing. (The torque converter may stay on the engine, and the bolt head will support the torque converter, when the transmission is removed.)

/

c

A

14-118

BACK

39. Place a transmission jack under the transmission.

42. Pull the transmission away from the engine until it clears the dowel pins, then lower it on the transmission jack.

40. Remove the transmission housing mounting bolts.

NOTE: If the torque converter is stuck to the drive plate, reach through the starter opening, and pull it toward the transmission housing. 43. Remove the shift cable cover, then remove the torque converter assembly from the torque converter housing.

41. Remove the transmission housing mounting bolts (A) and connector bracket bolt (8).

B

A

44. Remove the transmission lower front mount.

(cont'd)

BACK

14-119

Automatic Transmission Transmission Removal (cont'd) 45. Inspect the drive plate, and replace it if it's damaged.

46. Remove the 6 x 1.0 x 14 mm bolt (A) and nut (B) from the shift cable cover (C).

B~~

/

A

14-120

BACK

Transmission Installation 1. Flush the ATF cooler (see page 14-127).

6. Attach the transmission to the engine, then install the transmission housing mounting bolts (A) and connector bracket bolt (8).

2. Install the transmission lower front mount.

B 12x 1.25mm 64 N·m (6.5 kgf.m, 47 Ibf·ttl


3. Install the torque converter assembly (A) on the mainshaft (8) with a new O-ring (e).

A 12 x 1.25 mm 64 N·m (6.5 kgf·m, 47 Ibf·ttl

D

7. Install the transmission housing mounting bolts.

A\ \ c

B E

4. Install the 14 mm dowel pin (D) and 10 mm dowel pin (E) in the torque converter housing (F).

/


5. Place the transmission on a transmission jack, and raise it to engine level.

(cont'd)

BACK

14-121

Automatic Transmission Transmission Installation (cont'd) 13. Install the control lever (A) with the shift cable (8) on the control shaft (C). Do not bend the shift cable excessively.

8. Install the front mount bracket. 10x 1.25 mm 38 N·m (3.9 kgf·m, 28 Ibf·ft)

6x 1.0mm 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft)

c

~

B

'8x1.25mm 22 N·m (2.2 kgf·m, 16Ibf·ft)

B

14. Install the lock bolt (D) with a new lock washer (E), then bend the lock washer tab against the bolt. 15. Install the shift cable cover (F), then install the shift cable holder (G) on the shift cable cover.

A

/

~ ~:~: :'i,~

NOTE: To prevent damage to the control lever joint, be sure to install the shift cable holder after installing the shift cable cover to the torque converter housing. kgf·m, •.7Ibl·ft)

10x 1.25 mm 38 N·m (3.9 kgf·m, 28 Ibf·tt)

10. Attach the torque converter to the drive plate (8) with eight bolts (C). Rotate the crankshaft pulley as necessary to tighten the bolts to 1/2 of the specified torque, then to the final torque, in a crisscross pattern. After tightening the last bolt, check that the crankshaft rotates freely.

16. Clean the areas where the intermediate shaft contacts the transmission (differential) with solvent or carburetor cleaner, and dry with compressed air. Then install the intermediate shaft in the differential. While installing the intermediate shaft, be sure not to allow dust or other foreign particles to enter the transmission.

11. Install the torque converter cover (D). 12. Tighten the crankshaft pulley bolt as necessary (see page 6-17).

14-122

BACK

10x 1.25 mm 39 N·m (4.0 kgf·m, 30 Ibf·ft)

~

17. Install new set rings on the right and left driveshafts.

20. Install the front beam (A) by aligning both reference marks (8) on both rear beam (C), and tighten the bolts.

18. Install the right and left drives haft, refer to the '98-02 Accord Service Manual (see page 16-20). While installing the left driveshaft in the differential, be sure not to allow dust or other foreign particles to enter the transmission.

A

NOTE: • Clean the areas where the left driveshaft contacts the transmission (differential) with solvent or carburetor cleaner, and dry with compressed air. • Turn the right and left steering knuckle fully outward, and slide the left driveshaft into the differential until you feel its spring clip engage the side gear. Slide the right driveshaft into the intermediate shaft until you feel its spring clip engage the intermediate shaft. 19. Install the transmission lower rear mount on the transmission.


D 10x 1.25 mm 38 N·m (3.9 kgf·m, 28lbf·ftl

~

10x1.25mm 38 N·m 13.9 kgf.m, 28 Ibf·ftl

21. Install the transmission lower mount nuts (D). 22. Connect the vacuum tube (E), and install the power steering fluid pipe (F) on its clamps.

(cont'd)

BACK

14-123

Automatic Transmission Transmission Installation (cont'd) 23. Install the damper forks (A), then install the ball joints on each lower arms (8) with the castle nuts (hex nuts) (C) and new cotter pins (D).

27. Install and tighten the nut on the front mount.

10x 1.25 mm 43 N·m (4.4 kgf·m, 32 Ibf·ft)

12x 1.25mm 64 N·m (6.5 kgf·m, 47Ibf·ft)

14x 1.5 mm 179 N·m (18.3 kgf·m, 132Ibf·ft)

28. Remove the hoist, then remove the hoist bracket from the engine.

E

./ D/.

29. Connect the transmission range switch connector (A), then install it on its connector bracket (8) . D

A

~

12x 1.25mm 49-59 N·m (5.0-6.0 kgf.m, 36-43 Ibf·ft)

24. Install the radius rods (E) on each lower arm. 25. Remove the jack from the transmission. 26. Install the splash shield.

c 30. Connect the connectors to the countershaft speed sensor (C) and 2nd clutch pressure switch (D). Do not allow water, fluid, oil, dust, or other foreign particles to enter the 2nd clutch pressure switch connector.

14-124

BACK

31. Install the harness cover (A) on the transmission hanger (8), then install the ignition coil (C). ('98-99 models)

34. Connect the connectors to the shift solenoid valve 8 (A) and shift solenoid valve C (8), then install the clamp on the clamp bracket.

A

B

D

8x1.25mm 26 N·m (2.7 kgf·m, 20Ibf·ft)

32. Install the torque converter clutch solenoid valve/ shift solenoid valve A assembly connector (D) on the harness cover, then connect the connector. 33. Connect the connectors to the 3rd clutch pressure switch (A), mainshaft speed sensor (8), and AfT clutch pressure control solenoid valves A and 8 (C), then install the clamps on the clamp brackets. Do not allow water, fluid, oil, dust, or other foreign particles to enter the 3rd clutch pressure switch connector.

12x 1.25 mm 64N·m (6.5 kgf·m, 47Ibf·ft)

c

9 N·m (0.9 kgf·m, 6.5Ibf·ft)

35. Install the transmission ground terminal (C). 36. Install the starter (D) on the torque converter housing. Connect the starter cables (E) to the starter, and install the harness clamp on the clamp bracket. Make sure the crimped side of the starter cable ring terminal is facing out. 37. Connect the ATF cooler hoses (A) to the ATF cooler lines (8) (see page 14-128). Clamp the ATF cooler hose with the clamp (C) on the starter.

r

(cont'd)

BACK

14-125

Automatic Transmission Transmission Installation (co nt'd) 38. Install the battery base bracket and battery base. 39. Install the battery cable clamps on the battery base. 40. Install the battery tray and battery, then secure the battery with its hold-down bracket. 41. Install the intake air duct and air cleaner housing assembly. 42. Refill the transmission with ATF (see page 14-113). 43. Connect the battery positive terminal, then connect the negative terminal. 44. Set the parking brake. Start the engine, and shift the transmission through all gears three times. 45. Check the shift lever operation, AfT gear position indicator operation, and shift cable adjustment. 46. Check and adjust the front wheel alignment, refer to the '98-02 Accord Service Manual (see page 185). 47. Start the engine and let it reach normal operating temperature (the radiator fan comes on) with the transmission in ~ or [t!l position, then turn it off and check the ATF level (see page 14-112). 48. Perform a road test (see page 14-101). 49. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 50. Loosen the front mount nut after the road test, then retighten the nut to the specified torque. 12x 1.25 mm 54 N·m (5.5 kgf·m, 40 Ibf·ft)

14-126

BACK

ATF Cooler Flushing 7. With the water and air valves (A) off, attach the water and air supplies to the flusher. (Hot water if available.)

Special Tools Required Commercially available transmission cooler flusher Kent-Moore J38405-A or equivalent This procedure should be performed before reinstalling the transmission. 1. Check the equipment for wear and cracks before using it. Replace any worn or cracked components. 2. Using the measuring cup, fill the flusher (A) with 21 ounces (approximately 2/3 full) of biodegradable flushing fluid (J35944-20). Do not substitute with any other fluid. Follow the handling procedure on the fluid container.

8. Turn on the water valve for 10 seconds. If water does not flow through the cooler, it is completely plugged, cannot be flushed, and must be replaced. 9. Depress the trigger to mix the flushing fluid into the water flow. Use the wire clip to hold the trigger down. 10. While flushing with the water and flushing fluid for two minutes, turn the air valve on for five seconds every 15-20 seconds to create a surging action. AIR PRESSURE: MAX 845 kPa (8.45 kgf/cm', 120 psi) 11. Turn the water valve off. Release the trigger, then reverse the hoses to the cooler so you can flush in the opposite direction. Repeat steps 8 through 10. 3. Secure the flusher filler cap, and pressurize the flusher with compressed airto 550-829 kpa (5.68.45 kgf/cm2, 80-120 psi). The air line should be equipped with a water trap to ensure a dry air system. 4. Hang the flusher under the vehicle. 5. Attach the flusher discharge hose (8) to the return line of the ATF cooler using a clamp. 6. Connect the drain hose (C) to the inlet line on the ATF cooler using a clamp. Securely clamp the opposite end of the drain hose to a bucket (D) or floor drain.

12. Release the trigger, and rinse the cooler with water for one minute. 13. Turn the water valve and the water supply off. 14. Turn the air valve on for two minutes, or until no moisture is visible leaving the drain hose. Residual moisture in the cooler or lines can damage the transmission. 15. Remove the flusher from the cooler line. Attach the drain hose to an ATF container. 16. Install the transmission, and leave the drain hose attached to the cooler line.

(cont'd)

BACK

14-127

Automatic Transmission ATF Cooler Flushing (cont'd) 17. Make sure the transmission is in [fJ position. Fill the transmission with ATF, and run the engine for 30 seconds or until approximately 0.95 2 (1.0 US qt., 0.8 Imp qt.) is discharged.

ATF Cooler Hoses Replacement 1. Connect the cooler hoses (A) to the lines (B) and the ATF cooler, and secure them with the clips (C).

E

D

18. Remove the drain hose, and reconnect the cooler return hose to the transmission. 19. Refill the transmission with ATF to the proper level (see page 14-113).

""""\

I

2. Clamp the ATF cooler hose with the yellow mark .(0) on the clamp (E).

14-128

BACK

Shift Lever Removal 1. Shift the transmission into [RJ position.

5. Disconnect the shift lock solenoid connector (A) and park pin switch 4P connector (B).

2. Remove the center console, refer to '98-02 Accord Service Manual (see page 20-83). 3. Remove the nut securing the shift cable end (A), then separate the shift cable end from the shift lever assembly.

c 6. Remove the four bolts (C) securing the shift lever bracket base, then remove the shift lever assembly.

A

4. Rotate the socket holder (A) on the shift cable (B) counterclockwise a quarter turn, then slide the holder to remove the shift cable from the shift lever bracket base (C). NOTE: Do not remove the shift cable by twisting the shift cable guide pipe (D).

BACK

14-129

Automatic Transmission Shift Lever Installation 1. Install the shift lever assembly. 2. Turn the ignition switch ON (\1), and verify that the IRJ position indicator comes on.

5. Insert a 6.0 mm (0.24 in.) pin (A) into the positioning hole (8) on the shift lever bracket base through the positioning hole on the shift lever assembly.

(I) 3. If necessary, push the shift cable until it stops, then release your hand. Pull the shift cable back one step so that the shift position is in IRJ.

@/""'->. . .I)_---J,.J-.I~ .

+++++[8]+

6. Rotate the socket holder (A) on the shift cable (8) counterclockwise a quarter turn, then slide the holder onto the shift lever bracket base (C). Install the shift cable end (D) over the mounting stud (E) by aligning its square hole (F) with the square shape (G) at the bottom of the stud. Rotate the holder clockwise a quarter turn to secure the shift cable. NOTE: Do not install the shift cable by twisting the shift cable guide (H).


D

14-130

BACK

F

10. Remove the 6.0 mm (0.24 in.) pin that was installed to hold the shift lever.

7. Verify that the shift cable end (A) is properly installed on the mounting stud (B). Properly Installed:

@D)= I

T

\

A

11. Connect the shift lock solenoid connector and park pin switch 4P connector. 12. Move the shift leverto each gear, and verify that the AfT gear position indicator follows the transmission range switch. B





BACK

14-131

Automatic Transmission Shift Lever DisassemblyIReassembly SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service, refer to '98-02 Accord Service Manual (see page 23-28). Apply silicone grease to these parts: • Movable parts of the shift lever. • Movable parts of the shift lock mechanism. • Sliding surfaces on the detent spring. PUSHBUTTON

I

SPRING

~ SHIFT LOCK SOLENOID PLUNGER

/

/.SHIFTLEVER KNOB

~

~ ~

SCREW

/ 3 N·m (0.3 kgf·m, 2lbf·ftl APely non-hardening thread loc sealant.

PLUNGER SPRING

O~ SHIFT LOCK

~~~"'-<"~

/

AfT GEAR POSITION INDICATOR PANEL

~

I

/

, V

AfT GEAR POSITION

~ INDICATOR PANEL ~ LIGHT HOUSING

SHIFT LOCK SOLENOID

---LEVER COVER

~8X1.2smm


)

~

SHIFT CABLE

8x1.2Smm 22 N·m (2.2 kgf·m, 16 Ibf·ftl

14-132

BACK

~

Shift Cable Replacement 1. Raise the front of the vehicle, and make sure it is securely supported, refer to the '98-02 Accord Service Manual (see page 1-17).

7. Remove the floor heat shield. 8. Remove the shift cable guide bracket (A) and grommet (8).

2. Set the parking brake, and block rear wheels securely. 3. Shift the transmission into IRl position. 4. Remove the center console, refer to the '98-02 Accord Service Manual (see page 20-83). 5. Remove the nut securing the shift cable end (A), then separate the shift cable end from the shift lever assembly. 6x 1.0mm 12 N·m 11.2 kgf.m, 8.7Ibf·ft)

9. Remove the bolts securing the shift cable holder (A), then remove the shift cable cover (8). NOTE: To prevent damage to the control lever joint, remove the bolts securing the shift cable holder before removing the bolts securing the shift cable cover.

A

6. Rotate the socket holder (A) on the shift cable (8) counterclockwise a quarter turn, then slide the holder to remove the shift cable from the shift lever bracket base (C). NOTE: Do not remove the shift cable by twisting the shift cable guide pipe (D).

)

10. Remove the lock bolt (C) securing the control lever (D), then remove the shift cable (E) with the control lever.

(cont'd)

BACK

14-133

Automatic Transmission Shift Cable Replacement (cont'd) 11. Insert the new shift cable through the grommet hole, then install the shift cable guide bracket.

17. Turn the ignition switch ON (II), and verify that the [RJ position indicator light comes on.

12. Verify that the transmission is in [RJ position on the control shaft.

18. If necessary, push the shift cable until it stops, then release your hand. Pull the shift cable back one step so that the shift position is in [RJ.

13. Install the control lever (A) with the shift cable (B) on the control shaft (C). 00 not bend the shift cable excessively. 6x 1.0 mm 9.a N·m 11.0 kgf·m, 7.2Ibf·ft)

@-). . .i)_----""'-'I~ ..

c

+++++1BJ+ 19. Turn the ignition switch OFF.


\ o

ax1.25mm 22 N·m 12.2 kgf·m, 16Ibf·ft)

6x 1.0 mm 14 N·m 11.4 kgf·m, 10Ibf·ft)

14. Install the lock bolt (0) with a new lock washer (E), then bend the lock washer tab against the bolt. 15. Install the shift cable cover (F), then install the shift cable holder (G) on the cover. NOTE: To prevent damage to the control lever joint, be sure to install the shift cable holder after installing the shift cable cover to the torque converter housing. 16. Install the floor heat shield.

14-134

BACK

21. Rotate the socket holder (A) on the shift cable (8) counterclockwise a quarter turn, then slide the holder onto the shift lever bracket base (e). Install the shift cable end (D) over the mounting stud (E) by aligning its square hole (F) with the square shape (G) atthe bottom ofthe stud. Rotate the holder clockwise a quarter turn to secure the shift cable.



\ //

8x1.25mm 22 N·m 12.2 kgf·m, 16 Ibf·ft)

25. Remove the 6.0 mm (0.24 in.) pin that was installed to hold the shift lever. 26. Move the shift lever to each gear, and verify that the AfT gear position indicator follows the transmission range switch. 27. Start the engine, and check the shift lever operation in all gears. 22. Verify that the shift cable end (A) is properly installed on the mounting stud (8). Properly Installed:

@D= /

A

T\

B



BACK

14-135

Automatic Transmission Shift Cable Adjustment 5. Push the shift cable until it stops, then release your hand. Pull the shift cable back one step so that the shift position is in [RI.

1. Shift the transmission into [RI position. 2. Remove the center console, refer to '98-02 Accord Service Manual (see page 20-83). 3. Remove the nut securing the shift cable end (A), then separate the shift cable end from the shift lever assembly.

©ii

~

• • • • • [8]+

6. Turn the ignition switch ON (II), and verify that the [RI position indicator light comes on. 7. Turn the ignition switch OFF.

4. Rotate the socket holder (A) on the shift cable (B) counterclockwise a quarter turn, then slide the holder to remove the shift cable from the shift lever bracket base (C).


NOTE: Do not remove the shift cable by twisting the shift cable guide (D).

)

14-136

BACK

9. Rotate the socket holder (A) on the shift cable (8) counterclockwise a quarter turn, then slide the holder onto the shift lever bracket base (C). Install the shift cable end (D) over the mounting stud (E) by aligning its square hole (F) with the square shape (G) at the bottom of the stud. Rotate the holder clockwise a quarter turn to secure the shift cable.



) 8x 1.25 mm 22 N·m (2.2 kgf·m, 16Ibf·ft)

13. Remove the 6.0 mm (0.24 in.) pin that was installed to hold the shift lever. 14. Move the shift lever to each gear, and verify that the AfT gear position indicator follows the transmission range switch. 15. Push the shift lock release, and verify that the shift lever releases.

10. Verify that the shift cable end (A) is properly installed on the mounting stud (8). Properly Installed:

@D= I

A

r

\

B



BACK

14-137

AIT Gear Position Indicator Component Location Index

AfT GEAR POSITION INDICATOR Indicator Input Test, page 14-143 Indicator Bulb Replacement, page 14-144


TRANSMISSION RANGE SWITCH Test, page 14-140 Replacement. page 14-141

14-138

BACK

Circuit Diagram

UNDER·HOOD FUSE/RELAY BOX No.41 (IOGA)


IGNITION SWITCH

No.42 (50A)

YEL - - - - - - - - - - - '

POWIERTRAIN CONTROL MODULE (PCM)

VSP OUT

D4 IND

ATP R

AS

AI4

D6

BLUlWHT

GRN!BLK


015 0131'88-99 models) BI4 '00-02 modols)

YEL WHT

BlUlW1HT

BlU PNK

BRN

MUlTIPLEX CONTROL

GAUGE ASSEMBLY

~~I~ER's

C.2 C.S

82

C4

811

C.i iH_ _ _-I cs }-t_ _ _-I C7

H-----i

8'.

ATP NP

C5

STARTER CUT RELAY

BlKIBLU W1HT

REDIBLK

---1 11

PNK----; BLU ----; BRN----;

.0

REDIBLK

-l .0

REDlBLK ~-+-..,

PNK ---l 11

PNK-+-+--I--t-~

---l.2 BRN ---l.3

BLU

BlU

LTBlU

-[>

CRUISE CONTROL UNIT

-+-t--I--I--+--1'

BRN---\--+-+--II--+-+--+

J----4---..J .0

BLK

BLK

1.

1. G501

ST

A

E

Gl01


BACK

14-139

AfT Gear Position Indicator Transmission Range Switch Test 1. Remove the transmission range switch connector (A) from the connector bracket (8), then disconnect the transmission range switch connector. 2. Check for continuity between the terminals in each switch position according to the table below. NOTE: Terminal No.1: Neutral position switch

B

Transmission Range Switch Continuity Check

1\

Terminal

Position

[f]

\

1

2

~ ~

14-140

4

5

6

7

8

9

,...

,...

-

-

,...

-

-

,... -

[!]

- -

[IJ

'"

-

10

,...

,...

IRl 1m

3

,...

-

BACK

Transmission Range Switch Replacement 1. Raise the front of the vehicle, and make sure it is securely supported, refer to the '98-02 Accord Service Manual (see page 1-17).

7. Set the transmission range switch to

00 position.

NOTE: The transmission range switch clicks in 00 position.

2. Set the parking brake, and block both rear wheels securely. 3. Shift to 00 position. 4. Remove the transmission range switch connector (A) from the connector bracket (B), then disconnect the transmission range switch connector.

8. Set the control shaft to 00 position.

6. Remove the transmission range switch cover (C), then remove the transmission range switch (0) from the end cover.

(cont'd)

BACK

14-141

A/T Gear Position Indicator Transmission Range Switch Replacement (cont'd) 9. Install the transmission range switch (A) on the control shaft (B), then secure it with the bolts. NOTE: Do not move the transmission range switch when tightening the bolts.

12. Turn the ignition switch ON (II). Move the shift lever through all gears, and check the transmission range switch synchronization with the AfT gear position indicator (A).

E

CD A

13. Move the shift lever through all gears, and verify the following:

B

• The engine will not start in any position other than [HI or [fl . .• The back-up lights come on when the shift lever is in [RJ position.

10. Install the transmission range switch cover (C), and the harness clamp (D) on the end cover (E). 11. Connect the transmission range switch connector (A), then install it on the connector bracket (B).

14-142

BACK

Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service, refer to the '98-02 Accord Service Manual (see page 23-28). 1. Remove the instrument panel, refer to the '98-02 Accord Service Manual (see page 20-84). 2. Remove the gauge assembly from the dashboard, refer to the '98-02 Accord Service Manual (see page 22-68), then disconnect the gauge assembly B (22P) and C (16P) connectors. 3. Inspect the connectors and connector terminals to be sure they are all making good contact . • If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system . • If the terminals look OK, make the following input tests at the gauge assembly B (22P) and C (16P) connectors. - If a test indicates a problem, find a correct the cause, then recheck the system. - If all the input tests prove OK, but the indicator is faulty, replace the printed circuit board.

GAUGE ASSEMBLY CONNECTORS


Cavity Wire Color

Test Condition



B11

VEL



B16

BLK

C4

WHT

CS

BRN

Check for continuity to ground: There should be continuity. Check for voltage to ground: There should be 1 V or less. There should be battery voltage in any other shift lever position.

C6

PNK

C7

BLU

C12

GRN/BLK

Under all conditions Ignition switch ON (II) and shift lever in IRl Ignition switch ON (II) and shift lever in [I] Ignition switch ON (II) and shift lever in ~ Ignition switch ON (II) and shift lever in 00 Ignition switch ON (II) and shift lever in ~

C1S

BLK/BLU

Shift lever in ~

C16

RED/BLK

Ignition switch ON (II) and shift lever in IHl


Check for continuity to ground: There should be no continuity in any other shift lever Dosition. Check for voltage to ground: There should be 1 V or less. There should be battery voltage in any other shift lever position.

BACK

• Blown No.9 (7.S A) fuse in the driver'S under-dash fuse/relay box • An ODen in the wire • Poor ground (GS01) • An ODen in the wire • Faulty transmission range switch • An open in the wire

• Faulty transmission range switch • Faulty PCM • An open in the wire • Faulty transmission range switch • An open in the wire

14-143

AfT Gear Position Indicator Indicator Bulb Replacement SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service, refer to the '98-02 Accord Service Manual (see page 2328). 1. Remove the instrument panel, refer to the '98-02 Accord Service Manual (see page 20-84). 2. Remove the gauge assembly, refer to the '98-02 Accord Service Manual (see page 22-68). 3. Disassemble the gauge assembly, refer to the '98-02 Accord Service Manual (see page 22-68). NOTE: Disassembly is not required on all models. 4. Replace the bulbs (A) at the reverse side of the gauge assembly (B).

14-144

BACK

AIT Interlock System Component Location Index




PARK PIN SWITCH

Test, page 14-150


SHIFT LOCKSOLENOID STEERING LOCK ASSEMBLY KEY INTERLOCK SOLENOID KEY INTERLOCK SWITCH


Test, page 14-149

BACK

14-145

AfT Interlock System Circuit Diagram UNDER-HOOD FUSE/RELAY BOX BATIERY

No.47 (20A)

~~+-~
IGNITION SWITCH No.41 (10DA)

No.42 (SOA)

DRIVER'S UNDER-DASH FUSE/RELAY BOX WHTNEL

NO.9 (7.SA)

BAT

IGl

YEL

STEERING LOCK ASSEMBLY

KEY INTERLOCK SWITCH KEY INTERLOCK SOLENOID

SHIFT ~OCK SOLENOID

2

WHT/RED

GRN

YEL

1

B22

A12

SHIFT LOCK SOLENOID

IGl


AlP P

LG Bll

BLK

BLK

A1S

BLKlBLU

PARK PIN SWITCH

ILU


B12

WHT/RED

~

BLK

WHTIBLK

1 G501


A28 ILU

L:H POWER TRAIN CONTROL MODULE (PCM)

G401

14-146

BACK

A32 BKSW

H

Control Unit Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service, refer to the '98-02 Accord Service Manual (see page 23-28). 1. Disconnect the 22P connector from the multiplex control unit (driver's), then remove the mUltiplex control unit (driver's) from the driver's under-dash fuse/relay box. 2. Inspect the connectors and connector terminals to be sure they are all making good contact. • If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. • If the terminals look OK, go to step 3. NOTE: If the shift lock solenoid clicks when the ignition switch is turned ON (II) while depressing the brake pedal with the shift lever in [f] position, the shift lock system is OK. If the shift lever cannot be shifted from [f] position, test the transmission range switch. 3. With the driver's unit still disconnected from its connector and the fuse/relay box, make these input tests at its connector or its fuse/relay box socket. • If a test indicates a problem, find and correct the cause, then recheck the system. • If all the input tests prove OK, go to step 4.

(cont'd)

BACK

14-147

AfT Interlock System Control Unit Input Test (cont'd)

MULTIPLEX CONTROL UNIT, DRIVER'S CONNECTORS

22P


" (0 river's 24PConnector Multiplex Control Umt Test Condition Cavity Wire Color




A3

--

Shift lever in ~


A12

--



• • • •

•

A14

--

A24

--

Under all conditions Ignition switch turned ON (II)


• • • • •

" (0" ' ) 22P Connector M uI" I Contro I Umt tlJ)lex rivers Test Condition Cavity Wire Color


Faulty transmission range switch Poor ground (G101) An open in the wire Blown No. 13 (7.5A) fuse in the passenger's under-dash fuse/ relay box Faulty passenger's under-dash fuse/relay box An open in the wire Poor ground (G401) An open in the wire Blown No.9 (7.5 A) fuse in the driver's under-dash fuse/relay box An open in the wire


B11

BLK

B22

GRN

Under all conditions Ignition switch ON (II)


• Poor ground (G503) • An op_en in the wire • Blown No.9 (7.5A) fuse in the driver's under-dash fuse/relay box • Faulty shift lock solenoid • An open in the wire

4. Reconnect the connectors to the multiplex control unit (driver's), and make this input test. B12

WHT/RED

Ignition switch ON (II) and brake pedal pushed Ignition switch ON (II), brake pedal and accelerator pedal pressed at the same time

Check for voltage to ground: There should be battery voltage. Check for voltage to ground: There should be 1 V or less.

• Faulty brake pedal position switch • Faulty PCM • Faulty multiplex control unit (driver's) • An open in the wire

• If a test indicates a problem, find and correct the cause, then recheck the system . • If all the input tests prove OK, substitute a known-good multiplex control unit (driver's), and recheck the system. Ifthe system is OK, the multiplex control unit (driver's) must be faulty; replace it.

14-148

BACK

Key Interlock Solenoid/Switch Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service, refer to the '98-02 Accord Service Manual (see page 2328).

Shift Lock Solenoid Test 1. Remove the center console, refer to the '98-02 Accord Service Manual (see page 20-83). 2. Disconnect the shift lock solenoid 2P connector.

1. Remove the driver's dashboard lower cover, refer to the '98-02 Accord Service Manual (see page 2084).

2. Disconnect the key switch 7P connector from the steering lock assembly. 3. Check for continuity between the No.5 and No.7 terminals when the key is pushed, and check for no continuity when the key is released. KEY SWITCH CONNECTOR (7P)

3. Connect the No.1 terminal of the shift lock solenoid connector to the battery positive terminal, and connect the No.2 terminal to the battery negative terminal. 4. Check that the shift lever can be moved from the (f] position. Release the battery terminals from the shift lock solenoid connector. Move the shift lever back to the (f] position, and make sure it locks. Terminal side of male terminals

4. Check that the key cannot be removed with power connected to the No.7 terminal and ground connected to the No.3 terminals. • If the key cannot be removed, the key interlock solenoid is OK . • If the key can be removed, replace the steering lock assembly (the key interlock solenoid is not available separately).

BACK

NOTE: Do not connect power to the No.2 terminal (reverse polarity) or you will damage the diode inside the solenoid. 5. Check that the shift lock releases when the release lever is pushed, and check that it locks when the release lever is released. 6. If the solenoid does not work, replace it.

14-149

AIT Interlock System Shift Lock Solenoid Replacement

Park Pin Switch Test

1. Remove the center console, refer to the '98-02 Accord Service Manual (see page 20-83).

1. Remove the center console, refer to the '98-02 Accord Service Manual (see page 20-83).

2. Disconnect the shift lock solenoid 2P connector.

2. Disconnect the park pin 4P connector.

3. Pry the shift lock solenoid clamp (A) with a screwdriver, then remove the shift lock solenoid (8). E

A

4. Install the shift lock solenoid plunger (e) and plunger spring (D) in the new shift lock solenoid.

3. Shift the shift lever into the [f) position, then check for continuity between the No.3 and No.4 terminals. There should be no continuity. 4. Shift the shift lever out of the [f) position, and check for continuity between the terminals in step 3. There should be continuity.

5. Install the shift lock solenoid by aligning the joint of the shift lock solenoid with the tip of the shift lock stop (E).

5. If the park pin switch is faulty, replace the shift lever bracket base.

6. Secure the shift lock solenoid with the clamp, then connect the shift lock solenoid connector.

NOTE: The park pin switch is not available separately from the shift lever bracket base.

14-150

BACK

Transmission End Cover End Cover Removal Exploded View

HARNESS CLAMP BRACKET

END COVER

TRANSMISSION RANGE SWITCH COVER

END COVER GASKET Replace.

SHAFT

TRANSMISSION RANGE SWITCH PITOTPIPE ('00-02 models) ~LUBRICATION ~ PITOTPIPE

('00-02 models)

CONICAL SPRING WASHER Replace. BEARING HUBI BALL BEARING ASSEMBLY -(:OI\lIlCA~L

SPRING WASHER

Replace. PITOT FLANGE ('00-02 models) MAINSHAFT IDLER GEAR -'COINIC:ALSPRING WASHER


PARK PAWL SHAFT

LINE BOLT

(cant'd)

BACK

14-151

Transmission End Cover End Cover Removal (cont'd) 5. Slip the special tool onto the mainshaft.

Special Tools Required Mainshaft holder 07GAB-PF50101 or 07GAB-PF50100 NOTE: Refer to the Exploded View as needed during the following procedure. 1. Remove the transmission range switch cover. 2. Remove the bolts securing the harness clamp (one bolt) and transmission range switch (two bolts), then remove the transmission range switch. 3. Remove the bolts securing the end cover (sixteen bolts), then remove the end cover. 4. For '00-02 models: Remove the pitot pipe (A) and the lubrication pitot pipe (B) from the transmission housing (C), then remove the pitot flange (0) from the mainshaft idler gear (E).

6. Engage the park pawl with the park gear. 7. Cut the lock tabs (A) of each shaft locknut (B) using a chisel (C). Then remove the locknuts and conical spring washers from each shaft. NOTE: • Countershaft and secondary shaft locknuts have left-hand threads. • Clean the old locknuts; they are used to install the press fit idler gears on the mainshaft and secondary shaft, and the park gear and bearing hub on the countershaft. • Keep all of the chiseled particles out of the transmission.

I/c

A

8. Remove the special tool (mainshaft holder) from the mainshaft.

14-152

BACK

Park Lever Stop Inspection and Adjustment 9. Remove the mainshaft idler gear (A) and the secondary shaft idler gear (B) with a puller (e).

D

1. Set the park lever (A) in the ~ position.

c\

A

6x 1.0mm 14 N·m 11.4 kgf·m, 10 Ibf·ft)

B

2. Measure the distance (B) between the park pawl shaft (e) and the park lever roller pin (0).

10. Remove the bearing hub (0) with the puller from the countershaft, then remove the counters haft idler gear (E) and bearings.

STANDARD: 84.6-85.6 mm (3.33-3.37 in.)

11. Remove the park gear (F) with the puller.

3. If the measurement is out of tolerance, select and install the appropriate park lever stop (E) from the table below.

12. Remove the park pawl, spring, shaft, and shaft stop. 13. Remove the park lever from the control shaft. 14. Remove the Ii ne bolts, then remove the ATF cooler lines.

PARK LEVER STOP Mark 1

Part Number 24537-PA9-003

2

24538-PA9-003

3

24539-PA9-003

L1 11.00 mm (0.433 in.) 10.80 mm (0.425 in.) 10.60 mm (0.417 in.)

L2 11.00 mm (0.433 in.) 10.65mm (0.419 in.) 10.30 mm (0.406 in.)

4. After replacing the park lever stop, make sure the distance is within tolerance.

BACK

14-153

Transmission Housing Housing and Shaft Assemblies Removal Exploded View

REVERSE IDLER GEAR SHAFT HOLDER REVERSE IDLER GEAR SHAFT

~Jt

~

COUNTERSHA~ ~ EAR ~FT ~

~

/

~

TRANSMISSION HOUSING MOUNTING BOLTS

ii /

HARNESS CLAMP BRACKET

~/OA

2ND

TRANSMISSION HANGER! HARNESS CLAMP BRACKET

~ISSION

~~~~~~c~~,

HOUSING

~

~ TRANSMISSION HANGER

MAINS HAFT SUB-ASSEMBLY

/


COUNTERSHAFT SUB-ASSEMBLY


14-154

BACK

4. Align the spring pin (A) on the control shaft (B) with the transmission housing groove (e) by turning the control shaft.

Special Tools Required Housing puller 07HAe-PK40102 NOTE: Refer to the Exploded View as needed during the following procedure.

A

C

07HAC-PK40102

'"

1. Remove the two bolts securing the reverse idler gear shaft holder, then remove the reverse idler gear shaft holder (A), shaft (B), and washer (e).

5. Install the special tool over the mainshaft, then remove the transmission housing (0). NOTE: If the top arm of your housing puller is too short, replace it with Housing Puller Arm, 205 mm, 07SAe-POZ0101.

2. Remove the transmission housing mounting bolts, transmission hangers, and harness clamp bracket.

6. Remove the reverse idler gear, needle bearings, and thrust washer from the transmission housing.

3. Move the reverse idler gear (A) to disengage it from the mainshaft and countershaft reverse gears.

7. Remove the countershaft 2nd gear, then remove the countershaft reverse gear and the needle bearing.

NOTE: The transmission housing will not separate from the torque converter housing if the reverse idler gear is not moved.

8. Remove the lock bolt securing the shift fork, then remove the shift fork with the reverse selector, reverse selector hub, and countershaft 4th gear. If the reverse selector hub is press-fitted, leave it and 4th gear on the countershaft. 9. Remove the secondary shaft sub-assembly. If the reverse selector hub is press-fitted, remove the secondary shaft sub-assembly, countershaft sub-assembly and mainshaft sub-assembly together. 10. Remove the countershaft sub-assembly. 11. Remove the mainshaft sub-assembly. 12. Remove the differential assembly.

BACK

14-155

Transmission Housing Bearing Replacement Special Tools Required • Driver 07749-0010000 • Seal driver attachment 07GAD-PG40101 • Attachment, 62 x 68 mm 07746-0010500 • Attachment, 72 x 75 mm 07746-0010600

4. Release the pliers, then push the bearing down into the housing until the snap ring snaps in place around it.

NOTE: Coat all parts with ATF before assembly. 1. To remove the mainshaft bearing (A), countershaft bearing (B) and secondary shaft bearing (C) from the transmission housing, expand each snap ring with the snap ring pliers, then push the bearing out. NOTE: Do not remove the snap rings unless it's necessary to clean the grooves in the housing.

A

5. After installing the bearings verify the following: • The snap rings (A) are seated in the bearing and housing grooves . • The ring end gaps (B) are correct. B:0-7mm (0-0.28 in.)

A

2. Install the bearings in the direction shown. 3. Expand each snap ring with the snap ring pliers, and insert the bearing part-way into the housing.

14-156

BACK

Valve Body Valve Bodies and ATF Strainer Removal Exploded View

ATF FEED PIPE, 8x198mm

/6x1.0mm, , . Two Bolts SERVO DETENT BASE

ATFSTRAINE~ ~.~

6x1.0mm, Two Bolts /


ACCUMULATOR COVER

/J ~

ATFFEED PIPES

~

I/

ATF FEED PIPES, 8x85mm Three Pipes

\Y

Replace.

DETENT ARMSHAFT

~

8x 1.25mm, Three Bolts

~~~P::7I---COOLER CHECK VALVE

ATF PUMP DRIVEN GEAR SHAFT

6x 1.0mm, Six Bolts

ACCUMULATOR BODY



(cant'd)

BACK

14-157

Valve Body Valve Bodies and ATF Strainer Removal (cont'd) NOTE: Refer to the Exploded View as needed during the following procedure. 1. Remove the ATF feed pipes from the regulator valve body, servo body, and accumulator body.

16. Clean the inlet opening (A) of the ATF strainer (8) thoroughly with compressed air, then check that it is in good condition, and the inlet opening is not clogged.

2. Remove the servo detent base (two bolts). 3. Remove the ATF strainer (two bolts). 4. Remove the accumulator cover (two bolts). NOTE: The accumulator cover is spring loaded. To prevent stripping the threads in the servo body, press down on the accumulator cover while unscrewing the bolts in a crisscross pattern. 5. Remove the bolts securing the servo body (nine bolts), then remove the servo body, servo separator plate and dowel pins (two).

17. Testthe ATF strainer by pouring clean ATF through the inlet opening, and replace it if it is clogged or damaged.

6. Remove the accumulator body (six bolts). 7. Remove the regulator valve body (eight bolts). 8. Remove the stator shaft and stator shaft stop. 9. Remove the regulator separator plate and dowel pins (two). 10. Unhook the detent spring from the detent arm, then remove the detent arm shaft, detent arm, and control shaft. 11. Remove the cooler check valve spring and cooler check valve (steel ball). 12. Remove the main valve body (four bolts). 13. Remove the torque converter check valve and spring. 14. Remove the ATF pump driven gear shaft, then remove the ATF pump gears. 15. Remove the main separator plate and dowel pins (three).

14-158

BACK

Valve Body Repair 5. Remove the # 600 paper. Thoroughly wash the entire valve body in solvent, then dry it with compressed air.

NOTE: This repair is only necessary if one or more of the valves in a valve body do not slide smoothly in their bores. Use this procedure to free the valves. 1. Soak a sheet of # 600 abrasive paper in ATF for about 30 minutes.

6. Coat the valve with ATF, then drop it into its bore. It should drop to the bottom of the bore under its own weight. If not, repeat step 4, then retest. Ifthe valve still sticks, replace the valve body.

2. Carefully tap the valve body so the sticking valve drops out of its bore. It may be necessary to use a small screwdriver to pry the valve free. Be careful not to scratch the bore with the screwdriver. 3. Inspect the valve for any scuff marks. Use the ATFsoaked # 600 paper to polish off any burrs that are on the valve, then wash the valve in solvent and dry it with compressed air. 4. Roll up half a sheet of ATF-soaked # 600 paper and insert it in the valve bore of the sticking valve. Twist the paper slightly, so that it unrolls and fits the bore tightly, then polish the bore by twisting the paper as you push it in and out. NOTE: The valve body is aluminum and doesn't require much polishing to remove any burrs.

7. Remove the valve, and thoroughly clean it and the valve body with solvent. Dry all parts with compressed air, then reassemble using ATF as a lubricant.

BACK

14-159

Valve Body Valve Body Valve Reassembly 1. Coat all parts with ATF before assembly. 2. Install the valves and springs in the sequence shown for the main valve body (see page 14-161), regulator valve body (see page 14-164), and servo body (see page 14-165). Refer to the following valve cap illustrations, and install each valve cap so the end shown facing up will be facing the outside of the valve body.

14-160

BACK

Main Valve Body Disassembly, Inspection, and Reassembly 1. Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blowout all passages. 2. Do not use a magnet to remove the check valve ball; it may magnetize the ball. 3. Check all valves for free movement. If any fail to slide freely, refer to Valve Body Repair (see page 14-159). 4. Replace the valve body as an assembly if any parts worn or damaged. 5. Coat all parts with ATF during assembly. 6. Install the filter in the direction shown. SHIFTVALVEC

MODULATOR VALVE

SHIFT VALVE D MAIN VALVE BODY Inspect for scoring and damage. FILTER Install in this direction. REVERSECPC VALVE

~

.A!ilv_~I---

SHIFT VALVE E

VALVE SLEEVE

LOCK-UP SHIFT VALVE

MANU.:v:~ /~\ VALVE CAP CLIP

~ \

COO"'" CHECK

VAL~ IBALLJ

TORQUE CONVERTE" CHECK VALVE

® SERVO CONTROL VALVE

(cont'd)

BACK

14-161

Valve Body Main Valve Body Disassembly, Inspection, and Reassembly (cont'd) Sectional View

®

®

o

®

®

/

®

MAIN VALVE BODY Sectional View


CD ® @ G)

® ® CD

® ® @

14-162

Spring Modulator valve spring Shift valve C spring Shift valve D spring Shift valve E spring Relief valve spring Lock-up shift valve spring Cooler check valve spring Torque converter check valve Servo control valve spring Reverse CPC valve spring

WireOia. 1.6 (0.063) 0.8 (0.031) 0.7 (0.028) 0.7 (0.028) 1.1 (0.043) 0.9 (0.035) 0.6 (0.024) 1.2 (0.047) 0.7 (0.028) 0.7 (0.028)

Standard (New)-Unit: mm (in.) Free Length 0.0. 10.4 (0.409) 33.5 (1.319) 49.1 (1.933) 6.6 (0.260) 35.7 (1.406) 6.6 (0.260) 32.2 (1.268) 6.6 (0.260) 30.1 (1.185) 8.6 (0.339) 7.6 (0.299) 63.0 (2.480) 5.8 (0.228) 14.5 (0.571) 35.1 (1.382) 8.6 (0.339) 35.7 (1.406) 6.6 (0.260) 6.1 (0.240) 17.8 (0.701)

BACK

No. of Coils 9.8 21.7 17.2 .13.4 10.7 22.4 6.8 14.3 17.2 7.9

ATF Pump Inspection 1. Install the ATF pump drive gear (A), driven gear (8) and ATF pump driven gear shaft (C) in the main valve body (0). Lubricate all parts with ATF, and

install the ATF pump driven gear with its grooved and chamfered side facing up.

2. Measure the side clearance of the ATF pump drive gear (A) and driven gear (8). ATF Pump Gears Side (Radial) Clearance: Standard (New): ATF Pump Drive Gear 0.210-0.265 mm (0.0083-0.00104 in.) ATF Pump Driven Gear 0.035-0.063 mm (0.0014-0.0025 in.)

3. Remove the ATF pump driven gear shaft. Measure the thrust clearance between the ATF pump driven gear (A) and the valve body (8) with a straight edge (C) and a feeler gauge (0). ATF Pump Drive/Driven Gear Thrust (Axial) Clearance: Standard (New): 0.03-0.05 mm (0.001-0.002 in.) Service Limit: 0.07 mm (0.003 in.)

B

BACK

14-163

Valve Body Regulator Valve Body Disassembly, Inspection, and Reassembly 1. Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blowout all passages. 2. Check all valves for free movement, If any fail to slide freely, refer to Valve Body Repair (see page 14-159). 3. Replace the valve body as an assembly if any parts are worn or damaged. 4. Hold the regulator spring cap in place while removing the stop bolt. The regulator spring cap is spring loaded. Once the stop bolt is removed, release the spring cap slowly so it does not pop out. 5. Reassembly is the reverse of the disassembly. Install the filter in the direction shown. 6. Coat all parts with ATF during reassembly. 7. Align the hole in the regulator spring cap with the hole in the valve body, then press the spring cap into the valve body, and tighten the stop bolt.

;®

REGULATOR SPRING CAP

~

~

S. _______ ..

~~..

____

~

REGULATOR VALVE STOPBOLT 6x1.0mm

12 N·m 11.2 kgf·m, 8.7Ibf·ft)

LOCK-UPTIM~GVALVE ;,'

@

® ~

VALVE CAP

----------=:::: 4S;~

REGULATOR VALVE BODY Inspect for scoring and damage.

~t/\

VALVE CAP CLIP __________

"

®

VALVE SLEEVE

FILTER Install in this direction.

\

LOCK-UP CONTROL VALVE


CD ® ® G)

®

14-164

Spring Stator reaction spring Regulator valve spring A Regulator valve spring B Lock-up control valve spring Lock-up timing valve spring

WireOia. 5.5 (0.217) 1.8 (0.071) 1.7 (0.067) 0.7 (0.028) 0.65 (0.026)

Standard (New)-Unit: mm (in.) 0.0. Free Length 37.4 (1.472) 30.3(1.193) 14.7 (0.579) 87.5 (3.445) 9.4 (0.370) 44.0 (1.732) 6.6 (0.260) 42.9 (1.689) 6.6 (0.260) 34.8 (1.370)

BACK

No. of Coils 2.12 16.5 13.4 14.2 15.6

Servo Body Disassembly, Inspection, and Reassembly 1. Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blowout all passages. 2. Check all valves for free movement. If any fail to slide freely, refer to Valve Body Repair (see page 14-159). 3. Replace the valve body as an assembly if any parts worn or damaged. 4. Coat all parts with ATF during reassembly. CPC VALVE A CPCVALVEB SHIFT VALVE A

_______ VALVE CAP

~~~~

~i"\~

VALVE CAP CLIP

SERVO BODY Inspect for scoring and damage.

~O-RINGS Replace.


CD ® ® @

® ®

(J)

®

Spring Shift valve B spring Shift valve A spring CPC valve A spring CPC valve B spring 4th accumulator spring A 4th accumulator spring B 3rd accumulator spring A 3rd accumulator spring B

WireOia. 0.8 (0.031) 0.8 (0.031) 0.7 (0.028) 0.7 (0.028) 2.6 (0.102) 2.4 (0.094) 2.6 (0.102) 2.4 (0.094)

BACK

Standard (New)-Unit: mm (in.) 0.0. Free Lenath 7.1 (0.280) 40.4 (1.591) 7.1 (0.280) 40.4 (1.591) 6.1 (0.240) 17.8 (0.701) 6.1 (0.240) 17.8 (0.701) 19.6 (0.772) 66.4 (2.614) 12.8 (0.504) 51.5 (2.028) 19.6 (0.772) 66.4 (2.614) 12.8 (0.504) 51.5 (2.028)

No. of Coils 16.9 16.9 7.9 7.9 9.7 11.5 9.7 11.5

14-165

Valve Body Accumulator Body Disassembly, Inspection, and Reassembly 1. Do not use a magnet to remove the check balls: it may magnetize the balls. 2. Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blowout all passages.

/

WBRlCA110N CHECK VALVE

....

~iI-I=:::j?~~~;;.;

VALVE CLIP

_ _ _ _ _ ACCUMULATOR BODY

Inspect for scoring and damage.

~

CHECK BALLS, 2

~/ ~~

~~~ I

1ST ACCUMULATOR PISTON

I.

:

~

:I

2ND ACCUMULATOR PISTON

\0

~O'RING

~

O·RING Replace.

Replace.

SNAP RINGS


CD

® ®
14-166

Springs 1st accumulator spring B 1st accumulator spring A 2nd accumulator spring B 2nd accumulator spring A

Wire Dia. 2.7 (0.106) 2.5 (0.098) 2.4 (0.094) 2.7 (0.106)

Standard (New)·Unit: mm (in.) Free Length O.D. 15.0 (0.591) 52.5 (2.067) 21.6 (0.850) 87.5 (3.445) 12.6 (0.496) 53.5 (2.106) 19.6 (0.772) 66.3 (2.610)

BACK

No. of Coils 10.3 11.8 12.9 9.9

Torque Converter Housing Mainshaft Bearing and Oil Seal Replacement 3. Install the new oil seal flush with the housing with the special tools.


• Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A • Driver 07749-0010000 • Attachment, 62 x 68 mm 07746-0010500 • Attachment, 72 x 75 mm 07746-0010600

07749-0010000

1. Remove the mainshaft bearing and oil seal with the special tool and a commercially available 3/8"-16 slide hammer (A).

07746-0010600

07736-A01000B or 07736-A01000A

2. Install the new mainshaft bearing until it bottoms in the housing with the special tools. 07749-0010000

07746-0010500

BACK

14-167

Torque Converter Housing Countershaft Bearing Replacement

Secondary Shaft Bearing Replacement

Special Tools Required • Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A • Driver 07749-0010000 • Attachment, 62 x 68 mm 07746-0010500

Special Tools Required • Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A • Driver 07749-0010000 • Driver attachment 07947-6340500

1. Remove the countershaft bearing (A) with the special tool and a commercially available 3/8"-16 slide hammer (B).

07736-A01000B or 07736-A01000A

1. Remove the secondary shaft bearing (A) with the special tool and a commercially available 3/8"-16 slide hammer (B).

A

07736-A01000B or 07736-A01000A


A


0-0.03mm (0-0.001 in.'

B 0-0.03mm (0-0.001 in.'


A


14-168

BACK

Shafts and Clutches Mainshaft Disassembly, Inspection, and Reassembly 1. Lubricate all parts with ATF during reassembly. LOCKNUT (FLANGE NUT) Replace. 226 N·m (23.0 kgf·m, 166Ibf·ft)-0167 N·m (17.0 kgf·m, 123Ibf·ft)

THRUST WASHER, 27x47x5mm THRUST NEEDLE BEARING

4TH GEAR

I

\

~

o

GCONICAL SPRING WASHER

~Replace.

nk=""~6 x 1.0 mm 9.8N·m (1.0 kgf·m, 7.2Ibf·ft) ~ ('00-02 models)

~

I

PITOT FLANGE

~('OO-02 models) IDLER GEAR

TRANSMISSION HOUSING BEARING

3RD/4TH CLUTCH ASSEMBLV

-----SEALING RINGS, 32mm

~3:B ---SEALING RINGS, ~ 29mm ~ NEEDLE BEARING

2. 3. 4. 5. 6. 7. 8.

0

Install sealing ring mating faces as shown.

~

~EEDLE BEARING

THRUST NEEDLE BEARING "" SET RING

Check the clearance of the 3rd/4th clutch assembly (see page 14-170). Inspect the thrust needle bearing and the needle bearing for galling and rough movement. Inspect the splines for excessive wear and damage. Check shaft bearing surfaces for scoring, scratches, and excessive wear. Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings. Install the conical spring washer and 41 x 73 mm thrust shim in the direction shown. Inspect condition of the sealing rings. If the sealing rings are worn, distorted, or damaged, replace them (see page 14-171).

BACK

14-169

Shafts and Clutches 3rd/4th Clutch Clearance Inspection 1. Remove the O-rings from the mainshaft.

2. Assemble the 41 x 73 mm thrust shim (A), 3rd/4th clutch assembly (B), and 4th gear collar (C) on the mainshaft (D).

~c

3. Hold the 4th gear collar (C) against the clutch assembly (B), then measure the clearance between the clutch guide (E) and the 4th gear collar with a feeler gauge (F) in at least three places. Use the average as the actual clearance. STANDARD:

0.03 - 0.11 mm (0.001 - 0.004 in.)

~B

F

\

c

~F 4. If the clearance is out of standard, remove the thrust shim and measure its thickness. 5. Select and install a new shim, then recheck. THRUST SHIM, 41 x 73 mm No. 1

2 3 4 5 6

Part Number 90414-P7X-00O 90415-P7X-000 90416-P7X-000 90417 -P7 X -000 90418-P7X-000 90419-P7X-000

7.85 7.90 7.95 8.00 8.05 8.10

Thickness mm (0.309 in.) mm (0.311 in.) mm (0.313 in.) mm (0.315 in.) mm (0.317 in.) mm (0.319 in.)

6. After replacing the thrust shim, make sure the clearance is within standard.

14-170

BACK

Mainshaft Sealing Rings Replacement The sealing rings are synthetic resin with chamfered ends. Check condition of the sealing rings, and replace them only if they are worn, distorted, or damaged. 1. For a better fit, squeeze the sealing rings (A) together slightly before installing them.

2. Apply ATF to the new sealing rings then install them on the mainshaft.

3. After installing the sealing rings, verify the following: • The rings are fully seated in the groove. • The rings are not twisted. • The chamfered ends ofthe rings are properly joined.

BACK

14-171

Shafts and Clutches Countershaft Disassembly, Inspection, and Reassembly 1. Remove the locknut, and take off components down to the reverse selector hub. LOCKNUT (FLANGE NUT) Replace. Left·hand threads 226 N·m (23.0 kgf.m, 166 Ibf·ft}-O167 N·m (17.0 kgf·m, 123Ibf·ft)

~ CONICAL SPRING WASHER Replace. -BEARING HUB Selective part THRUST NEEDLE BEARING NEEDLE BEARING

-------:

IDLER GEAR

REVERSE SELECTOR

_____...rfilUlllLUlllh"

REVERSE SELECTOR HUB 4TH GEAR NEEDLE BEARING

PARK GEAR

SNA~ODOO~

COUNTERSHAFT

1ST GEAR

2. Remove the reverse selector hub, 3rd gear, and 1st gear (see page 14-173). 3. Check the bearing in the bearing hub for wear and rough movement. If the bearing is worn or damaged, replace it (see page 14-175). 4. Inspect the thrust needle bearing and the needle bearing for galling and rough movement. 5. Check the splines for excessive wear and damage. 6. Check the shaft bearing surfaces for scoring, scratches, and excessive wear. 7. Lubricate all parts with ATF, and reassemble the shafts and gears. 8. Install the conical spring washer, reverse selector, reverse selector hub, and distance collar in the direction shown.

14-172

BACK

Countershaft Reverse Selector Hub, 3rd Gear, and 1st Gear Replacement Special Tools Required Driver 40 mm I.D. 07746-0030100

2. Remove the needle bearing, snap ring, distance collar, and 31 mm cotters from the countershaft.

Removal

3. Remove the 1st gear (A) and 3rd gear (8) together from the countershaft (C) with a puller (D). Place a shaft protector (E) between the puller and countershaft to prevent damaging the countershaft.

1. Remove the reverse selector hub (A) and the 4th gear (8) with a universal two-jaw (or three-jaw) puller (C). Place a shaft protector (D) between the puller and countershaft (E) to prevent damaging the countershaft.

NOTE: Some of the reverse selector hubs are not press-fitted, and can be removed without using a puller.

E

__--I+-f----c

E

(cont'd)

BACK

14-173

Shafts and Clutches Countershaft Reverse Selector Hub, 3rd Gear, and 1st Gear Replacement (cont'd) 4. Install the 31 mm cotters, distance collar, snap ring, needle bearing, and 4th gear (A) on the countershaft.

Installation 1. Apply ATF to the parts.

5. Slide the reverse selector hub (B) over the countershaft (C), and then press it into place with the special tool and a press.

2. Install the 1st gear on the countershaft by hand. 3. Align the shaft splines with those on 3rd gear, then press the countershaft (A) into the 3rd gear with press.

NOTE: Some of the reverse selector hubs are not press-fitted and can be installed without using the special tool and a press .

• Place an attachment (B) between the press and countershaft to prevent damaging the countershaft. • Stop pressing the countershaft when the 3rd gear contacts the 1st gear (C).

I

/07746-0030100

c

14-174

BACK

I""" \

Countershaft Bearing Hub/Bearing Replacement Special Tools Required • Driver 07749-0010000 • Attachment, 42 x 47 mm 07746-0010300 • Attachment, 62 x 68 mm 07746-0010500 1. Check the bearing for wear, damage, and rough movement. If the bearing is worn or damaged, replace it. 2. Remove the bearing (A) from the bearing hub with the special tools, a bearing separator (8), and a press.

07746-0010300

~

/

." .....,....

3. Install the new bearing on the bearing hub with the special tools and a press.

~

/

07'.....' ....

r BACK

14-175

Shafts and Clutches Secondary Shaft Disassembly, Inspection, and Reassembly 1. Remove the locknut, and disassemble the shaft and gears. LOCKNUT (FLANGE NUT) Replace. Left-hand threads 226 N·m (23.0 kgf·m, 166Ibf·ft)-0CONICAL SPRING WASHER 167

No/m (17.0 kgf·m, 123 Ibf·ft)

\

Replace.

B~BALLBEARING

AfiiJ.~~


~

SECONDARY SHAFT

~

~IDLERGEAR

NEEDLE BEARING ~~~ri1

THRU~ BEARING

ro-"""t:""'::~

/

TRANSMISSION HOUSING BEARING

~~

""


/

'ni'i'~~~~~ ~ 1ST/2ND CLUTCH ASSEMBLY

~

/

SPLINED WASHER, 38 x 56.5 mm Selective part

O-RINGS Replace.

~

_ _ _ COTTERS, 32 mm _COTTER RETAINER

---SEALING RINGS, 25 mm

2. 3. 4. 5. 6.

Inspect the thrust needle bearing and the needle bearing for galling and rough movement. Check clearance ofthe secondary shaft assembly (see page 14-177). Check the splines for excessive wear and damage. Check the shaft bearing surfaces for scoring, scratches, and excessive wear. Check the idler gear bearing for wear and rough movement. If the bearing is worn or damaged, replace it (see page 14-179). 7. Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings. 8. Lubricate all parts with ATF during reassembly. 9. Install the conical spring washer and 38 x 56.5 mm splined washer in the direction shown.

14-176

BACK

Secondary Shaft Clearance Inspection 1. Remove the O-ri ngs from the shaft. 2. Assemble the thrust needle bearing (A), needle bearing (B), 1st gear (C), thrust needle bearing (D), 38 x 56.5 mm splined washer (E), 32 mm cotters (F), cotter retainer (G), and snap ring (H) on the secondary shaft (I).

3. Measure the clearance between the 38 x 56.5 mm splined washer (E) and cotters (F) with a feeler gauge (J) in at least three places. Use the average as the actual clearance. STANDARD: 0.07-0.15 mm (0.003-0.006 in.)

-----J \

__----G ...-----H J

c

/

4. If the clearance is out of standard, remove the splined washer, and measure its thickness. 5. Select and install a new splined washer, then recheck. SPLINED WASHER, 38 x 56.5 mm No. 1 2 3 4 5 6

Part Number 90502-POZ-000 90503-POZ-000 90504-POZ-000 90505-POZ-000 90506-POZ-000 90507 -POZ-000

Thickness 6.85 mm (0.270 in.) 6.90 mm (0.272 in.) 6.95 mm (0.274 in.) 7.00 mm (0.276 in.) 7.05 mm (0.278 in.) 7.10 mm (0.280 in.)

(cont'd)

BACK

14-177

Shafts and Clutches Secondary Shaft Clearance Inspection (cont'd) 6. Remove the 27 x 47 x 5 mm thrust washer from the mainshaft. 7. Assemble the 1st/2nd clutch assembly (A), 37 x 55 mm thrust shim (8), thrust needle bearing (e), needle bearing (D), 2nd gear (E), thrust needle bearing (F), and 27 x 47 x 5 mm thrust washer (removed from mainshaft) (G) on the secondary shaft (H).

9. Hold the 27 x 47 x 5 mm thrust washer (G) against the clutch assembly (A), and measure the 2nd gear axial clearance in at least three places while moving the 2nd gear (E). Use the average as the actual clearance. STANDARD: 0.04 - 0.12 mm (0.002 - 0.005 in.)

© __

~_--G

__- - F

A

A

10. Ifthe clearance is out of standard, remove the 37 x 55 mm thrust shim and measure its thickness. 11. Select and install a new thrust shim, then recheck. THRUST SHIM, 37 x 55 mm S. Set the dial indicator (I) on 2nd gear (E).

\

/

No. 1 2 3 4 5 6 7

Part Number 90406-POZ-000 90407 -POZ-000 9040S-POZ-000 90409-POZ-000 9041 O-POZ-000 90411-POZ-000 90412-POZ-000

Thickness 4.90 mm (0.193 in.) 4.95 mm (0.195 in.) 5.00 mm (0.197 in.) 5.05 mm (0.199 in.) 5.10 mm (0.201 in.) 5.15 mm (0.203 in.) 5.20 mm (0.205 in.)

12. Disassemble the shaft and gears. 13. Reinstall the 27 x 47 x 5 mm thrust washer on the mainshaft.

14-178

BACK

Secondary Shaft Idler Gear Bearing Replacement Special Tools Required • Driver 07749-0010000 • Attachment, 62 x 68 mm 07746-0010500

4. Install the bearing on the secondary shaft idler gear with the special tool and a press .

1. Check the bearing for wear, damage, and rough movement. If the bearing is worn or damaged, go to step 2.

07749-0010000 07746-0010500

2. Place the secondary shaft idler gear in a vise with soft jaws. 3. Remove the bearing (A) from the secondary shaft idler gear (8) with a commercially available 3-jaw slide hammer (C).

r BACK

14-179

Shafts and Clutches Clutch Disassembly 3. Install the special tools on the 3rd/4th clutch assembly.


• Clutch spring compressor attachment 07LAE-PX40100 • Clutch spring compressor attachment 07HAE-PL50101 • Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A

07LAE-PX40100

/

1. Remove the snap ring (A), then remove the clutch end plate, the clutch discs, and the plates with a screwdriver (B). B

\

07LAE-PX40100 or 07HAE-PL50101

07GAE-PG40200 or 07GAE-PG4020A

2. Remove the disc spring (A) from the 1st, 3rd and 4th clutches.

4. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 3rd and 4th clutches.

NOTE: The 2nd clutch does not have a disc spring. A

B

14-180

BACK

5. Set the special tool (A) on the spring retainer (8) of the 1st and 2nd clutches in such a way that the special tool works on the clutch return spring (C).


7. Compress the spring until the snap ring can be removed.

8. Remove the snap ring (A). Then remove the special tools (8), spring retainer (C), return spring.

(cont'd)

BACK

14-181

Shafts and Clutches Clutch Disassembly (cont'd) 9. For 3rd and 4th clutch: Wrap a shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove the piston (B). Place a finger tip on the other end while applying air pressure.

B

14-182

BACK

Clutch Inspection 1ST/2ND CLUTCH NOTE: There are two types of spring retainer, you may find either type in the clutch assembly. Some spring retainers have seal lips, and do not have O-rings. The seal lip is undetachable from the spring retainer.

CLUTCH PLATES Standard thickness: 2.0 mm (0.079 in.) CLUTCH DISCS Standard thickness: 1.94 mm (0.076 in.)

_ _ _,....r

CLUTCH DISCS Standard thickness: 1.94 mm (0.076 in.) CLUTCH PLATES Standard thickness: 2.0 mm (0.079 in.)

CLUTCH END PLATE

~

SNAP RING

/SPRING RETAINER

~

~O-RING ~ Replace.

~RETURN SPRING

JI ....- - - - SNAP RING

-'STCLUTCH DRUM

(cont'd)

BACK

14-183

Shafts and Clutches Clutch Inspection (cont'd) 3RD/4TH CLUTCH

CLUTCH DISCS Standard thickness: 1.94 mm (0.076 in.)

-"""'=:::0::"../

SNAP RING

~~~(,/ CLUTCH END PLATE CLUTCH PLATES Standard thickness: 2.0 mm (O.079 in.)

~

I

CLUTCH PLATES Standard thickness: 2.3 mm (O.091 in.)

CLUTCH DISCS Standard thickness: 1.94 mm (0.076 in.)

/ ....o----=~ O-RINGS Replace.

4TH CLUTCH DRUM

CLUTCH END

14-184

PLAT~

l~==,=,,~JIII ~

BACK

3RD CLUTCH DRUM

Clutch Reassembly 2. Install new O-rings (A) on the piston (B) and the spring retainer (1st and 2nd clutches).

Special Tools Required • Clutch spring compressor attachment 07LAE-PX40100 • Clutch spring compressor attachment 07HAE-PL50101 • Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A • Clutch compressor attachment 07ZAE-PRP0100

NOTE: Some spring retainers of the 1st and 2nd clutch have seal lips and do not have O-rings. A

Note these items during reassembly: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. • Blowout all passages. • Apply ATF to all parts before assembly. 1. Inspect the check valve (A) on the 3rd and 4th clutch pistons (B); if it's loose, replace the piston.

j 3. Install the piston (A) in the clutch drum (B). Apply pressure and rotate to ensure proper seating. Lubricate the piston O-ring with ATF before installing. NOTE: Do not pinch the O-ring by installing the piston with too much force. A

(cont'd)

BACK

14-185

Shafts and Clutches Clutch Reassembly (cont'd) 4. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the retainer.

5. Install the special tools on the 3rd/4th clutch assembly.

6. Be sure the special too (A) is adjusted to have full contact with the spring retainer (8) on the 3rd and 4th clutches.

7. Set the special tool (A) on the spring retainer (8) of the 1st and 2nd clutches in such a way that the special tool work on the clutch return spring (C).

07LAE-PX40100

o~

07LAE-PX40100 or 07HAE-PL50101 07GAE-PG40200 or 07GAE-PG4020A

14-186

BACK


10. Install the snap ring (A).

11. Remove the special tools. 9. Compress the return spring.

12. Install the disc spring in the 1st, 3rd, and 4th clutches in the direction shown. NOTE: The 2nd clutch does not have a disc spring.

(cont'd)

BACK

14-187

Shafts and Clutches Clutch Reassembly (cont'd) 13. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes. Before installing the plates and discs, make sure the inside of the clutch drum is free of dirt and other foreign matter.

16. Set a dial indicator (A) on the clutch end plate (B).

14. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate (A) with the flat side toward the disc (B). A

B

17. Zero the dial indicator with the clutch end plate lifted up to the snap ring (e).

15. Install the snap ring (A) with a screwdriver (B).

14-188

BACK

18. Release the clutch end plate to lower the clutch end plate, then put the special tool on the end plate (A).

20. If the clearance is out of the service limit, select a new clutch end plate from the following table. NOTE: If the thickest clutch end plate is installed, but the clearance is still over the service limit, replace the clutch discs and clutch plates as a set.

t 19. Press the special tool down with 40 N (4 kgf, 9lbf) using a force gauge, and read the dial indicator (B). The dial indicator reads the clearance (e) between the clutch end plate and top disc (D). Take measurements in at least three places, and use the average as the actual clearance.

1ST and 2ND CLUTCH END PLATES Mark 6 7 8 9 0 1 2 3 4

Clutch End Plate-to-Top Disc Clearance: Clutch 1st 2nd 3rd 4th

Service Limit 1.2-1.4 mm (0.047-0.055 in.) 0.85-1.05 mm (0.033-0.041 in.) 0.55-0.75 mm (0.022-0.030 in.) 0.55-0.75 mm (0.022-0.030 in.)

Part Number 22551-P7Z-003 22552-P7Z-003 22553-P7Z-003 22554-P7Z-003 22555-P7Z-003 22556-P7Z-003 22557 -P7Z-003 22558-P7Z-003 22559-P7Z-003

Thickness 2.6mm (0.102 in.) 2.7 mm (0.106 in.) 2.8 mm (0.110 in.) 2.9 mm (0.114 in.) 3.0 mm (0.118 in.) 3.1 mm (0.122 in.) 3.2 mm (0.126 in.) 3.3 mm (0.130 in.) 3.4 mm (0.134 in.)

3RD and 4TH CLUTCH END PLATES Mark 1 2 3 4 5 6 7 8 9

BACK

Part Number 22551-PX4-003 22552-PX4-003 22553-PX4-003 22554-PX4-003 22555-PX4-003 22556-PX4-003 22557 -PX4-003 22558-PX4-003 22559-PX4-003

Thickness 2.1 mm (0.083 in.) 2.2 mm (0.087 in.) 2.3 mm (0.091 in.) 2.4 mm (0.094 in.) 2.5 mm (0.098 in.) 2.6 mm (0.102 in.) 2.7 mm (0.106 in.) 2.8 mm (0.110 in.) 2.9 mm (0.114 in.)

14-189

Valve Body Valve Bodies and ATF Strainer Installation Exploded View

Torque: - 6 x 1.0 mm: 12 N·m (1.2 kgf·m, 8.7Ibf.ft) - 8 x 1.25 mm: 18 N·m (1.8 kgf·m, 13Ibf·ft)

./6x1.0mm, 'T B Its wo 0

SERVO DETENT BASE

ATFSTRAIN~

~~~

~:'~.~~~'

I

610 x . mm, Eight Bolts


ACCUMULATOR COVER

~.' ~

~

_____ ATF FEED PIPE, 8x198mm _ _ _ ATF FEED PIPES, 8x85mm Three Pipes

ATFFEED PIPES

/

ACCUMULATOR BODY

/



14-190

BACK

NOTE: Refer to the exploded view as needed during the following procedure.

4. Install the cooler check valve and spring on the main valve body, then install the two dowel pins and the regulator separator plate.

1. Install the main separator plate (A) and three dowel pins on the torque converter housing. Then install the ATF pump drive gear (B), driven gear (C) and ATF pump driven gear shaft (0). Install the ATF pump driven gear with its grooved and chamfered side facing down.

5. Install the stator shaft and stator shaft stop. 6. Install the regulator valve body (eight bolts). 7. Install the two dowel pins and the servo separator plate on the main valve body. 8. Install the control shaft (A) in the torque converter housing along with the manual valve (B).

A~

-------0 2. Install the torque converter check valve and spring, then install the main valve body (one 6 mm bolt and three 8 mm bolts). Make sure the ATF pump drive gear (B) rotates smoothly in the normal operating direction, and the ATF pump driven gear shaft (0) moves smoothly in the axial and normal operating direction. B

E

9. Install the detent arm (C) and arm shaft (0) in the main valve body (E), then hook the detent arm spring (F) to the detent arm.

10. Install the servo body (G) (nine bolts). 11. Install the accumulator cover (two bolts). 12. Install the ATF strainer (two bolts). 13. Install the servo detent base (two bolts). B

o

14. Install the accumulator body (six bolts).

3. Ifthe ATF pump drive gear and ATF pump driven gear shaft do not move smoothly, loosen the main valve body bolts. Realign the ATF pump driven gear shaft, and retighten the bolts to the specified torque, then recheck. Failure to align the ATF pump driven gear shaft correctly will result in a seized ATF pump drive gear or ATF pump driven gear shaft.

15. Install the two ATF feed pipes in the servo body, four pipes in the regulator valve body, and one pipe in the accumulator body.

BACK

14-191

Transmission Housing Shaft Assemblies and Housing Installation Exploded View 8x1.25mm 26 N·m (2.7 kgf·m, 20 Ibf·ft)

TRANSMISSION HOUSING MOUNTING BOLTS 10x1.25mm 44 N·m (4.5 kgf·m, 33 Ibf.ft)

,H.G,RNIFSS

CLAMP BRACKET

TRANSMISSION HANGERI HARNESS CLAMP BRACKET /

TRANSMISSION HOUSING TRANSMISSION HANGER TRANSMISSION HOUSING GASKET Replace.

REVERSE IDLER GEAR

MAINSHAFT SUB·ASSEMBLY

COUNTERSHAFT SUB·ASSEMBLY


14-192

BACK

NOTE: Refer to the Exploded View as needed during the following procedure.

5. Place the thrust washer (A) in the transmission housing.

1. Install the differential assembly, countershaft subassembly, mainshaft sub-assembly, and secondary shaft sub-assembly in the torque converter housing. 2. Install the countershaft 4th gear and reverse selector hub on the countershaft. If the reverse selector hub is a press-fitted type, refer to the installation procedure (see page 14-173). 3. Turn the shift fork shaft (A) so the large chamfered hole is facing the fork bolt hole. Then install the shift fork (8) and reverse selector (C) together on the shift fork shaft and countershaft (0). Secure the shift fork to the shift fork shaft with the lock bolt (E) and a new lock washer (F), then bend the lock washer against the bolt head. E

6. Place the reverse idler gear (A) in the transmission housing as shown, then slide it in the direction shown.

6x 1.0mm 14 N·m (1.4 kgf·m, 10 Ibf·ft)

~~~F ~

~B

c

~

4. Install the needle bearing, countershaft reverse gear, and countershaft 2nd gear on the countershaft.

(cont'd)

BACK

14-193

Transmission Housing Shaft Assemblies and Housing Installation (cont'd) 7. Align the spring pin (A) on the control shaft (B) with the transmission housing groove (e) by turning the control shaft. A

10. Engage the reverse idler gear with the countershaft reverse gear and the mainshaft reverse gear. Then install the needle bearings (A), reverse idler gear shaft (B) and thrust washer (e) in the reverse idler gear, and install the reverse idler gear shaft holder (0) on the transmission housing.

B

8. Install three dowel pins and a new gasket on the torque converter housing. 9. Place the transmission housing on the torque converter housing, then install the transmission housing mounting bolts along with the harness clamp bracket (A), transmission hanger (B) and transmission hanger/harness clamp bracket (e). Tighten the bolts in two or more steps in the sequence shown.

14-194

BACK

Transmission End Cover End Cover and Idler Gears Installation Special Tools Required

Mainshaft holder 07GAB-PF50101 or 07GAB-PF50100 1. Install the park lever (A) and park lever stop (B) on the control shaft (e), then install the lock bolt (D) with a new lock washer (E). Do not bend the lock tab of the lock washer in this step; bend it after checking park pawl engagement.

3. Install the park gear (A) using the old locknut (B) and a collar (e). Hold the park pawl (D) to engage with the park gear, then tighten the old locknut until the shaft splines come out slightly over the park gear splines. NOTE: • Do not use an impact wrench. • eountershaft locknut has left-hand threads.

~B

o

..---------E

o

/

6x 1.0 mm 14 N·m (1.4 kgf·m, 10 Ibf·ft)

2. Lubricate the following parts with ATF: • Splines ofthe countershaft, the park gear, and the old locknut. • Threads of the countershaft and the old locknut. • Old conical spring washer.

4. Remove the locknut and the collar, then install only the bearing hub/bearing assembly (A) and old conical spring washer (B). Tighten the old locknut (e) to seat the park gear to 226 N·m (23.0 kgf·m, 166 Ibf·ft), then remove the locknut and conical spring washer. NOTE: Do not use an impact wrench, always use a torque wrench to tighten the locknut.

c~

A------....

(cont'd)

BACK

14-195

Transmission End Cover End Cover and Idler Gears Installation (cont'd) 5. Remove the bearing hub/bearing assembly (A) with a puller (B).

6. Install the thrust needle bearing (A), needle bearing (B), countershaft idler gear (C), thrust needle bearing (D), bearing hub/bearing assembly (E), and the old conical spring washer (F). Then tighten the old locknut (G) to seat the bearing hub/bearing assembly to 164 N·m (17.0 kgf·m, 123Ibf·ft).

7. Setthe dial indicator (A) to the countershaft idler gear (B) as shown.

8. Measure the countershaft idler gear axial clearance in at least three places, while moving the countershaft idler gear (A). Use the average as the actual clearance. STANDARD: 0.015-0.045 mm (0.0006-0.0018 in.)

NOTE: Do not use an impact wrench, always use a torque wrench to tighten the locknut.

A

14-196

BACK

9. If the clearance is out of standard, remove the bearing hub/bearing assembly using a puller as described on the previous page. 10. Select and install the new bearing hub/bearing assembly, then recheck.

14. Lubricate the following parts with ATF: • Splines of the mainshaft, secondary shaft, and idler gears. • Threads ofthe mainshaft, secondary shaft, and new locknuts. • Old conical spring washers. 15. Install the mainshaft idler gear (A) and the old conical spring washer (8) on the mainshaft (C). Tighten the old locknut (D) to seat the mainshaft idler gear to 226 N·m (23.0 kgf·m, 166 Ibf·ft). NOTE: Do not use an impact wrench, always use a torque wrench to tighten the locknut.

BEARING HUB Mark A

8 C D

Part Number 90520-P6H-000 90521-P6H-000 90522-P6H-000 90523-P6H-000

Difference 3.503 mm (0.1379 in.) 3.490 mm (0.1374 in.) 3.477 mm (0.1369 in.) 3.464 mm (0.1364 in.)

11. After replacing the bearing hub/bearing assembly make sure the clearance is within standard. 12. Remove the old locknut and old conical spring washer from the counters haft. 13. Install the special tool onto the mainshaft.

16. Install the secondary shaft idler gear (E) and the old conical spring washer (F) on the secondary shaft (G). Tighten the old locknut (H) to seat the secondary shaft idler gear to 226 N·m (23.0 kgf·m, 166Ibf·ft) NOTE: • Do not use an impact wrench, always use a torque wrench to tighten the locknut. • Secondary shaft locknut has left-hand threads. 17. Remove the old locknuts and old conical spring washer from the mainshaft and the secondary shaft.

(cont'd)

BACK

14-197

Transmission End Cover End Cover and Idler Gears Installation (cont'd) 18. Lubricate the threads of each shaft and new locknuts, and new conical spring washers with ATF.

19. Install the new conical spring washers (A) in the

22. For '00-02 models: Install the pitot flange (A) on the mainshaft idler gear (B), then install the lubrication pitot pipe (C) and the pitot pipe (D) on the transmission housing.

direction shown, and install the new locknuts (B).

6x 1.0mm 12 N·m 11.2 kgf·m, 8.7Ibf·ft)

c

~_-B

20. Tighten the locknuts to 167 N·m (17.0 kgf·m, 123 Ibf·ft).

23. Set the park lever in the ~ position, then verify that the park pawl (A) engages the park gear (B).

NOTE: • Do not use an impact wrench, always use a torque wrench to tighten the locknut. • Coutershaft and secondary shaft locknuts have left-hand threads.

c

21. Stake each locknut into its shaft using a 3.5 mm punch.

A

F

24. If the park pawl does not engage fully, check the distance between the pawl shaft (C) and the park lever roller pin (D) (see page 14-153). 25. Tighten the lock bolt (E), and bend the lock tab of the lock washer (F) against the lock bolt head.

14-198

BACK

26. Install the end cover (A) along with two dowel pins, new O-rings, new gasket, and harness clamp bracket (B). Tighten the 16 bolts to 12 N·m, (1.2 kgf·m, 8.7 Ibf·ft).

28. Set the control shaft (A) to the IHl position by turning it.

B

NOTE: Be careful not to squeeze the end ofthe control shaft tips together when turning into position. If the tips are squeezed together it will cause a faulty shift signal or position due to the play between the control shaft and the switch.

27. Set the transmission range switch to IHl position. NOTE: The transmission range switch clicks in IHl position.

(cont'd)

BACK

14-199

Transmission End Cover End Cover and Idler Gears Installation (co nt'd) 29. Install the transmission range switch (A) loosely on the control shaft (B), then secure it with the bolts. Do not move the transmission range switch when tightening the bolts. ___- - - 7 7 6 x 1.0 mm 12 N·m(1.2 kgf·m, 8.7 Ibf·ft) .

B

30. Install the transmission range switch cover (C), and install the harness clamp (D) on the clamp bracket (E) on the transmission housing, then install the harness clamp (F) on the end cover (G). 31. Install the ATF cooler lines and new sealing washers. Tighten the line fittings to 28 N·m (2.9 kgf·m, 21 Ibf·ft) 32. Install the breather tube. 33. Install the ATF dipstick.

14-200

BACK

AIT Differential Backlash Inspection


1. Install both axles, and place the differential assembly on V-blocks (A).

c

~-~.

--

BEARING OUTER RACE Replacement, page 14-204

1(f)'ff~~i01~IER BEARING Replacement, page 14-202

A

/

"

B

A

2. Check the backlash of both pinion gears (B) with a dial indicator (C). STANDARD: 0.05-0.15 mm (0.002-0.006 in.)

3. If the backlash is out of standard, replace the differential carrier.

\\fi':;;;=:~fll

--

CARRIER BEARING Replacement, page 14-202

-------

BEARING OUTER RACE Replacement, page 14-204

-----THRUST WASHER

BACK

14-201

AIT Differential ~I

Carrier Bearing Replacement


Special Tools Required Attachment, 40 x 50 mm 07LAO-PW50601

1. Remove the final driven gear from the differential carrier.

NOTE: • The bearing and outer race should be replaced as a set. • Inspect and adjust the bearing preload whenever bearing is replaced. • Check the bearing for wear and rough rotation. If the bearing is OK, removal is not necessary.

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

~//IJf~

. 1. Remove the carrier bearing (A) with a commercially available bearing puller (B), bearing separator (C), and stepped adapter (0).

D

2. Install the final driven gear with the chamfered side on the inner bore facing the differential carrier.

3. Tighten the bolts to the specified torque in a crisscross pattern.

2. Install the new carrier bearings with the special tool TORQUE: 101 N·m (10.3 kgf·m, 74.5 Ibf·ft)

and a press. NOTE: • Press the bearings on until they bottom. • Use the small end of the special tool to install the bearing. • Press the bearings on securely so there is no clearance between the bearings and the differential carrier.

14-202

BACK

Oil Seal Replacement 4. Install the oil seal (A) in the transmission housing with the special tools.

Special Tools Required • Driver 07749-0010000 • Seal driver attachment 07GAD-PG40101 or 07 GAD-PG401 00 • Pilot, 28 x 30 mm 07JAD-PH80400 • Oil seal driver attachment 07JAD-PH80101

07749-0010000

1. Remove the differential assembly. 2. Remove the oil seal (A) from the transmission housing (B).

07 JAD-PH80400 A

5. Install the oil seal (A) in the torque converter housing with the special tools. 07749-0010000

A

3. Remove the oil seal (A) from the torque converter housing (B).

07 JAD-PH80400

BACK

14-203

AfT Differential Carrier Bearing Outer Race Replacement Special Tools Required

• Driver 07749-0010000 • Attachment, 78 x 80 mm 07NAD-PX40100 NOTE: • Replace the bearing with a new one whenever the outer race is to be replaced. • Do not use shim(s) on the torque converter housing side. • Adjust preload after replacing the bearing and outer race. • Coat all parts with ATF during installation.

4. Install the thrust washer (A) and outer race (8) in the torque converter housing (C), and be sure to install the outer race until it bottoms in the housing with the special tools. B A

1. Remove the bearing outer race from the transmission housing by heating the housing to about 212°F (100°C) with a heat gun. Do not heat the housing morethan 212°F (100°C). 2. Remove the bearing outer race from the torque converter housing. 3. Install the thrust shim (A), thrust washer (8) and outer race (C) in the transmission housing (D) with the special tools.

07749-0010000

07NAD-PX40100

14-204

BACK

Carrier Bearing Preload Inspection 4. Select the 2.60 mm (0.102 in.) thrust shim from the middle of the table below.

Special Tools Required • Driver 07749-0010000 • Attachment, 78 x 80 mm 07NAD-PX40100 • Preload inspection tool 07HAJ-PK40201

THRUST SHIM, 76 mm

NOTE: If the transmission housing, torque converter housing, differential carrier, tapered roller bearing, outer race, or thrust shim were replaced, the bearing preload must be adjusted. 1. Remove the bearing outer race (A), thrust washer (8) and thrust shim (e) from the transmission housing (D) by heating the housing to about 212°F (100 0e) with a heat gun (E). Do not heat the housing more than 212°F (1000e).

No. S T U A 8 e D E F G

NOTE: Let the transmission housing cool to room temperature before adjusting the bearing preload.

/E

~

H I J K L M N

0 P Q R

Part Number 41438-PX4-700 41439-PX4-700 41440-PX4-700 41441-PK4-000 41442-PK4-000 41443-PK4-000 41444-PK4-000 41445-PK4-000 41446-PK4-000 41447 -PK4-000 41448-PK4-000 41449-PK4-000 41450-PK4-000 41451-PK4-000 41452-PK4-000 41453-PK4-000 41454-PK4-000 41455-PK4-000 41456-PK4-000 41457 -PK4-000 41458-PK4-000

2.05 2.01 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05

Thickness mm (0.081 mm (0.083 mm (0.085 mm (0.087 mm (0.089 mm (0.091 mm (0.093 mm (0.094 mm (0.096 mm (0.098 mm (0.100 mm (0.102 mm (0.104 mm (0.106 mm (0.108 mm (0.110 mm (0.112 mm (0.114 mm (0.116 mm (0.118 mm (0.120

in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.) in.)

o

2. Replace the tapered roller bearing when the outer race is to be replaced. 3. Do not use a shim on the torque converter housing side.

(cont'd)

BACK

14-205

AIT Differential Carrier Bearing Preload Inspection (cont'd) 5. Install the thrust shim (A), thrust washer (8), and bearing outer race (C) in the transmission housing

8. Install the differential assembly (A), gasket (8), and dowel pins (C) on the torque converter housing (D). Align the spring pin on the control shaft (E) with the transmission housing groove.

(D).

10 x 1.25 mm

«N~.ftl

H

F~~1~1 6. Drive the outer race with the special tools, and install it securely in the transmission housing. 7. Check that there is no clearance between the thrust washer, outer race, shim, and transmission housing.

G

A

c

D

9. Install the transmission housing (F) with the transmission hangers (G) and harness clamp bracket (H), and tighten the bolts.

14-206

BACK

10. Rotate the differential assembly in both directions to seat the bearings. 11. Measure the starting torque of the differential assembly with the special tool and a torque wrench (A). Measure the starting torque at normal room temperature in both directions. STANDARD: New bearing:

2.7-3.9 N·m (28-40 kgf·cm, 24-35Ibf·in.) Reused bearings: 2.5-3.6 N·m (25-37 kgf·cm, 22-32Ibf·in.)

07HAJ-PK40201

12. To increase the starting torque, increase the thickness of the shim. To decrease the starting torque, decrease the thickness of the shim. Changing the shim to the next size will increase or decrease starting torque about 0.3-0.4 N·m (3-4 kgf·cm, 3-3Ibf·in.).

BACK

14-207

BACK

Transaxle Drivelinel Axle Special Tools ............................................................. Driveshafts Reassembly ........................................... Intermediate Shaft Removal.................................... Intermediate Shaft Disassembly ............................. Intermediate Shaft Resassembly ............................ Intermediate Shaft Installation ................................

16-2 16-3 16-14 16-14 16-16 16-18

NOTE: Refer to the '98-02 Accord Service Manual, PIN 6158400, for the items not shown in this section.

Outline of Model Changes '98 model: • The installation length of the driveshafts is different; installation instructions and specifications are included. • The installation position ofthe intermediate shaft is different; related service information is included. '99 model: • The Thermoplastic Polyester Elastomer (TPE) outboard boot has been added. • The replacement procedure for ear clamp type boot bands has been added. • The outboard joint disassembly/reassembly procedure has been added. '01 model: • The replacement procedure for low profile type boot bands has been added.

Drivelinel Axle Special Tools Ref. No.

CD ill ®

CD ® ® IJ)

Tool Number 07LAF-SM40300 077 46-0010300 077 49-0010000 07947-SD90101 07947 -4630100 07947 -6340500 07965-S D90 100

Description Support Base Attachment Attachment, 42 x 47 mm Driver Oil Seal Driver, Attachment Fork Seal Driver, 39.2x49.5x15 mm Driver Attachment Support Base

CD

®

®

16-2

at'[ 1 1 1 1 1 1 1

BACK

®

Driveshafts Reassembly Exploded View '98-00 models

DOUBLE LOOP BAND Replace.

Pack cavity with grease. ~ DRIVESHAFT

~~STOPRING Replace. G

(Rubber typel

DOUBLELOOPB~

Replace.

OUTBOARD BOOT

(Rubber) DOUBLE LOOP BAND Replace.

OUTBOARD JOINT


EAR CLAMP BAND Replace.

(cont'd)

BACK

16-3

DrivelinelAxle Driveshafts Reassembly (cont'd) '01-02 models ROLLER

DOUBLE LOOP BAND Replace. (Replacement parts only)

SET RING Replace.


LOW PROFILE BAND Replace.

BOOT BANDS Replace.

OUTBOARD BOOT (TPE)

.. ~


16-4

BACK


• Boot band tool, KD-3191 or equivalent commercially available • Boot band pincers, Kent-Moore J-35910 or equivalent commercially available • Boot band pincer, commercially available

3. Install the spider (A) onto the driveshaft by aligning the marks (B) on the spider and the end of the driveshaft.


Inboard Joint Side 1. Wrap the splines with vinyl tape (A) to prevent damage to the inboard boot. A

~

4. Fit the circlip (C) into the driveshaft groove. Always rotate the circlip in its groove to be sure it is fully seated. 5. Fit the rollers (A or B) onto the spider (C) with their high shoulders facing outward, and note these items:

2. Install the inboard boot to the driveshaft, then remove the vinyl tape.Take care not to damage the inboard boot.

• Reinstall the rollers in their original positions on the spider by aligning the marks (D). • Hold the driveshaft pointed up to prevent the rollers from falling off. • Roller (A) is used on '98-00 AfT models and all '01-02 models. • Roller (B) is used on '98-00 MIT models.

(cont'd)

BACK

16-5

DrivelinelAxle Driveshafts Reassembly (cont'd) 6. Pack the inboard joint with the joint grease included in the new driveshaft set. Grease quantity Inboard joint: 120 -130 g (4.2 - 4.6 oz) ('98-00 models) 150-160 g (5.3-5.6 oz) ('01-02 models)

8. Adjust the length of the driveshafts to the figure below, then adjust the boots to halfway between full compression and full extension. Make sure the ends of the boots seat in the grooves of the driveshaft and joint. Left driveshaft: Right driveshaft:

554-559 mm (21.8-22.0 in.) 544-549 mm (21.4-21.6 in.'

9. Install the boot bands. 7. Fit the inboard joint onto the driveshaft, and note these items: o

o

o

16-6

For the double loop type, go to step 13. • For the low profile type, go to step 11.

o

Reinstall the inboard joint (A) onto the driveshaft by aligning the marks (8) on the inboard joint and the rollers. Hold the driveshaft so the inboard joint points up to prevent it from falling off. For Mrr models, align the roller holders (e) with the grooves in the inboard joint ('98-00 models).

BACK

10. Install the new low profile band (A) onto the boot (8) and dynamic damper, then hook the tab (C) of the band.

12. Fit the boot ends onto the driveshaft and the inboard joint, then install the band (A) onto the boot

11. Close the hook portion of the band with a commercially available boot band pincers (A) then hook the tabs (8) ofthe band.

13. Pull up the slack in the band by hand.

(8).

14. Mark a position (A) on the band 10-14 mm (0.40.6 in.) from the clip (8).

B

(cont'd)

BACK

16-7

DrivelinelAxle Driveshafts Reassembly (cont'd) 15. Thread the free end ofthe band through the nose section of the commercially available boot band tool KD-3191 or equvialent (A), and into the slot on the winding mandrel (B).



16. Place a wrench on the winding mandrel ofthe boot band tool, and tighten the band until the marked spot (C) on the band meets the edge of the clip.

NOTE: • Make sure the band and clip do not interfere with anything and the band does not move . • Remove any grease remaining on the surrounding surfaces

17. Lift up the boot band tool to bend the free end of the band 90 degrees to the clip. Center-punch the clip, then fold over the remaining tail onto the clip.

16-8

BACK

20. Install the new set ring.

Outboard Joint Side: 1. Wrap the splines with vinyl tape (A) to prevent damage to the outboard boot. Rubber type

TPEtype

2. Install the new boot band (B) (TPE type). 3. Install the outboard boot. Take care not to damage the outboard boot. 4. Remove the vinyl tape.

(cont'd)

BACK

16-9

DrivelinelAxle Driveshafts Reassembly (cont'd) 5. Install the new stop ring (A) into the driveshaft groove (8).

7. To completely seat the outboard joint, pick up the driveshaft and joint, and drop them from about 10 cm (4 in.) onto a hard surface. Do not use a hammer as excessive force may damage the driveshaft.

A

~

6. Insert the driveshaft (A) into the outboard joint (8) until the stop ring (C) is close on the joint.

10cm (4in.1

8. Check the alignment of the paint mark (A) with the outboard joint end (8).

16-10

BACK

9. Pack the outboard joint with the joint grease included in the new joint boot set.

12. Set the new double loop band (A) onto the boot.

Grease quantity Outboard joint (Rubber): 130-140 9 (4.6-4.9 oz) Outboard joint (TPE): 140-150 9 (4.9-5.3 oz)

13. Pull up the slack in the band by hand. 14. Mark a position (A) on the band 10-14 mm (0.40.6 in.) from the clip (8). 10. Install the outboard boot and boot bands. • For TPE type boot, go to step 20. • For rubber type boot, go to step 11. 11. Fit the boot (A) ends onto the driveshaft (8) and outboard joint (e).

B

(cont'd)

BACK

16-11

DrivelinelAxle Driveshafts Reassembly (cont'd) 15. Thread the free end of the band through the nose section of a commercially available boot band tool KD-3191 or equivalent (A), and into the slot on the winding mandrel (B).


c


16. Place a wrench on the winding mandrel of the boot band tool, and tighten the band until the marked spot (C) on the band meets the edge of the clip.

NOTE: • Make sure the band and clip do not interfere with anything, and the band does not move. • Remove any grease remaining on the surrounding surfaces.

17. Lift up the boot band tool to bend the free end of the band 90 0 to the clip. Center-punch the clip, then fold over the remaining tail onto the clip.

16-12

A

BACK

20. Fit the boot (A) ends onto the driveshaft (B) and outboard joint (C).

21. Close the ear portion (A) of the band with a commercially available boot band pincers (B).

A

22. Check the clearance between the closed ear portion of the band. If the clearance is not within the standard, close the ear portion of the band further. 6.0mm (0.24 in.) MAX

3.0 mm (0.12 in.) MAX

BACK

16-13

DrivelinelAxle Intermediate Shaft Removal 1. Drain the ATF, refer to the '98-02 Accord Service Manual (see page 14-113). 2. Remove the left driveshaft; refer to the '98-02 Accord Service Manual (see page 16-3).

Intermediate Shaft Disassembly Special Tools Required • Driver 07749-0010000 • Driver attachment 07947-6340500 • Support base attachment 07LAF-SM40300 • Support base 07965-SD90100 • Attachment, 42 x 47 mm 07746-0010300

3. Remove the flange bolt (A) and 2 dowel bolts (B).

B\~

1. Remove the heat shield (A) and intermediate shaft outer seal (B) from the bearing support (C).

c~

,~

~,,""

o

6)

4. Remove the intermediate shaft (A) from the differential. Hold the intermediate shaft horizontal until it is clear of the differential to prevent damage to the differential oil seal (B). A

2. Remove the external snap ring (D). 3. Press the intermediate shaft (A) out of the intermediate shaft bearing (B) using the special tools and a press. Be careful not to damage the metal rings (C) on the intermediate shaft during disassembly. Press

07749-0010000

B

16-14

BACK

4. Remove the internal snap ring.

5. Press the intermediate shaft bearing (A) out of the bearing support (8) using the special tools and a press.

BACK

16-15

DrivelinelAxle Intermediate Shaft Reassembly Exploded View

FLANGE BOLTS 6x1.0mm 10 N·m (1.0 kgf.m, 7.2Ibf·ft)

BEARING SUPPORT RING

SNAP RING

Grease splines. 0.3-1.0 9 (0.01-0.04 oz)

BEARING SUPPORT OUTER SEAL Replace.

Pack the interior of the outer seal. 3.0-4.0 9 (0.11-0.14 oz)

16-16

BACK

Special Tools Required • Driver 07749-0010000 • Support base attachment 07LAF-SM40300 • Support base 07965-S090100 • Oil seal driver attachment 07947-S090101 • Fork seal driver, 39.2 x 49.5 x15 mm 07947-4630100

4. Press the intermediate shaft (A) into the shaft bearing using the special tool and a press.

NOTE: Refer to the Exploded View as needed during this procedure. 1. Clean the disassembled parts with solvent, and dry them with compressed air. Do not wash the rubber parts with solvent. 2. Press the intermediate shaft bearing (A) into the bearing support (8) using the special tools and a press.

_--'-...L.-_.L..J...~__ 07947-4630100 5. Seat the external snap ring (A) into the groove of the intermediate shaft (8).

3. Seatthe internal snap ring in the groove ofthe bearing support.

A

(cont'd)

BACK

16-17

DrivelinelAxle Intermediate Shaft Installation

Intermediate Shaft Reassembly (cont'd) 6. Pack the interior of the outer seal (A). Install the outer seal into the bearing support (8) using the special tools and a press.

A

1. Clean the areas where the intermediate shaft (A) contacts the transmission (differential) thoroughly with solvent or carburetor cleaner, and dry with compressed air. Insert the intermediate shaft assembly into the differential. Hold the intermediate shaft horizontal to prevent damage to the differential oil seal (8).

Pack the interior ofthe outer seal.

3.0-4.0g 10.11-0.14ozl

B

A

2. Install the flange bolt (A) and 2 dowel bolts (8). 7. Install the heat shield onto the bearing support.

3. Refill the transmisson with recommended ATF, refer to the '98-02 Accord Service Manual (see page 14-113).

16-18

BACK

Steering Power Steering Special Tools ............................................................. Component Location Index ..................................... Symptom Troubleshooting Index ........................... Symptom Troubleshooting ..................................... Pump Pressure Test-with TIN 07406-0010001 ..... Pump Pressure Test-with TIN 07406-001000A .... Fluid Leakage Inspection ......................................... Pump Belt Inspection and Adjustment ................... Hoses and Lines Replacement ................................ Pump Replacement .................................................. Pump Overhaul ......................................................... Rack Guide Adjustment ............................................ Steering Gearbox Overhaul .....................................

17-2 17-3 17-4 17-6 17-7 17-8 17-9 17-10 17-12 17-13 17-14 17-19 17-20

NOTE: Refer to the 1998-2002 Accord Service Manual, PIN 61S8400 for items not shown in this section.

Outline of V6 Model Changes The Steering System has been changed to suitthe V6 engine.

Power Steering Special Tools Ref.No.

Descri~tion

Tool Number

Oty 1 1 1 1 1 1 1 1 1 1

07LAG-SM40100 or 07LAG-SM4010A Piston Seal Ring Guide 07LAG-SM40200 or 07LAG-SM4020A Piston Seal Ring Sizing Tool ® 07 JGG-001 01 OA Belt Tension Gauge *® G) Cylinder End Seal Remover Attachment 07TAF-SZ50 100 PIS Joint Adaptor (Hose) 07RAK-S040122 ® PIS Joint Adaptor (Pump) 07VAK-P8A011 A ® PIS Joint Adaptor Plate (Pump) 07VAK-P8A012B CD 07406-0010001 or 07406-001000A PIS Pressure Gauge ® Attachment, 42 x 47 mm 077 46-00 10300 ® @ Driver 077 49-00 10000 *Included In the Belt Tension Gauge Set, 07TGG -001000A.

~
eIJ ~ e~

®

!

®

®

~~

~ ~~

®

CD

,~

~-

®

17-2

BACK

~ G)

®

Component Location Index RESERVOIR Hoses and Lines Replacement, page 17-12 Fluid Leakage Inspection, page 17-9

POWER STEERING PUMP Pump Pressure Test, page 17-7 Pump Belt Adjustment, page 17-10 Pump Replacement, page 17-13 Pump Overhaul, page 17-14

POWER STEERING GEARBOX Rack Guide Adjustment, page 17-19 Steering Gearbox Overhaul, page 17-20

BACK

17-3

Power Steering Symptom Troubleshooting Index Find the symptom in the chart below, and do the related procedures in the order listed until you find the cause.

SvmDtom

Procedurelsl

Hard Steering

Troubleshoot the system (see page 17-61.

Assist (excessively light steering at high speedl

Check the rack guide adjustment (see page 17-191.

Shock or vibration when the wheel is turned to full lock

1. 2. 3.

Steering wheel will not return smoothly

1. 2. 3.

Uneven or rough steering

1. 2. 3. 4. 5. 6.

Steering wheel kicks back during wide turns

1. 2.

Humming

1.

2. 3.

17-4

Check the rack guide adjustment (see page 17-191. Check the power steering pump belt for slippage and adjust as necessary (see page 17-101. Replace the steering gearbox; refer to the '98-02 Accord Service Manual (see paae 17-301. Check cylinder lines A and B for deformation. Check wheel alignment; refer to the '98-02 Accord Service Manual (see page 18-51. Replace the steering gearbox; refer to the '98-02 Accord Service Manual (see paae 17-301. Check the rack guide adjustment (see page 17-191. Check power steering pump belt adjustment (see page 17-101. Check for low or erratic engine idle speed (see page 11-871. Check for air in the power steering system due to low fluid level. Check for low fluid level in the power steering reservoir due to possible leaks in system. Replace the steering gearbox; refer to the '98-02 Accord Service Manual (see paae 17-301. Check power steering pump belt adjustment (see page 17-101. Check the power steering pump fluid pressure with TIN 07406-0010001 (see paae 17-7) with TIN 07406-001000A (see paae 17-8). Check when the noise occurs • If the noise happens 2-3 minutes after starting the engine in cold weather, this is normal . • If the noise happens when the wheel is turn with the vehicle stopped, this is normal due to the fluid pulsation. Check for the high-pressure hose touching the sub-frame or body. Check for automatic transmission convertor noise. Remove the power steering belt and recheck.

BACK

Also check for: • Modified suspension • Tire sizes, tire varieties, and air pressure • Power steering pump belt adjustment Front wheel alignment; refer to the '98-02 Accord Service Manual (see Daae 18-51.

Rattle or chattering

Hissing

Pump noise

Saueaking Fluid Leaks from the steering gearbox

Fluid leaks from line

Fluid leaks from pump

Fluid leaks from reservoir

Fluid leaks from pump outlet hose (high-pressure) Fluid leaks from pump inlet hose (low-Dressure)

Check for loose steering components (tie-rod and ball joints). Tighten or replace as necessary. 2. Check the steering column shaft for wobbling. If the steering columns wobbles, replace the steering column assembly, refer to the '98-'02 Accord Service Manual (see page 17-25). 3. Check the rack guide adjustment (see page 17-19). 4. Check the power steering pump pulley. • If the pulley is loose, tighten it (see page 17-14) . • Ifthe DumD shaft is loose reDlace the DumD (see Dage 17-13). • Check the fluid level. If low, fill the reservoir to the proper level and check for leaks. • Check the reservoir for leaks. • Check for crushed inlet hose or loose hose clamp allowing air into the suction side ofthe system. • Check the Dower steerina DumD shaft oil seal for leaks. • Compare the pump noise at normal operating temperature to another vehicle, (pump noise up to 2- 3 minutes after starting the engine in cold weather is normal). • Remove and insDectthe DumD for wear and damage (see steD 1 on Dage 17-15). Check the Dower steering belt tension and adiust as necessary (see Dage 17-10). • Fluid leaks from the top of the valve body unit: Replace the valve body unit. • Fluid leaks from the left tie-rod boot: Replace the valve oil seal on the pinion shaft. Replace the cylinder end seal on the gearbox side. • Fluid leaks from the right tie-rod boot: Replace the cylinder end seal. • Fluid leaks from pinion shaft near the lower steering joint bolt: Replace the valve body unit. • Fluid leaks from the cylinder line A or B connections (flare nuts): Tighten the connection and retest. If it still leaks, replace the fitting a-rings. • Fluid leaks from a damaged cylinder line A or B: Replace the cylinder line. • Fluid leaks from the pump outlet hose or return line fitting on the valve body unit (flair nuts): Tighten the fitting and retest. If it still leaks, replace the hose, the line or valve body unit as necessary. • Fluid leaks from the front oil seal: Replace the front oil seal. • Fluid leaks from the power steering pump housing: Replace the leaking a-rings or seals (see page 17-14), and if necessary replace (see Dage 17-13) • Fluid leaks from around the reservoir cap: Fluid level is too high: drain the reservoir to the proper level. Aerated fluid: check for an air leak on the inlet side of pump. • Fluid leaks from reservoir: Check for the reservoir for cracks and replace as necessary. • Check the fitting for loose bolts. If the bolts are tight, replace the fitting a-ring. • Fluid leaks atthe swagruld joint: Replace the outlet hose. Check the hose for damage, deterioration, or improper assembly. Replace or reDair as necessarv.

1.

BACK

17-5

Power Steering Symptom Troubleshooting Hard Steering

6. Adjust the rack guide (see page 17-19), and retest.

1. Check the power assist, refer to the '98-02 Accord Service Manual (see page 17-7).

Is the steering OK?

YES-Repair is completed .• Is the power assist more than 29 N (3.0 kgf, 6.6Ibf)?

NO- Faulty gearbox .•

YES - Go to step 2. 7. Check for feed and return lines between the pump and the gearbox for clogging and deformation.

NO-Power assist is OK.• 2. Measure steady-state fluid pressure from the pump at idle with TIN 07406-0010001 (see page 17-7) or with TIN 07406-001000A (see page 17-8).

Are the lines clogged or deformed?

YES- Repair or replace the lines .• NO- Faulty valve body unit.•

Is the pressure 1,500 kPa (15 kgflcrrf, 213 psi) or less?

8. Check the flow control valve, refer to the '98-02 Accord Service Manual (see page 17-17) for smooth movement and leaks.

YES- Go to step 3. NO-Goto step 7.

Is the flow control valve OK?

3. Measure the pump relief pressure at idle with TIN 07406-0010001 (see page 17-7) or with TIN 07406001000A (see page 17-8).

YES-Faulty pump assembly.• NO-Faulty flow control valve .•

Is the pressure 7,600-8,300 kPa (78-85 kgflcm

2, 1,100- 1,210 psi) or less? 9. Check the cylinder lines A and B for deformation (see page 17-12).

YES-Goto step 4.

Are the A or B lines deformed?

NO-Go to step 8.

YES- Replace the lines .•

4. With a spring scale, measure the power assist in both directions, to the left and to the right.

NO-Go to step 10. Are the two measurements within 5.0 N (0.51 kgf, 1.12Ibf) of each other?

10. Check for a bent rack shaft or misadjusted rack guide (to tight).

YES-Goto step 5. Is the rack shaft bent or the rack guide adjusted too tight?

NO- Go to step 9. 5. Measure the fluid pressure with TIN 07406-0010001 (see page 17-7) or with TIN 07406-001000A (see page 17-8) with both pressure gauge valves open (if so equipped), wheel turning the steering wheel fully to the left and fully to the right.

YES- Replace the rack shaft or readjust the rack guide.• NO- Faulty valve body unit.•

Is the pressure 7,600- 8,300 kPa (78- 85 kgflcrrf, 1,100- 1,210 psi) or less?

YES-Goto step 6. NO-Faulty gearbox.•

17-6

BACK

Pump Pressure Test with TIN 07406-0010001 5. Fully open the shut-off valve (A).


• PIS joint adapter (pump), 07VAK-P8A011A • PIS joint adapter plate (pump), 07VAK-P8A0128 • PIS joint adapter (hose), 07RAK-S040122 • PIS pressure gauge, 07406-0010001

B

Check the fluid pressure as follows to determine whether the trouble is in the pump or gearbox. 1. Check the power steering fluid level; refer to the '98-02 Accord Service Manual (see page 17-14) and pump belttension (see page 17-10).

A

2. Disconnect the pump outlet hose (A) from the pump outlet with care so as not to spill the power steering fluid on the frame and other parts, then install the PIS joint adapter (pump) on the pump outlet (8) with the PIS joint outlet plate. 6. Fully open the pressure control valve (8). 7. Start the engine and let it idle. 8. Turn the steering wheel from lock-to-Iock several times to warm the fluid to operating temperature.

07VAK-P8A011A

9. Measure steady-state fluid pressure while the engine is idling. If the pump is in good condition, the gauge should read less than 1,500 kPa (15 kgf/cm 2, 213 psi). If it reads high, check for: • Clogged or deformed feed or return line between the pump and gearbox. • Clogged valve vody unit. 10. Close the pressure control valve, then close the shut-off valve gradually until the pressure gauge needle is stable. Read the pressure.

INOTICEI 3. Connect the PIS joint adapter (hose) to the PIS pressure gauge, then connect the pump outlet hose (A) to the PIS joint adapter (hose). 4. Install the PIS pressure gauge to the PIS joint adapter (pump).

BACK

Do not keep the pressure control valve closed more than 5 seconds or the pump could be damaged by over-heating. 11. Immediately open the pressure control valve fully. Ifthe pump is in good condition, the gauge should read at least 7,600-8,300 kPa (78-85 kgf/cm 2 , 1,110-1,210 psi). A low reading means pump output is too low for full assist. Repair or replace the pump.

17-7

Power Steering Pump Pressure Test with TIN 07406·001000A Special Tools Required • PIS joint adapter (pump), 07VAK-P8A011A • PIS joint adapter plate (pump), 07VAK-P8A0128 • PIS joint adapter (hose), 07RAK-S040122 • PIS pressure gauge, 07406-001000A

5. Open the pressure control valve (A) fully. A

Check the fluid pressure as follows to determine whether the trouble is in the pump or gearbox. 1. Check the power steering fluid level; refer to the '98-02 Accord Service Manual (see page 17-14) and pump belt tension (see page 17-10). 2. Disconnect the pump outlet hose (A) from the pump outlet with care so as not to spill the power steering fluid on the frame and other parts, then install the PIS joint adapter (pump) on the pump outlet (8) with the PIS joint outlet plate. 6. Start the engine and let it idle. 7. Turn the steering wheel from lock-to-Iock several times to warm the fluid to operating temperature. 8. Measure steady-state fluid pressure while the engine is idling. If the pump is in good condition, the gauge should read less than 1,500 kPa (15 kgf/cm2, 213 psi). If it reads high, check for: • Clogged or deformed feed or return line between the pump and gearbox . • Clogged valve vody unit. 07VAK-P8A011A 07VAK-P8A012B

9. Close the pressure control valve gradually and read the pressure.

INOTICEI Do not keep the pressure control valve closed more than 5 seconds or the pump could be damaged by over-heating. 3. Connect the PIS joint adapter (hose) to the PIS pressure gauge, then connect the pump outlet hose (A) to the PIS joint adapter (hose). 4. Install the PIS pressure gauge to the PIS joint adapter (pump).

17-8

10. Immediatery open the pressure control valve fully. If the pump is in good condition, the gauge should read at least 7,600-8,300 kPa (78-85 kgf/cm2, 1,110-1,210 psi). A low reading means pump output is too low for full assist. Repair or replace the pump.

BACK

Fluid Leakage Inspection PUMP ASSEMBLY Check for leaks at the pump inlet and outlet fittings.

GEARBOX and VALVE BODY UNIT Check for leaks at the mating surface flare nut connections.

HOSES and LINES Inspect hoses for damage, leaks, interference and twisting. Inspect fluid lines for damage, rusting and leakage. Check for leaks at hose and line joints and connections.

BACK

17-9

Power Steering Pump Belt Inspection and Adjustment Adjustment

Special Tools Required Belttension gauge set, 07JGG-001000A or Belt tension gauge, 07JGG-001010A

3. Loosen the power steering pump mounting nut (A) and bolt (B).

Belt Tension Gauge Method Inspection 1. Attach the belt tension gauge to the belt with the gauge face toward the engine, and measure the tension of the belt. Follow the manufacture's instructions. If the belt is worn or damaged, replace it. NOTE: Remove the belt tension gauge carefully to avoid hitting the gauge reset lever. Tension: Used Belt: New Belt:

A

390-540 N (40-55 kgf, 88-121Ibf) 740-880 N (75-90 kgf, 165-198Ibf) 07JGG-001000A or 07JGG-001010A

24 N·m (2.4 kgf·m, 17 Ibf·ft) B 24 N·m (2.4 kgf.m, 17 Ibf·ft)

4. Turn the adjusting nut (e) to get the proper belt tension, then retighten the mounting nut and bolt. 5. Start the engine and turn the steering wheel from lock-to-Iock several times, then stop the engine and recheck the tension of the belt.

2. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specifications.

~

I

17-10

BACK

Deflection Method

Adjustment 3. loosen the power steering pump mounting nut (A) and bolt (B).

Inspection 1. Apply a force of 98 N (10 kgf, 22 Ibf) and measure the deflection between the power steering pump pulley (A) and the crankshaft pulley (B). Deflection: Used Belt: 13.0-16.5 mm (0.51-0.65 in.) New Belt: 8.5-11.0 mm (0.33-0.45 in.)

A 24 N·m 12.4 kgf·m, 17 Ibf·tt)

B 24 N·m 12.4 kgf·m, 17 Ibf·tt)

4. Turn the adjusting nut (e) to get the proper belt tension, then retighten the mounting nut and bolt.

B

5. Start the engine and turn the steering wheel from lock-to-Iock several times, then stop the engine and recheck the tension of the belt .

.....

2. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specifications.

r BACK

17-11

Power Steering Hoses and lines Replacement Note these items during installation: • Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. • Check all clamps for deterioration or deformation; replace with the clamps new ones if necessary. • Add the recommended power steering fluid to the specified level on the reservoir and check for leaks.

ADJUSTABLE HOSE CLAMP (A)

HOSE CLAMP (B)

2.S-S.Smm (0.01-0.22 in.) 2.S-S.Smm (0.01-0.22 in.)

2.0-4.0mm (0.08-0.16 in.)

FEED HOSE


POWER STEERING PRESSURE SWITCH

10x1.25mm 12 N·m (1.2 kgf·m, 8.7Ibf·ftl

17-12

BACK

RETURN LINE

16x 1.5 mm 28 N·m (2.9 kgf·m, 21 Ibf·ft)

Pump Replacement 1. Place a suitable container under the vehicle.

7. Loosely install the pump in the pump bracket with the mounting bolts and nut.

2. Drain the power steering fluid from the reservoir. 8. Install the pump belt (A) on the pulley (8). 3. Remove the intake manifold cover. 4. Cover the crankshaft pulley with several shop towels to protect if from spilled power steering fluid. Disconnect the pump inlet hose (A) and pump outlet hose (8) from the pump (C), and plug them. Take care not to spill the fluid on the body or parts. Wipe off any spilled fluid at once.

Note these items during belt installation: • Make sure that the power steering belt is properly positioned on the pulleys. • Do not get the power steering fluid or grease on the belt or pulley faces. Clean off any fluid or grease before installation.

6x 1.0 mm BOLT

11 N·m 11.1 \m. 81bf·ftl F 24N·m 12.4 kgf.m, 17 Ibf·ftl

9. Adjust the pump belt adjustment (see page 17-10).

G 24N·m 12.4 kgf·m, 17 Ibf·ftl

10. Fill the reservoir to the upper level line; refer to the '98-02 Accord Service Manual (see page 17-14).

5. Remove the belt (D) by loosening the pump adjusting nut (E), then remove pump mounting bolts (F), nut (G) and pump. Do not turn the steering wheel with pump removed. 6. Connect the pump outlet hose and inlet hose. Tighten the pump fittings securely.

BACK

17-13

Power Steering Pump Overhaul Exploded View Replace the pump as an assembly if the parts indicated with asterisk (*1 are worn or damaged. 4.5 mm ROLLER

~ FLANGE BOLTS

*OUTER SIDE PLATE

20 N·m (2.0 kgf·m, 14lbf·ftl '~.I\)'-----*PUMP

COVER

~

~5mmROLLER

*SIDE PLATE

PUMP COVER SEAL Replace.

------------15.2 x 2.4 mm O-RING

*PUMP CAM RING

v: V

*PUMPROTOR

Replace.

*SNAPR~

0

*SUB-VALVE

L~~~"(j~ /

\

/

'PUMP HOUSING

BALL BEARING

FLANGE BOLTS 11 N·m (1.1 kgf·m, 8lbf·ftl

-------*SPRING

g - - - - - 1 5 . 2 x 2.4 mm O-RING Replace.

~

~'FLOW

40 mm SNAP RING

PULLEY NUT 64 N·m (6.5 kgf·m, 47 Ibf·ftl

17-14

13 x 1.9 mm O-RING Replace.

INLET JOINT /

\

51 x 2.4 mm O-RING Replace.

CONTllOL VALVE CAP 49 N·m (5.0 kgf·m, 36 Ibf·ftl

BACK


Inspection

Universal holder, 07725-0030000 10. Check the flow control valve for wear, burrs, and other damage to the edges of the grooves in the valve.

Disassembly

NOTE: Refer to the Exploded View as needed during the following procedure. 1. Remove the power steering pump (see page 17-13). "... "...

'---

=

0

0

r--

-=-

2. Drain the fluid from the pump. 3. Hold the steering pump (A) in a vise with soft jaws, hold the pulley (B) with the special tool, and remove the pulley nut (C) and pulley. Be careful not to damage the pump housing with the jaws of the vise.

' -' -

11. Inspect the bore of the flow control valve on the pump housing for scratches and wear. 12. Slip the flow control valve back in the pump housing, and check that it moves in and out smoothly. If OK, go to step 13; if not, replace the pump as an assembly. The flow control valve is not available separately.

4. Loosen the flow control valve cap with a hex wrench, and remove it and the O-ring, flow control valve, and spring. 5. Remove the pump cover and pump cover seal. 6. Remove the outer side plate, pump cam ring, pump rotor, pump vanes, side plate, and O-rings. 7. Remove the snap ring, then remove the sub-valve from the pump housing. 8. Remove the circlip, then remove the pump drive shaft by tapping the shaft end with the plastic hammer. 9. Remove the pump seal spacer and pump seal.

(cont'd)

BACK

17-15

Power Steering Pump Overhaul (cont'd) 13. Attach a hose (A) to the end of the flow control valve (8) as shown. Then subl'l1erge the flow control valve (8) in a container of power steering fluid or solvent (C), and blow in th~ hose. • If air bubbles leak through the valve at less than 98 kPa (1.0 kgf/cm 2; 14.2 psi), replace the pump as an assembly. The flow control valve is not available separately. • If the flow control valve tests OK, set it aside for reassembly later.

Reassembly

16. Clean the disassembled parts with solvent, and dry them with compressed air. 00 not dip rubber parts in solvent. 17. Align the pin (A) of the sub-valve (8) with the oil passage (C) in the pump housing, and push the sub-valve into place. then install the snap ring (0).

A

14. Inspect the ball bearing by rotating the outer race slowly. If you feel any play (axial or radial) or roughness remove the faulty ball bearing (A), and install a new one (8).

18. Install the new pump seal (A)(with its grooved side facing in) into the pump housing by hand, then install the pump seal spacer (8).

O---F

B

~

__-c

A

~

19. Position the pump drive shaft (C) in the pump housing (0), then drive it in using a 29 mm socket (E).

15. Inspect each part shown with an asterisk in the Exploded View; if any ofthem are worn or damaged, replace the pump as an assembly.

17-16

20. Install the 40 mm snap ring (F) with its radiused side facing out.

BACK

21. Coatthe new pump cover seal (A) with power steering fluid, and install it into the groove in the pump cover (B).

24. Assemble pump rotor (A) to the pump cover (B). A

c

}oo

aD

D

25. Set the 10 vanes (C) in the grooves in the rotor. Make sure that the round ends (0) of the vanes are in contact with the sliding surface of the cam ring. 22. Install the outer side plate (C) over the two rollers (0).

26. Coat the new O-ring (A) with power steering fluid, and install it into the groove in the side plate (B).

23. Set the pump cam ring (A) over the two rollers with its "." mark (B) facing up.

~A

/B

B

E E

c 27. Install the side plate on the cam ring (C) by aligning the roller set holes (0) in the side plate with the rollers (E).

(cont'd)

BACK

17-17

Power Steering Pump Overhaul (cont'd) 28. Coat the new O-ring (A) with power steering fluid, and position it in the bottom of the pump housing (B).

/

32. Install the pulley (A), then loosely install the pulley nut (B). Hold the steering pump in a vise with soft jaws. Be careful not to damage the pump housing with the jaws of the vise.

8x 1.25 mm /20N.m (2.0 kgf.m, 14Ibf·ft)

B 64 N·m (6.5 kgf·m, 47Ibf·ft)

/~A

29. Install the pump cover assembly (C) in the pump housing. 30. Coat the flow control valve (A) with power steering fluid, then install it and the spring (B) in the pump housing.

33. Hold the pulley (A) with the special tool, and tighten the pulley nut (B). 34. Check that the pump turns smoothly by turning the pulley by hand.

B

1/ Of((§)

/

o

49 N·m (5.0 kgf·m, 36Ibf·ft)

31. Coat the new O-ring (0) with power steering fluid, and install it on the flow control valve cap (E). Install the cap on the pump housing, and tighten it.

17-18

BACK

Rack Guide Adjustment 1. Set the wheels in the straight ahead position. 2. Loosen the rack guide screw locknut (A) with a commercially available 1 3/4" crowfoot wrench (B), then remove the rack guide screw (C). c A

7. Check for tight or loose steering through the complete turning travel. 8. Check the steering wheel rotational play and the power assist; refer to the '98-02 Accord Service Manual (see page 17-7).

69 N·m (7.0 kgf.m, 51Ibf·ft)

f

3. Remove the old sealant from rack guide screw threaded section, and apply new sealant all the way around the first three threads (A). Loosely install the rack guide screw on the steering gearbox.

4. Tighten the rack guide screw to 25 N·m (2.5 kgf·m, 18 Ibf·ft), then loosen it. 5. Retighten the rack guide screw to 3.9 N·m (0.4 kgf·m, 2.9 Ibf·ft), then back it off to specified angle. Specified Return Angle:

600± 50

6. Tighten the locknut while holding the rack guide screw.

r BACK

17-19

Power Steering Steering Gearbox Overhaul Exploded View

FLANGE BOLTS

FLARE NUTS

19 N·m 11.9 kgf.m, 1.4Ibf·ttl

13 N·m (1.3 kgf·m, 9.4Ibf·ttl O·RING Replace.

til

~

~GASKET

/" CYLINDER LINE B

\

~ ~~

GEARBOX HOUSING

CIRCLIP O·RING Replace.

Ifj) J@

\

1

I

%5)-,()CI \

----LOCKNUT

\ \


fi). \ .

/OO@J(@ RACK STOP ______ ~j ( ) 0 RACK BUSHING /

_ Replace.

\

'\

RACK GUIDE SCREW

SPRING RACK GUIDE

~~.m 12.5 kgf.m. ,.,bf.ft) END PLUG

59 N·m (6.0 kgf.m, 43 Ibf·ttl

PISTON SEAL RING Replace. O·RING Replace.

(j STEERING RACK

/


17-20

BACK

3. Unbend the lock washer (A).


• Cylinder end seal remover attachment, 07TAF-SZ50100 • Driver, 07749-0010000 • Attachment, 42 X 47 mm, 07746-0010300 • Piston seal ring guide, 07LAG-SM4010A or 07LAG-SM40100 • Piston seal ring sizing tool, 07LAG-SM4020A or 07LAG-SM40200 • Pincer Oetiker 1098, or equivalent, commercially available

A

NOTE: Refer to the Exploded View as needed during the following procedure. Removal

1. Remove the steering gearbox; refer to the '98-02 Accord Service Manual (see page 17-30). Note these items during removal: • Disconnect the primary H02S sensor connector. • Remove exhaust pipe A (see page 5-2) to allow clearance for the steering gearbox. Disassembly

4. Hold the flat surface sections (A) of the right side steering rack (B) with a wrench, and unscrew both rack ends (C) with a wrench. Be careful not to damage the rack surface with the wrench. Remove the lock washer (D) and stop washer (E).

I

2. Remove the boot band (A) and tie-rod clips (B). Pull the boots away from the ends of the gearbox.

(cont'd)

BACK

17-21

Power Steering Steering Gearbox Overhaul (cont'd) 5. Loosen the locknut (A), then remove the rack guide screw (B).

9. Remove the end plug (A) from the gearbox housing, then remove the nut (B) from the pinion shaft end. C

6. Remove the spring (C) and the rack guide (D) from the gearbox. 7. Remove the cylinder lines from the gearbox.

__- - A 10. Remove the two flange bolts, the valve body unit (C), and gasket (D) from the gearbox. Check that the valve turns smoothly by turning the pinion shaft. If any play or roughness is felt, replace the valve body unit with a new part if necessary. Do not try to disassemble the valve body unit. 11. Slide the steering rack all the way to the left. 12. Turn the rack stop (A) counterclockwise until the end of the circlip (B) sticks out from the hole (C) in the rack stop. Then turn it clockwise to remove the circlip (D). B

8. Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth.

D

17-22

BACK

16. Install a washer (0.0.27.5 mm, PIN 94103-10400) (A) so it will fit through the rack guide hole of the gearbox housing, then position the washer on the cylinder end seal (B). Make sure that the washer is securely positioned on the cylinder end seal edges.

13. Remove the rack stop (AI, rack bushing (B), and steering rack (C) from the steering gearbox.

A

14. Remove the a-ring (A) and cylinder end seal (B) from the rack bushing (C).

17. Install a socket with a 27.5 mm 0.0. (A) onto a 24" long, 3/8" drive extension (B), and carefully place it on the washer (C). ..

~

15. Carefully pry the piston seal ring (A) and a-ring (B) off the rack piston. Be careful not to damage the inside of seal ring groove and piston edges when removing the seal ring.

B

---..o:1ilI-'~=i 5-6 mm

(0.20-0.24 in.)

18. Install a bearing separator (D) on the gearbox. housing. Set the steering gearbox in a press so the gearbox housing points upward, then push outthe cylinder end seal (E) 5-6 mm (0.20-0.24 in.) by pressing on the end of the extension.

19. Remove the steering gearbox from the press, and remove the washer from the gearbox inside.

r

(cont'd)

BACK

17-23

Power Steering Steering Gearbox Overhaul (cont'd) 20. Turn the special tool so it will fit through the rack guide hole of the steering gearbox, then position the special tool on the cylinder end seal (A). Make sure that the special tool is securely positioned on the seal edges.

Reassembly 22. Coat the special tool with power steering fluid, then slide it onto the rack, big end first. 23. Position the new C-ring (A) and new piston seal ring (B) on the special tool, then slide them down toward the big end of the tool. Note these items during reassembly: • Do not over expand the resin seal rings. Install the resin seal rings with care so as not to damage them. After installation, be sure to contract the seal ring using the special tool (sizing tool) . • Replace the piston's C-ring and seal ring as a set.

.~

f~»i

/

i

07TAF-SZ501 00

1/

07LAG-SM4010A or 07LAG-SM40100

A

21. Insert a 24 in. long, 3/8 in. drive extension (A), on the special tool. Place the steering gearbox in a press, then remove the cylinder end seal (B) from of the gearbox by pressing on the end of the extension. Note these items when pressing the cylinder end seal: • Keep the tool straight to avoid damaging the cylinder wall. Check the tool angle, and correct it if necessary, when removing the cylinder end seal. • Use a press to remove the cylinder end seal. Do not try to remove the seal by striking the tool; striking the tool would break the cylinder end seal, and the seal would remain in the gearbox.

B

24. Pull the C-ring off into the piston groove, then pull the piston seal ring off into the piston groove on top of the C-ring. 25. Coat the piston seal ring (A) and the inside of the special tool with power steering fluid, then carefully slide the tool onto the rack and over the piston seal ring.

A~

A

i 07TAF-SZ50100

07LAG-SM4010A or 07LAG-SM40100

B

26. Move the special tool back and forth several times to make the piston seal ring fit snugly in the piston.

17-24

BACK

27. Wrap vinyl tape around the rack teeth and rack end edges, then coat the surface of the tape with power steering fluid. Make sure that the vinyl tape is wrapped carefully so that there is no stepped portion.

30. Grease the steering rack teeth, then insert the steering rack into the gearbox housing. Be careful not to damage to inner surface of the cylinder wall with the rack edges.

28. Coat the inside surface of the new cylinder end seal (A) with power steering fluid, then install it onto the steering rack with its grooved side toward the piston. When installing the cylinder end seal, be careful not damage the lip of the seal with the edges or teeth ofthe steering rack.

31. Insert a deep socket (A) onto the steering rack as shown. Press

A

~B 32. Install the cylinder and seal (B) into the bottom of the cylinder by pressing on the tool with a press. Do not push on the tool with excessive force as it may damage the cylinder end seal. 33. Remove the tool, and center the steering rack.

29. Remove the vinyl tape from the steering rack, then remove any adhesive residue.

(cont'd)

BACK

17-25

Power Steering Steering Gearbox Overhaul (cont'd) 34. Wrap vinyl tape around the rack end edges, and coat the surface of the tape with power steering fluid. Make sure that the vinyl tape is wrapped carefully so there is no stepped portion.

37. Install the rack bushing onto the steering rack with the cylinder end seal grooved side toward the piston. Push in the rack bushing with your finger.

35. Coat the inside surface of the new cylinder end seal (A) with power steering fluid, then press it into the rack bushing (8) using the special tools.

i

<

07749-0010000

/A

~

38. Remove the vinyl tape from the steering rack, then remove any adhesive residue. 39. Install the rack stop (A) onto the steering rack so the hole (8) is aligned with the slot (C) on the steering rack.

0"40-0010300

B

i

I .........--~

36. Coat the new O-ring (C) with power steering fluid, and carefully fit it in the groove of the rack bushing.

17-26

BACK

40. Insert the end of the circlip (A) into the hole (B) of the rack stop (e). Turn the rack stop counterclockwise until the circlip is fully seated in the rack stop.

45. Before installing the cylinder lines, coat the new 0rings with power steering fluid, then install the lines. Note these items during reassembly: • Thoroughly clean the joints of the cylinder lines. The joints must be free of foreign material. • Install the cylinder lines by tightening the flare nuts by hand first, then tighten the flare nuts to the specified torque.

A

13 N·m (1.3 kgf.m, 9.4Ibf·ft)

c 41. Apply grease to the needle bearing (A) in the gearbox housing, and install the valve body unit (B) and gasket (e) by engaging the gears. Note the valve body unit installation position (direction of line connections). Then loosely install the two flange bolts. B

~_19N.m

46. Apply mUltipurpose Grease to the sliding surface of the rack guide (A), and install it onto the gearbox housing.

(1.9 kgf·m, 1.4Ibf·ft)

42. Install the nut (D) onto the pinion shaft end, and tighten to specified torque. After tightening, use a drift to stake the nut shoulder (E) against the pinion shaft. 43. Apply sealant all the way around the threads on the end plug (F), install the end plug onto the gearbox housing, and tighten it to the specified torque.

47. Apply new sealant all the way around the first three threads ofthe rack guide screw (B), then install the spring (e), rack guide screw, and locknut (D). 48. Adjust the rack guide screw (see page 17-19). After adjusting, check that the rack moves smoothly by sliding it right and left.

44. Tighten the flange bolts to the specified torque.

r (cont'd)

BACK

17-27

Power Steering Steering Gearbox Overhaul (cont'd) 49. Install the stop washer (A) with the chamfered side facing out, and screw each rack end (B) into the rack while holding the lock washer (C) so its tabs (D) are in the slots (E) in the end of the rack.

83N·m (8.5 kgf·m, 61 Ibf·ft)

52. Apply mUltipurpose grease (A) to the circumference of the rack end joint housing. A

53. Apply a light coat of silicone grease (B) to the boot grooves (B) on the rack ends.

50. Hold the flat surface sections ofthe right side steering rack with a wrench, and tighten both rack ends. Be careful not to damage the rack surface with the wrench.

54. Center the steering rack within its stroke. Install the boots on the rack ends with the tie-rod clips. After installing the boots, wipe the grease off the threaded section (A) of the rack end.

51. Bend the lock washer back against the flat spots on the rack end joint housing.

A

17-28

BACK

55. Install the new boot bands by aligning the tabs (A) with the holes (8) ofthe band.

56. Close the ear portion (A) of the band with a commercially available Oetiker 1098 pincer or equivalent (8).

57. Slide the rack right and left to be certain that the boots are not deformed or twisted. Installation

58. Install the steering gearbox; refer to the '98-02 Accord Service Manual (see page 17-47). Note these items during installation: • Reinstall exhaust pipe A with new gasket (see page 5-11) . • Reconnect the primary H02S sensor connector.

BACK

17·29

BACK

Brakes Conventional Brake Components Front Brake Pads Inspection and Replacement .................................................. 19-2 Rear Brake Caliper Overhaul .................................... 19-4

ABS (Anti-lock Brake System) Components ..................... 19-7 NOTE: Refer to the 1998-2002 Accord Service Manual, PIN 6158400 for the items not shown in this section.

Outline of V6 Model Change The front brake caliper is different; the brake pad replacement and the brake caliper overhaul procedures are included.

Conventional Brake Components Front Brake Pads Inspection and Replacement 3. Remove the pads (A), pad shims (B), and pad retainers (C).

ACAUTION Frequent inhalation of brake pad dust,regardless of material composition,could be hazardous to your health . • Avoid breathing dust particles . • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

c

1. Loosen the front wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels. Remove the brake hose mounting bolts (A) from the knuckle.

B

A 9.8N·m 11.0 kgf·m, 7.2Ibf·ft)

4. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include the pad backing plate (A) thickness. Brake Pad Thickness: 10.5-11.5 mm (0.41-0.45 in) Standard: Service Limit: 1.6 mm (0.06 in)

c 2. Remove the caliper bolt (B), and pivot the caliper (C) up out of the way. If the caliper pin head is the hex. type, the caliper bolt should be removed using a wrench while holding the caliper pin with another wrench. Check the hoses and pin boots for damage and deterioration.

f A

5. If the brake pad thickness is less than the service limit, replace the front pads and shims together as a set. 6. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. 7. Check the brake disc for damage and cracks.

19-2

BACK

8. Install the pad retainers (A).

11. Push in the piston (A) so the caliper will fit over the pads. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down. NOTE: Check the brake fluid level, the brake fluid may overflow the reservoir if too full. B 49 N·m 15.0 kgf·m, 36 Ibf.ft)

~

A

9. Apply Molykote M77 grease to both sides of the pad shims (A) and the back of the pads (8). Wipe excess grease off the shim. A

C

A

.(t_I. ..

...-. '

12. Pivot the caliper down into position, being careful not to damage the pin boot. Install the caliper bolt (8), and torque it to proper specification. If the caliper pin head (C) is the hex. type, the caliper bolt should be installed by using a wrench while holding the caliper pin with another wrench. Install the brake hose onto the knuckle . 13. Press the brake pedal several times to make sure the brakes work, then road-test.

10. Install the brake pads and pad shims correctly. Install the pad with the wear indicator (C) on the inside.lf you are reusing the pads,always reinstall the brake pads in their original positions to prevent loss of braking efficiency.

NOTE: Engagement of the brake may require 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. 14. After installation, check for leaks at hose and line joints and connections, and retighten if necessary.

BACK

19-3

Conventional Brake Components Front Brake Caliper Overhaul

ACAUTION Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health . • Avoid breathing dust particles . • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Remove, disassemble, inspect, reassemble, and install the caliper, and note these items: • Do not spill brake fluid on the vehicle; It may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. • Clean all parts in brake fluid and air dry; blowout all passages with compressed air. • Before reassembling, check that all parts are free of dirt and other foreign particles. • Replace parts with new ones as specified in the illustration. • Make sure no dirt or other foreign matter gets into the brake fluid. • Make sure no grease or oil gets on the brake discs or pads. • When reusing pads, always reinstall the brake pads in their original positions to prevent loss of braking efficiency. • Do not reuse drained brake fluid. • Always use Honda DOT 3 Brake Fluid. Non-Honda brake fluid can cause corrosion and decrease the life of the system. • Coat the piston, piston seal, and caliper bore with clean brake fluid. • Replace all rubber parts with new ones. • After installing the caliper, check the brake hose and line for leaks, interference, and twisting.

19-4

BACK

Sedan: _

~ : Silicone grease

~ : Rubber grease

\d

BANJO BOLT 34 N·m (3.5 kgf·m, 25 Ibf·tt) SEALING WASHERS Replace.

BRAKE HOSE 10 mm FLANGE BOLTS 34 N·m (3.5 kgf·m, 25 Ibf.tt) ARM CAM

~

~

CAM

RePI~

BLEED SCREW

$f~m (0.9 kgf·m, 6.5 Ibf·tt)

0

BO~

LEVER

\,

CALIPER BODY /SLEEVE PISTON

~

'-

PIN

\0 ~

~ ~~

-------= -

ADJUSTING BILT

--~l

BRAKEPA~

=------~~~~

OUTER PAD SHIM

SPRING COVER

~~

~o~,~~

SPACER ADJUSTING SPRING B

t@ ;

27 N·m (2.8 kgf·m, 20 Ibf·tt)

~

\

BEARING A

.1fN

~

\Yf~~

~:~ ~7

CALlPEIi BOLTS 23 N.m /f~ (2.3 kgf·m, 17Ibf·tt) ~ PIN A

CALIPER BRACKET 10 mm FLANGE BOLTS 38 N·m (3.9 kgf·m, 28 Ibf·tt)

PIN BOOT

-~

r (cont'd)

BACK

19-5

Conventional Brake Components Front Brake Caliper Overhaul (cont'd) Coupe:

_~

: Silicone grease

~

: Rubber grease

10 x 1.25 mm

tl!"k~f.m, 32 Ibf.ft)

BANJO BOLT 34 N·m (3.5 kgf·m, 25Ibf·ft)

~ ~~~I~~~~ WASHERS RAKE HOSE 'i BLEED SCREW ~ ~~ 9 N·m (0.9 kgf·m, 6.5Ibf.ft) \

~

~

ARM

CALIPER BODY

0

~

0

R,pl",

7;}- /

CAM ASSEMBLY

~_ ~

RETURN SPRING

CALIPER BOLTS 8x1.0mm 25 N·m (2.5 kgf·m, 19 Ibf·ft) "\ PIN A

JJ V f1

Y

/

----"""~\'\ --~

~

PINB PIN BOOTS

\ RETAINER RING BOOT CLIP Replace.

'~/~'~I~~!,TS

lJ-~~(((0 ~

OUTER PAD SHIM

-~

SPRING CASE

CONNECTOR Replace. ~

PAD SPRING

BRAKE PADS

PISTON ASSEMBLY

O~

Replace.

~

~

/SLEEV:PRING

/

-----~-~ .---__ ,4:~

CAM BOOT


~ /RETAINER

~

~

BUSH

SILICONE GREASE CALIPER BRACKET

FLANGE BOLTS 10x 1.25mm 55 N·m (5.6 kgf·m, 41 Ibf.ft)

PIN

19-6

BACK

Brakes Conventional Brake Components ................ 19-1 ABS (Anti-lock Brake System) Components ('98-00 Models) Component Location Index ..................................... DTC Troubleshooting Index ..................................... Symptom Troubleshooting Index ........................... Circuit Diagram ......................................................... DTC Troubleshooting ............................................... ABS Indicator Circuit Troubleshooting ................... Modulator Unit Removal and Installation .............. ABS Control Unit Replacement ...............................

19-8 19-9 19-10 19-12 19-14 19-18 19-21 19-22

ABS/TCS (Anti-lock Brake System/Traction Control System) Components ('01- 02 Models) ................................................ 19-23 NOTE: Refer to the 1998-2002 Accord Service Manual (PIN 61S8400) for the items not shown in this section.

Outline of V6 Model Changes • The locations of the modulator unit and ASS control unit were changed; - Component location index was added. - Modulator unit removal and installation was added. - ABS control unit replacement was added. • Ground numbers of pump motor ground and ABS control unit ground were changed; - DTC troubleshooting index was added. - Symptom troubleshooting index was added. - Circuit diagram was added. - DTC troubleshooting was added. - ABS indicator circuit troubleshooting was added.

ABS Components Component Location Index UNDER-HOOD ABS RELAY BOX (PUMP MOTOR RELAY) Inspection, page 22-52 in the '98-02 Accord Service Manual

/UI"DE:R-tIO(JID FUSE/RELAY BOX

/PA.SSIENC;ER'S UNDER-DASH FUSE/RELAY BOX

LEFT-REAR WHEEL SENSOR Inspection, page 19-70 in the '98-02 Accord Service Manual Replacement, page 19-71 in the '98-02 Accord Service Manual

DATA LINK CONNECTOR (16P)

RIGHT-FRONT SENSOR Inspection, page 19-70 in the '98-02 Accord Service Manual Replacement, page 19-71 in the '98-02 Accord Service Manual

19-8

LEFT-FRONT WHEEL SENSOR Inspection, page 19-70 in the '98-02 Accord Service Manual Replacement, page 19-71 in the '98-02 Accord Service Manual

BACK

RIGHT-REAR WHEEL SENSOR Inspection, page 19-70 in the '98-02 Accord Service Manual Replacement, page 19-71 in the '98-02 Accord Service Manual

~ E!I DTC Troubleshooting Index DTC DTC: 11

Detection Item Right-front wheel sensor (open/short to body ground/short to power)

DTC: 12

Right-front wheel sensor (electrical noise/intermittent interruption)

DTC: 13

Left-front wheel sensor (open/short to body ground/short to power)

DTC: 14

Left-front wheel sensor (electrical noise/intermittent interruption)

DTC: 15

Right-rear wheel sensor (open/short to body ground/short to power)

DTC: 16

Right-rear wheel sensor (electrical noise/intermittent interruption)

DTC: 17

Left-rear wheel sensor (open/short to body ground/short to power)

DTC: 18

Left-rear wheel sensor (electrical noise/intermittent interruption)

DTC: 21

Right-front pulser

DTC:22

Left-front pulser

DTC:23

Right-rear pulser

DTC:24

Left-rear pulser

DTC: 31

Right-front inlet solenoid

DTC:32

Right-front outlet solenoid

DTC:33

Left-front inlet solenoid

DTC:34

Left-front outlet solenoid

DTC:35

Right-rear inlet solenoid

DTC:36

Right-rear outlet solenoid

DTC:37

Left-rear inlet solenoid

DTC:38

Left-rear outlet solenoid

DTC: 41

Right-front wheel lock

DTC:42

Left-front wheel lock

DTC: 43

Right-rear wheel lock

DTC:44

Left-rear wheel lock

DTC: 51

Motor lock

DTC: 52 DTC:53 DTC:54

Motor stuck OFF Motor stuck ON Fail-safe relay

DTC: 61

Low ignition voltage

DTC:62

High ignition voltage

DTC: 71

Different diameter tire

DTC: 81

Central Processing Unit (CPU) diagnosis, and ROM/RAM diagnosis

BACK

Note Refer to the '98-02 Accord Service Manual (see paQe 19-52) Refer to the '98-02 Accord Service Manual (see paQe 19-53) . Refer to the '98-02 Accord Service Manual (see paQe 19-52) Refer to the '98-02 Accord Service Manual J$ee~e 19-53) Refer to the '98-02 Accord Service Manual (see Dace 19-52) Refer to the '98-02 Accord Service Manual (see paQe 19-53) Refer to the '98-02 Accord Service Manual (see paQe 19-52) Refer to the '98-02 Accord Service Manual (see paQe 19-53) Refer to the '98-02 Accord Service Manual (see paQe 19-54) Refer to the '98-02 Accord Service Manual Jl;ee~e 19-54) Refer to the '98-02 Accord Service Manual (see paQe 19-54) Refer to the '98-02 Accord Service Manual (see paQe 19-54) Refer to the '98-02 Accord Service Manual (see paQe 19-55) Refer to the '98-02 Accord Service Manual (!lee pa~e 19-55) Refer to the '98-02 Accord Service Manual (see Dace 19-55) Refer to the '98-02 Accord Service Manual (see paoe 19-55) Refer to the '98-02 Accord Service Manual (see paQe 19-55) Refer to the '98-02 Accord Service Manual (see paQe 19-55) Refer to the '98-02 Accord Service Manual (see Dace 19-55) Refer to the '98-02 Accord Service Manual (see paoe 19-55) Refer to the '98-02 Accord Service Manual (see paoe 19-58) Refer to the '98-02 Accord Service Manual (see paQe 19-58) Refer to the '98-02 Accord Service Manual (see paQe 19-58) Refer to the '98-02 Accord Service Manual (see page 19-58) Refer to the '98-02 Accord Service Manual (see~e 19-59) (see Dace 19-14) (see Dace 19-16) Refer to the '98-02 Accord Service Manual (see Dace 19-63) Refer to the '98-02 Accord Service Manual (see Dace 19-65) Refer to the '98-02 Accord Service Manual (see paQe 19-65) Refer to the '98-02 Accord Service Manual (see page 19-66) Refer to the '98-02 Accord Service Manual (see Dace 19-66)

19-9

ABS Components Symptom Troubleshooting Index Symptom


ABS indicator does not come on

ABS Indicator Circuit Troubleshooting (see page 19-18)

ABS indicator does not go off and no OTC is stored

ABS Indicator Circuit Troubleshooting (see page 19-18)

19-10

BACK

Also check for

r--------------~~~~·

BACK

19-11

ABS Components Circuit Diagram BAITERY

+

.B

UNDER·HOOD FUSE,RElAY BOX

BRAKE SWITCH

Closed: Brake pedal depressed ~

STOPI20A)

t - - -...-~cD'---o-- VIHT,~El--0- WHT/BlK---------------:~=~::::':'::~----- WHTIBlK--DRIVER'S UNDER·DASH FUSE/RElAY BOX

r-¢---cru:_-ffi- VEl---r--fJt+---@]-GRNlRED--'I'I----

IGNITION SWITCH

~'\~ UP LIGHT

GRNJRED

'U>---<>- WHT~VEl--'¢---:5\.l>---<1S), ~Bll(J'fEl

~G¢EW~WgH ~

Closed: low fluid:1::.

G3D2

ASS FtS (20AI

WHT/GRN~:::-;:====l-_+=

UNDER·HOOD ABS RElAY BOX

FAil-SAFE

RELAY

YEL~ED___".I

Li.-L*,,"-J~ :~;---8LUNlHT---

I! .

8R~N!8l-l_K_B_LK

_____

T

ABS INDICATOR CIRCUIT

GS01

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ YElJ8lK--------------------YEUGRN---

~

YEURED---

BRtfBlK WHT:SLU

BR

lK

... GRNI-----~~------------------------GRN---

t"~~::~::::~-

t------+"'OOO,~I__---..(!;~.;;,;,.--------... RED!8LU--t------+"'OOO,~I__---~~~~-------... YElJ8lU---

t------+"'OOO,~I__---~~~----------REMLK--

=,!----....(j~;;.;;;;.;,.--------YW8lK---

WHTBLU

+-----+-Jl:xv~I----~..:.::=---------RED/GRN-- +----+JXlOr.d-----
L...------WHT!8LU----ffi------1

UNDER·HOOD FUSE-RELAY BOX CONNECTORS laP CONNECTOR «() number)

7P CONNECTOR (0 number)

t"Zf:Zl"3I:5F3/1~/117V 14~' :6j~ t:m:J:ilij

3

';2i3456789 10'11:12,,3 14,15i16117 181920

4 12 13 14

7 8 9 10

7 ;8 ' 9

DRIVER'S UNDER·DASH FUSEIRELAY BOX CONNECTORS lOP CONNECTOR (0 number)

PASSENGER'S UNDER-DASH FUSE/RELAY BOX CONNECTORS lap CONNECTOA (0 number) 16P CONNECTOR (0 number)

1234 5678 9 10 11 12 13 1415 1617 18

17 18

r1'Gl tillJ

GAUGE ASSEMBLRY CONNECTORS 22P CONNECTOR

(0 number)

l6P CONNECTOR

19-12

(Onumbcr)

Q.J:TI FAll·SAFE RELAY

CONNECTOR

PUMP MOTOR

~

CONNECTOR (0 number)

cITb

Terminal side of female term"aIs

(0 number)

1 2 415 6 7' 8 9 10 j.,'+2+3+'T?+,:4,r,:.'+:,:6j,7'o1 L:'.:.'..:1::.2.:...t..:.~1:::6"',='_"''_'''.::.91''',2.::.0:::2''''::.22::1 8191011 12 141516 Wire

MOOULATOR UNIT CONNECTOR

JIJ:>'
BRAKE SWITCH CONNECTOR lap CONNECTOR (0 number)


side of female tenTinais

BACK

~ ~

PCM(SCS)

'V

-----WHT/BlK-----C})"'f"-WHT/BlK:-.;;.;,;~~,.. BRAKE

SCS

, 8ft

DATA LINK CONNECTOR (16P) 1

N

·--<"'-'--f.A""'''--BRN~BRN

LIGHT

PCM (DLC)

'J.8Y

WHT/GRN

lXU

BlKl

F""'[email protected]. Gl0l G.ol

-------------------------~~ -------------------------~~--~~~-,

---------------YElJR!:O IG2

GRN

MCK

A,6

FL-IN REO/BLU ~U8LU

REO/BLK ~U8LK

WHEEL SENSOR

RL-IN

RED,WHT ~INIHT

~RIGHT2 FRONT

FR-IN FR-OUT

RED/GRN

VElJGIIN

~LEFT2..... FRONT

FL-OUT

RL-OUT

~LEFT, - REAR

ttL

~R(GHTREAR

,

U§:\l :=4. _

RR-IN RR-OUT

G20'

ABS CONTROL UNIT CONNECTORS CONNECTOR A (22P)


G205

WHEEL SENSOR CONNECTOR

FR~R Tarminal side of male terminals

CONNECTOR B (12P) 123458 7 8 9 10 11 12


BACK

19-13

ABS Components OTC Troubleshooting DTC 52: Motor Stuck OFF 1. Check the ABS MOTOR (30 A) fuse in the underhood fuse/relay box, and reinstall the fuse if it is OK.

4. Connect the pump motor relay connector terminal No.3 to No.4 with a jumper wire for a moment, and check the fuse. PUMP MOTOR RELAY CONNECTOR

Is the fuse OK? YES-Go to step 3.•

~ 1

4

NO - Replace the fuse, and go to step 2. +B (WHT)

2. Connect the pump motor relay connector terminal No.3 to No.4 with a jumper wire for a moment, and check the fuse.

3

MOTOR (WHT/BLU)



~

Is the fuse blown?

1

4

+B (WHT)

3

MOTOR (WHT/BLU)

YES- Check for a short to body ground in the MCK circuit. • NO-Go to step 5.


5. Check the pump motor relay in the under-hood ABS relay box, refer to the '98-02 Accord Service Manual (see page 22-52).

Is the fuse blown?

Is the relay OK?

YES-Check for a short to body ground in the motor power source circuit .•

YES-Go to step 6. NO- Replace the pump motor relay .•

NO-Go to step 3. 3. Check the ABS MTR CHK (7.5 A) fuse in the passenger's under-dash fuse/relay box, and reinstall the fuse if it is OK.

6. Connect the pump motor relay connector terminal No.3 to No.4 with a jumper wire for a moment.

Does the pump motor operate?

Is the fuse OK?

YES- Go to step 11.

YES-Go to step 5.

NO-Go to step 7.

NO- Replace the fuse, and go to step 4.

7. Disconnect the pump motor connector. 8. Connect the pump motor relay connector terminal No.3 to No.4 with a jumper wire.

19-14

BACK

~ ~ 9. Measure the voltage between the pump motor connector terminal No.1 and body ground.

11. Disconnect the ABS control unit connector B (12P). 12. Connectthe pump motor relay connector terminal No.1 to No.4 with a jumper wire.


PUMP MOTOR RELAV CONNECTOR

cITP. 1fMOTOR (WHT/BlUJ

JUMPER WIRE

~MR (VEL/RED)

2

1

4

3

+B(WHT)



/s there battery voltage? YES-Go to step 10.

13. Measure the voltage between the ABS control unit connector terminal B12 and body ground.

NO-Repair open in the wire between the underhood ABS relay box and the pump motor.•


10. Measure the voltage between the pump motor connector terminal No.1 and No.2. PUMP MOTOR CONNECTOR PMR (VEL/RED)

MOTOR GND IBLK[!jMOTOR IWHT/BLU)

2 1


Y..

/s there battery voltage? YES - Go to step 14.


NO- Repair open in the wire between the underhood ABS relay box and the ABS control unit..

/s there battery voltage? YES- Replace the modulator unit.• NO- Repair open in the wire between the pump motor and body ground (G203) .•

(cont'd)

BACK

19-15

ABS Components DTC Troubleshooting (cont'd) 14. Remove the jumper wire from the pump motor relay connector.

Ole 53: Motor Stuck ON 1. Check that the pump motor operates with the ignition switch OFF.

15. Start the engine. 16. Measure the voltage between the ABS control unit connector terminal B12 and body ground. ABS CONTROL UNIT CONNECTOR B (12PI

Does the pump motor operate? YES- Replace the pump motor relay. (Pump motor relay stuck ON.). NO-Goto step 2. 2. Remove the ABS MTR CHK (7.5 A) fuse in the passenger's under-dash fuse/relay box.

PMR (VEL/REDI

/s the fuse OK? YES - Remove the fuse, and go to step 3. NO - Replace the fuse, and recheck.• Wire side of female terminals


/s there battery voltage? YES- Repair a short to power in the wire between the under-hood ASS relay box and the ABS control unit.•

4. Measure the voltage between the passenger's under-dash fuse/relay box 16P connector terminal No.5 and body ground. PASSENGER'S UNDER-DASH FUSE/RELAV BOX 16P CONNECTOR

NO -If the problem recurs, replace the ABS control unit..

MCK(GRNI


/s there about 10 V? YES- Go to step 5. NO- Repair open in the wire between the passenger's under-dash fuse/relay box and the ABS control unit.• 5. Reinstall the ABS MTR CHK (7.5 A) fuse in the passenger's under-dash fuse/relay box.

19-16

BACK

~ ~ 6. Disconnect the pump motor connector. 7. Measure the voltage between terminal No.1 and body ground.

9. Remove the pump motor relay, then connect relay terminals No.4 and No.5 together with ajumper wire.

Does the pump motor run?



~

NO- Replace the pump motor.•

iOTOR (WHT/BLUI

10. Disconnect the ABS control unit connector B (12P). 11. Check for continuity between terminal B12 and body ground.

=



Is there about 10 V? YES-Go to step 8. NO-Repair open in the wire between the underhood ABS relay box and the pump motor.•

=

8. Measure the voltage between the pump motor connector terminal No.1 and No.2.




MOTOR GND I B e : I MTOR IWHT/BLUI

YES - Repair short to body ground in the wire between the under-hood ABS relay box and the ABS control unit.• NO -If the problem recurs, replace the ABS control unit.•

Terminal side offemale terminals

Is there about 10 V? YES-Go to step 9. NO- Repair open in the wire between the pump motor and body ground (G203) .•

BACK

19-17

ABS Components ABS Indicator Circuit Troubleshooting 1. Turn the ignition switch ON(II), and watch the ABS indicator.

9. Check for continuity between the gauge assembly 16P connector terminal No.10 and body ground. GAUGE ASSEMBLY 16P CONNECTOR

Does the ABS indicator come on? NO - Go to step 2. YES-Ifthe ABS indicator comes on and goes off, it's OK. If the ABS indicator stays on, go to step 13. 2. Turn the ignition switch OFF then ON (II) again. Does the brake system indicator come on? YES-Go to step 3.


NO- Repair open in the brake system indicator circuit.• • Blown BACK-UP LIGHT (7.5 A) fuse. • Open in the wire between the BACK-UP LIGHT (7.5 A) fuse and the gauge assembly. • Open circuit inside the fuse box.

Is there continuity? YES-Repair short to body ground in the wire between the gauge assembly and the ABS control unit.. NO-Go to step 10.

3. Turn the ignition switch OFF. 10. Connect the gauge assembly 16P connector. 4. Disconnect the ABS control unit connector B (12P). 5. Turn the ignition switch ON (II). Does the ABS indicator come on?

11. Connect the gauge assembly 22P connector terminal No. 16 to body ground with a jumper wire. 12. Turn the ignition switch ON (II). GAUGE ASSEMBLY 22P CONNECTOR

YES-Check for loose ABS control unit connectors. If necessary, substitute a known-gooq ABS control unit, and recheck .• NO - Go to step 6. 6. Check the ABS indicator bulb in the gauge assembly.

JUMPER WIRE

GND (BLK)

-=

Is the bl,llb OK? YES-Go to step 7.


NO-Replace the ABS indicator bulb.• Does the ABS indicator come on? 7. Turn the ignition switch OFF. 8. Disconnect the gauge assembly 16P connector.

YES- Repair open in the wire between the gauge assembly and body ground (G501) .• NO-Replace the printed circuit board in the gauge assembly.•

19-18

BACK

~ ~ 13. Check the POWER MIRROR (7.5 A) fuse in the under-dash driver's fuse/relay box, and reinstall the fuse if it is OK.

16. Measure the voltage between the ABS control unit connector terminal A 11 and body ground. ABS CONTROL UNIT CONNECTOR A (22P)

Is the fuse OK? IG2 (YEL/BLK)

YES - Go to step 14. NO- Replace the fuse, and recheck .• 14. Connect the ABS control unit connector terminal A1 to body ground with a jumper wire.

=


Wire side of female terminals GND3(BLK)

Is there battery voltage? JUMPER WIRE

YES-Go to step 17.

=

NO- Repair open in the wire between the POWER MIRROR (7.5 A) fuse and the ABS control unit.• 17. Connect the ABS control unit connector terminal B1 to body ground with a jumper wire.




Does the ABS indicator go off? YES-Repair open in the wire between the ABS control unit and body ground (G204) .•

JUMPER WIRE

NO-Gotostep 16.

=


Does the ABS indicator go off? YES-Check for loose ABS control unit connectors. If necessary, substitute a known-good ABS control unit, and recheck.• NO-Go to step 18.

(cont'd)

BACK

19-19

ABS Components ABS Indicator Circuit Troubleshooting (cont'd) 18. Connect the gauge assembly 16P connector terminal No. 10 to body ground with a jumper wire. GAUGE ASSEMBLY 16P CONNECTOR

JUMPER WIRE

WALP (BLU/WHT)


Does the ABS indicator go off? YES-Repair open in the wire between the gauge assembly and the ABS control unit.. NO- Replace the printed circuit board in the gauge assembly .•

19-20

BACK

Modulator Unit Removal and Installation NOTE: • Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. • Take care not to damage or deform the brake lines during removal and installation. • To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel. Removal 1.

From right-front

From right-rear

6mmNUT 9.8 N·m 11.0 kgf.m, 7.2Ibf·ft)

From left-front

~

/m "gf·m, 6mmBOLT

(1 .•

7.2lbf·ft(

2. Disconnect the brake lines, then remove the modulator unit (C). Installation 3. Install the modulator unit, then connect the brake lines. Tighten the flare nuts to 15 N·m (1.5 kgf·m, 11 Ibf·ft). 4. Connect the modulator unit connector and the pump motor connector. 5. Bleed the brake system, starting with the front wheels. 6. Start the engine, and check that the ABS indicator goes off. 7. Test-drive the vehicle, and check that the ABS indicator does not come on.

BACK

19-21

ABS Components ABS Control Unit Replacement 1. Remove the passenger's kick panel. 2. Disconnect the ABS control unit connectors.

3. Remove the ABS control unit. 4. Install the ABS control unit in the reverse order of removal.

19-22

BACK

Brakes Conventional Brake Components .................... 19-1 ABS (Anti-lock Brake System) Components ('98-00 Models) .................................................. 19-7 ABS/TCS (Anti-lock Brake System/Traction Control System) Components ('01-02 Models) Component Location Index ......................................... General Troubleshooting Information ....................... DTC Troubleshooting Index ........................................ Symptom Troubleshooting Index ............................... System Description ...................................................... Circuit Diagram ............................................................. DTC Troubleshooting ................................................... ABS Indicator Circuit Troubleshooting ...................... TCS Indicator Circuit Troubleshooting ....................... Modulator Unit Removal and Installation .................. TCS Switch test ............................................................. ABS/TCS Control Unit Replacement ........................... Wheel Sensor Inspection ............................................. Wheel Sensor Replacement ........................................

19-24 19-25 19-30 19-31 19-32 19-46 19-48 19-76 19-78 19-80 19-81 19-82 19-82 19-83

~

~

Outline of V6 Model Changes • The ABS has been changed to ABS/TCS; troubleshooting was added.

ABS/TCS Components Component Location Index

UNDER-HOOD ABS RELAY BOX PUMP MOTOR RELAY Inspection, page 22-52 in the '98-02 Accord Service Manual ABS FAIL-SAFE RELAY Test, page 22-52 in the '98-02 Accord Service Manual TCSRELAY Test, page 22-31 UNDER-HOOD FUSE/RELAY BOX PASSENGER'S UNDER-DASH FUSE/RELAY BOX HT-REAR WHEEL SENSOR Inspection, page 19-82 Replacement, page 19-83

LEFT-REAR WHEEL SENSOR Inspection, page 19-82 Replacement, page 19-83

MODULATOR UNIT Removal and Installation, page 19-80 RIGHT-FRONT WHEEL SENSOR Inspection, page 19-82 Replacement, page 19-83

19-24

LEFT-FRONT WHEEL SENSOR Inspection, page 19-82 Replacement page 19-83

BACK

~ ~ General Troubleshooting Information ABS/TCS Indicators • If the system is OK, the ABS indicator goes off once after turning the ignition switch ON (II) without starting the engine, and then comes on again and goes off several seconds later after starting the engine. This occurs because the ABSrrCS control unit is turned on by the IG2 power source. • The TCS or ABS indicator comes on when the ABS/ TCS control unit detects a problem in the system. However, even though the system is operating properly, the TCS or ABS indicator will come on, under the following conditions: • For ABS or TCS Indicator: - Only drive wheels rotate - One drive wheel is stuck - The vehicle goes into a spin. - The ABS continues to operate for a long time. - The vehicle is subjected to an electrical signal disturbance. • For TCS Indicator: - The TCS operated when the front brake pad temperature rises excessively. - The TCS switch is OFF. - One or more of these components are faulty: Heated oxygen sensor, Manifold absolute pressure sensor, Crankshaft position sensor, Engine coolant temperature sensor, Throttle position sensor, Top dead center sensor, Top dead center sensor 2, Intake air temperature sensor, Exhaust gas recirculation, Barometric pressure sensor, Idle air control valve, VTEC pressure switch, Knock sensor, Fuel supply system, Automatic transaxle, Misfire detection system ofthe PGM-FI system. To determine the actual cause ofthe problem, question the customer about the problem, taking the above-listed conditions into consideration.

• The ABS is not operational when the ABS indicator is ON; the TCS is not operational when the TCS indicator is ON. • When the ABS and TCS indicators are both ON, troubleshoot the ABS first. • When the TCS indicator and MIL are both ON, troubleshoot the PGM-FI system first.

Diagnostic Trouble Code (DTC) • The memory can hold any number of DTCs. However, when the same DTC is detected more than once, the more recent DTC is written over the earlier one. Therefore, when the same problem is detected repeatedly, it is memorized as a single DTC. • The DTCs are indicated in ascending number order, not in the order they occur. • The DTCs are memorized in the EEPROM (nonvolatile memory). Therefore, the memorized DTCs cannot be canceled by disconnecting the battery. Do the specified procedures to clear the DTCs.

Self-diagnosis • Self-diagnosis can be classified into 2 categories: -Initial diagnosis: Done right after the engine starts and until the ABS or TCS indicator goes off. - Regular diagnosis: Done right after the initial diagnosis until the ignition switch is turned OFF. • When a problem is detected by self-diagnosis,the ABSrrCS control unit shifts to fail-safe mode.

Kickback The pump motor operates when the ABS is functioning, and the fluid in the reservoir is forced out to the master cylinder, causing kickback atthe brake pedal.

Pump Motor • When a problem is detected and the ABS or TCS indicator comes on, there are cases when the indicator stays on until the ignition switch is turned OFF, and cases when the indicator goes off automatically when the system returns to normal. For ABS DTCs 61 and 62, the indicator goes off automatically when the system returns to normal. For all other codes, the indicator stays on until the ignition switch is turned OFF. • For ABS DTCs 12, 14, 16, 18,21,22,23,24,51,52 and 53, the ABS indicator goes off when the vehicle is driven again and the system is OK after the ignition switch is turned from OFF to ON (II). However, if the DTC is cleared, the CPU resets and the indicator goes off right after the engine is started ifthe system is OK.

• The pump motor operates when the ABS is functioning. • The ABSrrCS control unit checks the pump motor operation during initial diagnosis when the vehicle is started. You may hear the motor operate at this time, but it is normal.

Brake Fluid ReplacementlAir Bleeding Brake fluid replacement and air bleeding procedures are identical to the procedures used on vehicles not equipped with ABSrrCS. To ease bleeding, start with the front wheels.

(cont'd)

BACK

19-25

ABS/lCS Components General Troubleshooting Information (cont'd) How to Troubleshoot ABS and TCS DTCs The troubleshooting flowchart procedures assume that the cause ofthe problem is still present and the ABS and/or TCS indicator is still on. Following the flowchart when the ABS and/or TCS indicator does not come on can result in incorrect diagnosis. The connector illustrations show the female terminal connectors with a single outline and the male terminal connectors with a double outline. 1. Question the customer about the conditions when the problem occured, and try to reproduce the same conditions for troubleshooting. Find out when the ABS and/or TCS indicator came on, such as during ABS control, after ABS control, when vehicle speed was at a certain speed, etc.

2. Turn the ignition switch ON (II), and follow the prompts on the Honda PGM Tester to display the DTC(s) on the screen. After determining the DTC, refer to the DTC Troubleshooting Index. NOTE: See the Honda PGM Tester user's manual for specific instructions.

Service Check Signal (SCSI Circuit Method: 1. With the ignition switch OFF, connect the Honda PGM Tester (A) to the 16P Data Link Connector (DLC) (B) behind the driver's kick panel.

2. When the ABS or TCS indicator does not come on during the test drive, but troubleshooting is done based on the DTC, check for loose connectors, poor contact of the terminals, etc. before you start troubleshooting. 3. After troubleshooting, clear the DTCs, and testdrive the vehicle. Make sure the ABS and TCS indicators do not come on.

How to Retrieve ABS or TCS DTCs Honda PGM Tester Method: 1. With the ignition switch OFF, connect the Honda PGM Tester (A) to the 16P Data Link Connector (DLC) (B) behind the driver's kick panel.

2. Short the SCS circuit to body ground using the Honda PGM Tester. 3. Turn the ignition switch ON (II) without pressing the brake pedal. NOTE: If the brake pedal is pressed when turning the ignition switch ON (II), the system shifts to the DTC clearing mode.

19-26

BACK

~ E!I How to Clear ABS DTCs

4. The blinking frequency indicates the DTC. NOTE: If the DTC is not memorized, the ABS or TCS indicator will go off for 3.6 seconds, and then come back on.

Honda PGM Tester Method: 1. With the ignition switch OFF, connectthe Honda PGM Tester (A) to the 16P Data Link Connector (DLC) (B) behind the driver's kick panel.

The system will not indicate the DTC unless these conditions are met: • The TCS switch is not pushed. • The brake pedal is not pressed. • The ignition switch is turned ON (II). • The engine is stopped. • The SCS circuit is shorted to body ground before the ignition switch is turned ON (II). Example of DTC15

t----t-, Long blink

ON

Short blinks (five times) t-,-- - - - J

OFF

2. Turn the ignition switch ON (II), and clear the DTC (s) by following the screen prompts on the Honda PGMTester.

Example of DTC22

-----1-, H Long blinks (two times)

::=J

Short blinks (two times)

!-.-,-

U

UUl

NOTE: See the Honda PGM Tester user's manual for specific instructions. Service Check Signal (SCSI Circuit Method:

5. Turn the ignition switch OFF. 6. Disconnect the Honda PGM Tester from the DLC.

1. With the ignition switch OFF, connect the Honda PGM Tester (A) to the 16P Data Link Connector (DLC) (B) behind the driver's kick panel.

2. Short the SCS circuit to body ground using the Honda PGM Tester.

(cont'd)

BACK

19-27

ABS/TCS Components General Troubleshooting Information (cont'd) 3. Press the brake pedal. 4. Turn the ignition switch ON (II) while keeping the brake pedal pressed. 5. After the ABS indicator goes off, release the brake pedal.

8. After a few seconds, the ABS indicator blinks twice and the DTC is cleared. If the indicator does not blink twice, repeat steps 1 through 7. If the indicator stays on after the indicator blinks twice, check the DTC because a problem was detected during initial diagnosis before shifting to DTC clearing mode. 9. Turn the ignition switch OFF.

6. After the ABS indicator comes on, press the brake pedal again.

10. Disconnect the Honda PGM Tester from the DLC.

7. After the ABS indicator goes off, release the brake pedal again. You cannot clear the DTC unless these conditions are met: • The vehicle speed is 6 mph (10 km/h) or less. • The SCS circuit is shorted to body ground before the ignition switch is turned ON (II). • The brake pedal is pressed before the ignition switch is turned ON (II).

c ON .... ABS

indicator

a OFF d

Depressed--+-...l..r Brake pedal Released .... .........

d

d

c

...... ,

Ignition switch ON (II) a: 2 sec. c: 0.3 sec. b: 4 sec. d: within 3 sec.

19-28

BACK

~

~

How to Clear

rcs orcs

Service Check Signal (SCS) Circuit Method:

Honda PGM Tester Method: 1. With the ignition switch OFF, connect the Honda PGM Tester (A) to the 16P Data Link Connector (DLC) (B) behind the driver's kick panel.

1. Press the parking brake pedal with the SCS circuit opened. Keep the pedal pressed during the entire DTC clearing procedure. 2. Press and hold the TCS switch, then turn the ignition switch ON (II) without starting the engine. 3~

Continue to hold the TCS switch for 4 seconds, then turn the ignition switch OFF.

4. Within 6 seconds, turn the ignition switch back ON (II) for at least 4 seconds, then release the TCS switch, and watch the TCS indicator. 5. After a few seconds, the TCS indicator will come on after blinking to indicate that the DTC is cleared. If the indicator blinks repeatedly, repeat steps 1 through 4. 6. Turn the ignition switch OFF. 2. Turn the ignition switch ON (II), and clear the DTC (s) by following the screen prompts on the PGM Tester.

Standard Indication Pattern ON-----r---,

Continues ON

TCS Indicator NOTE: See the Honda PGM Tester user's manual for specific instructions.

OFF----- -----------Ignition Switch ON (II) a a Abnormal Indication Pattern ON-----r--....,

blinks repeatedly

TCS Indicator

OFF----- -----------a

a

a: 0.3 sec.

Ignition Switch ON (II)

BACK

19-29

ABS/TCS Components DTC Troubleshooting Index ABSDTCs DTC 11 12 13 14 15 16 17 18 21 22 23 24 31 32 33 34 35 36 37 38 41 42 43 44 51 52 53 54 61 62 71 81

Detection Item Right-front wheel sensor (open/short to body ground/short to power) Right-front wheel sensor (electrical noise/intermittent interruption) Left-front wheel sensor (open/short to body ground/short to power) Left-front wheel sensor (electrical noise/intermittent interruption) Right-rear wheel sensor (open/short to body ground/short to power) Right-rear wheel sensor (electrical noise/intermittent interruption) Left-rear wheel sensor (open/short to body ground/short to power) Left-rear wheel sensor (electrical noise/intermittent interruption) Right-front pulser Left-front pulser Right-rear pulser Left-rear pulser Right-front inlet solenoid Right-front outlet solenoid Left-front inlet solenoid Left-front outlet solenoid Right-rear inlet solenoid Right-rear outlet solenoid Left-rear inlet solenoid Left-rear outlet solenoid Right-front wheel lock Left-front wheel lock Right-rear wheel lock Left-rear wheel lock Motor lock Motor stuck OFF Motor stuck ON ABS Fail-safe relay Low ignition voltage High ignition voltage Different diameter tire Central ProcessingUnit (CPU) diagnosis, and ROM/RAM diagnosis

Note (see page 19-48) (see page 19-49) (see page 19-48) (see page 19-49) (see page 19-48) (see page 19-49) (see page 19-48) (see page 19-49) (see page 19-50) (see page 19-50) (see page 19-50) (see page 19-50) (see page 19-51) (see page 19-51) (see page 19-51) (see page 19-51) (see page 19-51) (see page 19-51) (see page 19-51) (see page 19-51) (see Rage 19-54) (see page 19-54) (see page 19-54) (see page 19-54) (see page 19-55) (see page 19-55) (see page 19-57) (see page 19-59) (see page 19-61) (see page 19-61) (see page 19-62) (see page 19-62)

TCS DTCs DTC 24 25 26 27 28 31 32 34 36 61 81

Detection Item RF TCS NO solenoid RF TCS NC solenoid LF TCS NO solenoid LF TCS NC solenoid TCS relay Engine retard command (PFINH) signal Engine speed (NEP) signal Reference voltage (VREF) signal Throttle position sensor output (THLOUT) signal AfT shift position (ATSFTP) signal Continuous TCS operation

Note (see page 19-63) (see page 19-63) (see page 19-63) (see page 19-63) (see page 19-66) (see page 19-69) (see page 19-71) (see page 19-72) (see page 19-73) (see page 19-74) (see page 19-75)

19-30

BACK

~ ~ Symptom Troubleshooting Index Symptom

ABS indicator does not come on ABS indicator does not go off and no DTC is stored ABS indicator came on once, but it is OK now TCS indicator does not come on TCS indicator does not go off and no DTC is stored TCS indicator came on once, but it is OK now


Also check for

ABS indicator Circuit Troubleshooting (see page 19-76) ABS Indicator Circuit Troubleshooting (see page 19-76) The vehicle is OK at this time (see page 19-25) ABS indicator Circuit Troubleshooting (see page 19-78) ABS Indicator Circuit Troubleshooting (see page 19-78) The vehicle is OK at this time (see page 19-25)

BACK

19-31

ABS/TCS Components System Description ABS/TCS Control Unit Inputs and Outputs for Connector A (26P) ABS/TCS CONTROL UNIT CONNECTOR A (26P)

I><

11 12 1 2 4 6 3 F~W FF.r Fh} FRW GN01 NCL NOL ABS SCS (+1 STOP H 15 16 18 20 R~W 25 R~tv rCS1 NCR NOR MCK (+) RI} (-I FSR

V

/

L

/

V

;~

13 IG2 26 OLC


Terminal sign (Terminal namel

Terminal number

Wire color

1

BlK

2

VEL/GRN

3

GRV

4

BLU/WHT

ABS

6

BRN

SCS (Service check signal)

8

BRN

9

GRN/BlU

10

GRN

11

GRN/BlK

12

WHT/BlK

FlW(-) (Front-left wheel neaative) FlW(+) (Front-left wheel positive) FRW( ) (Front-right wheel negative) FRW(+) (Front-right wheel positive) STOP

13

VEL/BlK

GND1 (Ground 11 NCl (Normally closed leftl NOl (Normally open left)

IG2 (Ignition 2)

Description Terminal Ground

1-GND

Drives left TCS normally closed solenoid valve Drives left TCS normally open solenoid valve

2-GND

Drives ABS indicator (Turns the indicator drive transistor to ON, then turns off the indicatorl Detects service check connector signal (Use for DTC indication) Detects left-front wheel sensor signal

Detects right-front wheel sensor signal

Measurement Conditions IIgnition switch ON 11111

--

TCS Indicator

3-GNO

4-GND

ABS indicator

6-GNO

SCS Circuit

8-9

Wheel

BelowO.3V OFF

ON (Disconnect 16P connector to turn indicator on) ON OFF

Shorted Opened Turn wheel at 1 turn/second

10-11

4 6V Below 1.0V

Below 0.3 V About5V AC: 0.053 Vor above (Reference) Oscilloscope: 0.15 Vp-p or above

0.25V1.15 V Battery Voltage Below 0.3 V Battery Voltage BelowO.3V

Detects brake switch signal

12-GND

Brake pedal

Pressed

Power source for activating the system

13-GND

Ignition switch

Released ON (II)

BACK

Battery Voltage BelowO.3V

Stopped

Start (1111

19-32

Voltage

~ EBI Terminal sign !Terminal name)

Description Drives right TCS normally closed solenoid valve Drives right TCS normally open solenoid valve

15-GND

LTBLU

NCR (Normally closed right) NOR (Normally opened right)

18

RED/WHT

TCS1

18-GND

TCS indicator

20

GRN

MCK (Motor check)

Drives TCS indicator (Turns the indicator drive transistor to ON, then turns off the indicator) Detects pump motor drive signal

20-GND

Pump motor

Terminal number

Wire color

15

RED/GRN

16

21

LTBLU

22

GRY

23

GRN/YEL

24

BLU/YEL

25

YEL/GRN

26

LTBLU

RLW(+) (Rear-left wheel positive) RLW(-) (Rear-left wheel positive) RRW(+) (Rear-right wheel oositive) RRW(-) (Rear-right wheel neaative) FSR (Fail-safe relay)

DLC (Data link connector)

Terminal

16-GND

Detects left-rear wheel sensor signal

21-22

Detects right-rear wheel sensor signal

23-24

Drives ABS fail-safe relay (ABS fail-safe relay is turned OFF to shut off the power source to the solenoid and pump motor relay when a oroblem occurs.l Communicates with the Honda PGM Tester

Measurement Conditions (Ignition switch ON (II)) TCS indicator OFF

25-GND

--

ON (Disconnect 16P connector to turn indicator on) With engine running, and indicator OFF ON ON

OFF Remove MCK fuse Wheel Turn wheel at 1 turn/second

ABS (SCS circuit must be open)

Voltage Battery Voltage BelowO.3V

Battery Voltage About2V Battery Voltage Below 0.3 V About10V AC: 0.053Vor above (Reference) Oscilloscope: 0.15 Vp-p or above

Stopped

0.25V1.15 V

Warnina Normal

BelowO.3V About 11V

--

--

(cont'd)

BACK

19-33

ABS/TCS Components System Description (cont'd) ABS/TCS Control Unit Inputs and Outputs for Connector B (16P) ABS/TCS CONTROL UNIT CONNECTOR B (16P)


Terminal sign (Terminal name)

Terminal number

Wire color

1

PNK

2

ORN/GRN

4

ORN/WHT

TCSSW (TCS switch)

7

LTGRN

9

VEl/GRN

10

BLU

ATSFTP LAT shift ~osition) THLOUT (Th rottle out) PFINH (powertrain to frame inhibition)

FPTDR (Frame to powertrain torque down request) VREF (Voltage reference)

NEP (Engine speed pulse) TCSR (TCS relay)

Description Terminal Outputs engine retard request signal

1-GND

Reference voltage for the sensors of the PGM-FI svstem Detects TCS switch signal

2-GND

Detects AfT shift position signal Detects throttle position sensor sianal Detects TCS operation permission signal

7-GND

Ooeratina

4-GND

--

10-GND

TCS switch pressed OFF (TCS indicator isON) Shift the transmission to 1:eJ. then start the enaine. Fullvclosed Throttle I Fullvopened valve Permission (normal)

Detects engine speed signal Drives TCS relay (TCS relay is turned OFF to shut off the power source to the TCS solenoid and pump motor relay when a problem occurs) Detects parking brake switch signal

11-GND

Inhibition (the coolant temperature is O°C or below) Failure (TCS and/or PCM has failed) Engine idling

9-GND

11

BLU

13

GRN/YEL

14

GRN/RED

PARK (Parking)

15

VEl/RED

PMR (Pump motor relay)

Drives pump motor relay

15-GND

16

RED/WHT

TCS2

Drives TCS indicator (Turns the indicator drive transistor to ON. then turns off the indicatorl

16-GND

19-34

Measurement Conditions (Ignition switch ON (II)) Not operating TCS

TCS switch

Voltage About 2.5 V (5 V du!,/5QL About5V About5V

Battery Voltaae OV About 4 V AboutO.5V About4.8V About2.5V (5V dutv50) About 5 V AboutOV About6V

13-GND

TCS(SCS circuit must be opened)

Warnina Normal

Below 0.3 V About 11 V

14-GND

With engine running. parking brake ABS indicator

Pulled Released

BelowO.3V Battery Voltage

BACK

TCS indicator

OFF

I

Pump motor ON OFF ON

II

ON OFF

Below 1.0V Battery Voltaae Below 0.3 V Battery Voltaae About2V

~ ~ ABS/TCS Control Unit Inputs and Outputs for Connector C (12P) ABS/TCS CONTROL UNIT CONNECTOR C (12P)

4

oFb-T 9

7 GND3

FLIN

10

~-

5

6

RL- FROUT OUT 11 12 ~~- GND2


Terminal number

Wire color

2

BRN/BlK

3

VELlWHT

4

VEL/BlU

5

VEL/GRN

6

VEL/BlK

7

BlK

8

RED/WHT

9

RED/BLU

10

RED/GRN

11

RED/BlK

12

BlK

Terminal sign (Terminal name) lG (logic ground) RR-OUT (Rear-riaht outlet) Fl-OUT (Front-left outlet) Rl-OUT (Rear-left outlet) FR-OUT (Front-right outlet) GND3 (Ground 3) RR-IN (Rear-riaht inlet) FL-IN (Front-left inlet) Rl-IN (Rear-left inlet) FR-IN (Front-right inlet) GND2 (Ground 2)

Description Terminal

Measurement Conditions (Ignition switch ON (1111

Voltage

Ground for logic circuit

2-GND

--

BelowO.3V

Drives right-rear outlet solenoid valve Drives left-front outlet solenoid valve Drives left-rear outlet solenoid valve Drives right-front outlet solenoid valve

3-GND

Ground

7-GND

Drives right-rear inlet solenoid valve Drives left-front inlet solenoid valve Drives left-rear inlet solenoid valve Drives right-front inlet solenoid valve

8-GND

Ground

ABS indicator

OFF

Battery Voltage

ON (Disconnect 16P connector to turn indicator on)

BelowO.3V

4-GND 5-GND 6-GND

-ABS indicator

BelowO.3V OFF

Battery Voltage

ON (Disconnect 16P connector to turn indicator on)

BelowO.3V

9-GND 10-GND 11-GND

12-GND

--

BelowO.3V

(cont'd)

BACK

19-35

ABS/lCS Components System Description (cont'd) Outline This system consists of the ABS/TCS control unit, the modulator unit, four wheel sensors, and the PCM. The system integrates the ABS (Antilock Brake System) and the TCS (Traction Control System) and controls both systems using the brakes.

rl

I

ABS/TCS

ABS control

~ LJ

~ TCS control

.Improves maneuverability and stability when braking. ~

r--

·Improves accelerating ability from a standstill on slipperly road surfaces. .Improves traction when one drive wheel is on a slippery road surface.

MASTER CYLINDER

WHEEL SENSOR

.. _ .. -

RESERVOIR ·_··_··-IIiiODULATOR

RESERVOIR uillrr··-··_··

WHEEL SENSOR

NO: Normally Open NC: Normally Closed

19-36

BACK

~ ~ ABS Features When the brake pedal is pressed while driving, the wheels can lock before the vehicle comes to a stop. In such an event, the maneuverability of the vehicle is reduced ifthe front wheels are locked, and the stability of the vehicle is reduced if the rear wheels are locked, creating an extremely unstable condition. The ABS precisely controls the slip rate of the wheels to ensure maximum grip force from the tires, and it thereby ensures maneuverability and stability of the vehicle. The ABS calculates the slip rate of the wheels based on the vehicle speed and the wheel speed, then it controls the brake fluid pressure to reach the target slip rate.

Grip Force of Tire and Road Surface

COEFFICIENT OF FRICTION ROTATIONAL DIRECTION

RADIAL DIRECTION OF THE ROTATIONAL DIRECTION

SLIP RATE TCS Features The TCS provides low speed traction. When a drive wheel loses traction on a slipperly road surface and starts to spin, the ABS{TCS control unit sends a brake signal to the modulator unit, which applies brake pressure to slow the spinning wheel. At that time, the ABS{TCS control unit sends an engine retard signal to the PCM to prevent damage to the transmission.

__- -......~I

I I 1[',I[

[II',' ['['['

',I,'

[I,ll'

[1,1,'

SLIPPERY ROAD SURFACE

III [,I [1[',1

1

J

1',1

[I t I , ' [1 1 1 1 '

,1,1[1 ,III,'

,1'1',1

I 1',1,1,' [I

I

I

I

I

(cont'd)

BACK

19-37

ABS/TCS Components System Description (cont'd) ABS Main Control The ABS{fCS control unit detects the wheel speed based on the wheel sensor signal it received, then it calculates the vehicle speed based on the detected wheel speed. The control unit detects the vehicle speed during deceleration based on the rate of deceleration. The ABS{fCS control unit calculates the slip rate of each wheel, and it transmits the control signal to the modulator unit solenoid valve when the slip rate is high. The pressure reduction control has 3 modes: pressure intensifying, pressure retaining, and pressure reducing.

._ .. _ .. - .. _ .. - ._ .. _ .. - .. - .. - .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ABS/TCS .. _ .. _CONTROL .. _ .. - UNIT .. _!

i i i

~ ~

1-,-=,===_. .

rcs Main Control The ABS{fCS control unit controls the TCS based on signal inputs from the throttle position sensor, engine speed sensor, shift position sensor, and the wheel sensors. In addition, the ABS{fCS control unit sends an engine retard request signal to the PCM if necessary. The ABS{fCS control unit uses the modulator unit to control the TCS. The pressure intensifying control has three modes: pressure intensifying, pressure retaining, and pressure reducing.

Shift position signol-+------'

i i i i i

i.. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _

19-38

BACK

i i .-.. _ .. _ .. _ .. _ .. _ .. _ .. _ .. j

~ EJI ABS Self-Diagnosis • The ABS{fCS control unit is equipped with a main CPU and a sub CPU. Each CPU checks the other for problems. • The CPUs check the circuit of the system. • Self-diagnosis can be classified into 2 categories: -Initial diagnosis: Done right after the engine starts and until the ABS or TCS indicator goes off. - Regular diagnosis: Done right after the initial diagnosis until the ignition switch is turned OFF. • When a problem is detected by self-diagnosis, the ABS{fCS control unit shifts to fail-safe mode. " Tabl e ABSS eltd· - lagnosls Detection Timing

Detection Item

Diagnostic Trouble Code (DTC) 11,13,15,17

Wheel sensor (open/short to body ground/short to power)

12, 14, 16, 18

Wheel sensor (electrical noise/intermittent interruption)

21-24

Pulser

31-38

Solenoid (short to body ground/short to wire)

41-44

Wheel lock

51

Motor lock

52

Motor stuck OFF

53

Motor stuck ON

54

Fail-safe relay

61

Low ignition voltage

62

High ignition voltage

71

Different diameter tire

81

Central Processing Unit (CPU), ROM/RAM

Initial

Regular

Diagnosis

Diagnosis

0

0 0 0 0 0 0 0 0 0 0 0 0

0

0 0

0

Fail-safe Mode

AO AO,LO AO, LO S1 AO, LO AO, LO AO,LO AO,LO S1 BO BO S1

0

S1

o e abl e ABSO,perat"Ion MdT ABS Indicator

TCS Indicator

Regular operation


Description

OFF

OFF

Fail-safe mode-S1

The ABS/TCS control unit turns the system off (ABS fail-safe relay off) when the

ON

ON

ON

ON

ON

ON

ON

ON

Operation Mode

control unit detects a problem. Fail-safe mode-AO

If the ABS/TCS control unit detects a malfunction while the ABS or TCS is operating, it will turn off the malfunctioning component, and continue to modulate the rest of the ABS system until completing the ABS or TCS operation. At that time, the entire system will be turned off until the problem goes away.

Fail-safe mode-LO

The ABS/TCS control unit stores a DTC in back-up memory when it detects a problem. If a problem is detected when the ignition switch is turned ON (II), the ABS/TCS control unit will turn the system off. If the problem goes away, the ABS/TCS control unit will turn the system on again.

Fail-safe mode-BO

The ABS/TCS control unit will turn the system off if ignition voltage drops, and will turn it on again when ignition voltage returns to normal.

On-board Diagnosis Function The ABS can be diagnosed with the Honda PGM Tester. The ALB Checker cannot be used with this system. For air bleeding, and checking wheel sensor signals, use the Honda PGM Tester. See the Honda PGM Tester user's manuals for specific operating instructions.

(cont'd)

BACK

19-39

ABS/TCS Components System Description (cont'd)

Tes Self-diagnosis • The ABSrrCS control unit is equipped with a main CPU and a sub CPU. Each CPU checks the other for problems. • The CPUs check the circuit of the system. • Self-diagnosis can be classified into 2 categories: -Initial diagnosis: Done right after the engine starts and until the ABS or TCS indicator goes off. - Regular diagnosis: Done right after the initial diagnosis until the ignition switch is turned OFF. • When a problem is detected by self-diagnosis, the ABSrrCS control unit shifts to fail-safe mode.

- Ta bl e TCSS e ltd - iagnosls Diagnostic Trouble

Detection Item

Detection Timing

Code (DTC) 24-27

TCS solonoid (short to body ground/short to wire)

28

TCSrelay

31

Engine retard command (PFINH) signal (open/short to body

Fail-safe Mode

Initial

Regular

Diagnosis

Diagnosis

0 0

0

S1 S1

0

A2

0 0 0

A2

0 0

A2

ground) 32

Engine speed(NEP)signal (open/short to body ground)

34

Reference voltage(VREF) signal(open/short to body ground)

36

Throttle position sensor output(THLOUT)signal(open/short to

0 0

A2 A2

body ground) 61

AfT shift position(ATSFTP) signal (open/short to body ground)

81

Continuous TCS operation

A2

o e a bl e TCSOJperatlon MdT ABS Indicator

TCS Indicator

Regular operation


Description

OFF

OFF

Fail-safe mode-S1

The ABS/TCS control unit turns the system off (fail-safe relay off) when the

ON

ON

OFF

ON

Operation Mode

control unit detects a problem. Fail-safe mode-A2

Ifthe ABS/TCS control unit detects a malfuction while the TCS is operating. it will turn off the malfunctioning component, and continue to modulate the rest of the TCS system until completing the TCS operation. At that time. the TCS system will be turned off.

OFF

Comes ON when

TCS deactivate

If the front brake pad temperature rise excessively, the ABS/TCS control unit

mode

stops the TCS system and it turns the TCS indicator on. When the brake pad

the front brake pad

temperature lowers, the ABS/TCS control unit turns off the TCS indicator and

temperature rises excessively.

restarts the TCS system. TCS OFF mode

The ABS/TCS control unit cancels the TCS system under these conditions: • If the ABS/TCS control unit detects a problem with the PGM-FI

ON or OFF

ON

(ON: When the

communication circuit.

ABS system is

• The ABS system is faulty.

faulty)

• The TCS system is OFF. If these conditions return to normal, the ABS/TCS control unit restarts the TCS system. On-board Diagnosis Function

The TCS can be diagnosed with the Honda PGM Tester. The ALB Checker cannot be used with this system. For air bleeding, and checking wheel sensor signals, use the Honda PGM Tester. See the Honda Tester user's manuals for specific operating instructions.

19-40

BACK

~ ~ Modulator Unit The modulator unit consists of the inlet solenoid valve, outlet solenoid valve, TCS normally open (NO) solenoid valve, TCS normally closed (NC) solenoid valve, reservoir, pump, pump motor, and the damping chamber. The modulator controls the caliper fluid pressure directly. It is a circulating-type modulator because the brake fluid circulates through the caliper, the reservoir, and the master cylinder. The hydraulic control has three modes: pressure intensifying, pressure retaining, and pressure reducing. The hydraulic circuit is an independent four channel type, one channel for each wheel.

.'

ABSControl Pressure intensifying mode TCS NO valve open, TCS NC valve closed, inlet valve open, outlet valve closed. Master cylinder fluid is pumped out to the caliper.

Pump Motor When starting the pressure reducing mode, the pump motor is ON. When stopping ABS operation, the pump motor is OFF. The reservoir fluid is pumped out by the pump, through the damping chamber, to the master cylinder. MASTER CVUNDER

MODULATOR UNIT

r'-"-"-"-"-"-"-"-"-"-"-"-"-"-'

!

RL

FR

R.

RR

Pressure retaining mode TCS NO valve open, TCS NC valve closed, inlet valve closed, outlet valve closed. Caliper fluid is retained by the inlet valve and outlet valve. MASTER CYUNDER

MODULATOR UNIT

r"-"-"-"-"-"-"-"-"-"-"-"-"-"-'

RL

FR

FL

RR

(cont'd)

BACK

19-41

ABS/TCS Components System Description (cont'd) Pressure reducing mode TCS NO valve open, TCS NC valve closed, inlet valve closed, outlet valve open. Caliper fluid flows through the outlet valve to the reservoir. MASTER CYUNDER

,_______ .. .. ..

..

MODULATOR UNIT

..

..

..

_ _ _.. _.._.. _.. _.

.. ..

..

i i i ! ! ! ii RL

FR

FL

RR

TCSControl Pressure intensifying mode TCS NO valve closed, TCS NC valve open, inlet valve open, outlet valve closed, pump motor ON. The reservoir and master cylinder fluid is pumped out by the pump, through the damping chamber, to the front caliper.

,________ ____ ..

..

..

..

MODULATOR UNIT

..

..

..

..

..

_

..

..

..

..

..

MASTER CVUNDER

_.

i

! ! ! ! i ii

RL

19-42

FL

FA

BACK

RR

~

~

Pressure retaining mode

rcs NO valve open, rcs NC valve open, inlet valve closed, outlet valve closed, pump motor ON. Front caliper fluid is retained by the inlet valve and outlet valve. MASTER CVUNDER

, . _00_ . _00_00_00_00_00_00_ . _00_00_00_00_. MODULATOR UNIT

i i i i

i i ii RL

RR

FA

Pressure reducing mode

rcs NO valve closed, rcs NC valve open, front inlet valve closed, front outlet valve open, pump motor ON. Caliper fluid flows through the outlet valve to the reservoir. MASTER CYUNDER

(cont'd)

BACK

19-43

ABS/TCS Components System Description (cont'd) Wheel Sensor The wheel sensors are the magnetic contactless type. As the gear pulser teeth rotate past the wheel sensor's magnetic coil, AC current is generated. The AC frequency changes in accordance with the wheel speed. The ABS{TCS control unit detects the wheel sensor signal frequency and thereby detects the wheel speed. GEARPULSER

at HIGH SPEED

oa

at LOW SPEED

Wheel Speed and Modulator Control (ABS)

SPEED

VEHICLE SPEED

WHEEL SPEED

TIME

AA=

C0

When the wheel speed drops sharply below the vehicle speed, the outlet valve opens momentarily to reduce the caliper fluid pressure. The pump motor starts at this time. As the wheel speed is restored, the inlet valve opens momentarily to increase the caliper fluid pressure.

19-44

BACK

~ ~ Wheel Speed and Modulator control (TCS)

DRIVE WHEEL SPEED

I

SPEED

I DRIVEN WHEEL SPEED (VEHICLE SPEED)

-TIME

BRAKE

PRESSURE

OUTLET VALVE INLET VALVE TCSNCVALVE

r

TCS NO VALVE MOTOR

ON OFF ON OFF ON OFF ON OFF ON OFF

When the front wheel speed rises sharply above the vehicle speed, the TCS NC valve opens, the TCS NO valve closes, and the pump motor starts to intensify the front caliper fluid pressure. When the wheel speed drops, the front inlet valve closes momentarity to retain the front caliper fluid pressure. When the wheel speed drops further, the front outlet valve opens momentarity to reduce the front caliper fluid pressure.

BACK

19-45

ABS/lCS Components Circuit Diagram

+ +B


STOP (20A)


Closed: Brake pedal pressed

~--~~~~~~--¢-W~/~L~~3--------------------------~~~~~~----------------___W~/BLK

~

BATTERY I.UDAI

1-'V~~r-(i;:W---GRN/RED --~-------------

IGNITION SWITCH

~LK/~L L--~O-~-¢o-W~~~L---<:>-----o,,-o--IM1iM IG. MAIN I60AJ

BRAKE FLUID LEVEL SWITCH Closed: Low fluid

..ABS-6"F/~S~12OA.;...;.I________-
____________


WHT/BLU

UNDER-HOOD ABS RELAY BOX

ABS FAIL·SAFE RELAY

~ALTERNATOR

.),rt'1:....,-+t----o(§e>--BLU/W~

I

~

-----------------

L...-~"*---
I

.x.

L...--~kv+-----
YEL/ BLK

______....,BRN/BLK

YELl

BLK/

~_I_L

..!:====!..._____________ORN/~_----------

L ________ ________________________________

GRlN___

~L/BLK

~L/GRN - - - - - - - - - - L..-t--------------------------------------------------YEURED - - - - - - - - - - ~--_i--------------------------------------------------~RN/~L-----------

BRN/BLK

Rr.

GR FL-IN

~

RED/BLU

FL-OUT

YEL/BLU

FR~N

RED/BLK

19 FR'()UT

~L/BLK

RL~N

RED/GRN

RL-OUT

~L/GRN

13 RR·IN

RED/WHT

RR-OUT

~L/W~

GRY NCL

~LlGRN

NOR

LTBLU

NCR

RED/GRN

PUMP MOTOR

M

~/BLU

BLK----:l... G203

UNDER-HOOD FUSE/RELAY BOX CONNECTORS CONNECTOR A (1BP) CONNECTOR B (7P)

WitiILJ,,11l3kt/lk'17rn U, m ,3

DRIVER'S UNDER-DASH FUSE/RELAY BOX CONNECTORS CONNECTOR J (1BP) CONNECTOR M (20P)

71

PASSENGER'S UNDER-DASH FUSE/RELAY BOX CONNECTORS CONNECTOR 1116P) CONNECTOR B (1BP)

BRAKE SWITCH CONNECTOR

CRUISE CONTROL/ TCS SWITCH BP CONNECTORS

rID) GAUGE ASSEMBLY CONNECTORS

19-46

FAIL SAFE RELAY/ TCS RELAY 4PCONNECTOR

m

BACK

ffimrJID

ABS PUMP MOTOR RELAY 5P CONNECTOR

~

~ ~

PCM(SCS)

?

WHT/BLK ---~""'---WHT/BLK ---<~:HH BRAKE

_ i

LIGHT

~V-lC~C_QA2~6ID _L_C -L'~

-------..;;;-.--"
+8

DATA LINK

p'~I'~ yJ

11 HT/GRN

:

__

0401

G101

C!!J)----BLU---~W-"":~

C!!)---VEL/GRN ---<~~
RED/WHT ---"Lr--REDIWHT RED/WHT

---Q!l§)....

-------------------------ORN/WHT---QH)-~

H~---oQ!!V'----oRN/GRN

---Cau"

-----------------YEUBLK--~~~--~-.,,---, .....OO)----PN~---~W_{. - - - - - - - - - - - - - - - - - - y E L / G R N ---Q~--~--. ------------------YEL/RED

---
- - - - - - - - - - - - - - - - - - - G R N / y E L -=~iW...

.J--~:!!!!>_---sLul---~D ~-~~~--""TGRN---~»

BRN/BLK

:1.. WHEEL SENSOR

R N /Gl01 B L U~ l C!lD------BRNI----- 2 RN/BLK

-

~~NT

~ RIGHT.

C!1~.....;...;..-GRNI-----~ FRONT LTBlU

~

@@-----GRY'-------~ ~~R ~

GRN/YEL RIGHT. @!9----BLU/VEL _ _ _ _ _ ~ REAR

ABS/TCS CONTROL UNIT CONNECTORS CONNECTOR A (26P)

CONNECTOR B (16P)

CONNECTOR C (12P)

WHEEL SENSOR CONNECTOR FRONT/REAR

(ID) PCM CONNECTOR A (32P)


11 12 3 4 567 8 9 10 11 1 112113 14 1516 17 18 19 20 2122 23 24 1 25 26 27 28 29 30 31 ~

tdl2W!/\

BACK

19-47

ABS/TCS Components DTe Troubleshooting ABS DTC 11, 13, 15, 17: Wheel Sensor (Open/ Short to Body Ground/Short to Power)

4. Check for continuity between the appropriate wheel sensor (+) circuit terminal and body ground (see table).

1. Disconnect the ABS/TCS control unit connector A (26P).

DTC

2. Start the engine. 3. Measure the voltage between the appropriate wheel sensor (+) circuit terminal and body ground (see table). Ap~opriate

DTC 11 (Right-front) 13 (Left-front) 15 (Ri_ght-rear) 17 (Left-rear)


11 (Right-front) 13 (Left-front) 15 (Right-rear) 17 (Left-rear)

A 11: FRW(+) A9:FLW(+) A23: RRW(+) A21: RLW(+)

ABS/TCS CONTROL UNIT CONNECTOR A (26P)

Terminal

A 11: FRW(+) A9:FLW(+) A23: RRW(+) A21: RLW(+)

FLW(+)

FRW(+)

(GRN/BLU)

(GRN/BLK)


FLW(+)

FRW(+)

(GRN/BLU)

(GRN/BLK)


Is there continuity? YES-Go to step 5. NO-Goto step 6. Wire side of female terminals

Is there 2 V or more? YES-Repair short to power in the (+) circuit wire between the ABS/TCS control unit and the appropriate wheel sensor.• NO - Go to step 4.

5. Disconnect the harness 2P connector from the appropriate wheel sensor, then check for continuity between the (+) and (-) terminals of the harness and body ground.

Is there continuity? YES-Repair short to body ground inthe (+) or (-) circuit wire between the ABS/TCS control unit and the wheel sensor.• NO- Replace the wheel sensor.•

19-48

BACK

~ ~ 6. Check the resistance between the appropriate wheel sensor (+) and (-) circuit terminals (see table). DTe 11 (Right-front) 13 (Left-front) 15 (Right-rear) 17 (Left-rear)

Appropriate Terminal (-)Side (+) Side A11: FRW(+) A10:FRW(-) A8:FLW(-) A9:FLW(+) A23:RRW A24:RRW (-) (+) A21: RLW(+) A22:RLW(-)

ABS DTC 12, 14, 16, 18: Wheel Sensor (Electrical Noise/Intermittent Interruption) NOTE: If the ABS indicator comes on for the reasons described below,the indicator goes off when you testdrive the vehicle at 19 mph (30 km/h). • Only the drive wheel rotated • The vehicle spun • Electrical noise 1. Visually check for appropriate wheel sensor and pulser installation (see table).


DTe 12 14 16 18


Are they installed correctly? YES-Goto step 2. NO- Reinstall or replace the appropriate wheel sensor or pulser.•


Is the resistance between 450- 2,000 Q?


YES-Check for loose ABS/TCS control unit connectors.lf necessary, substitute a known-good ABS/TCS control unit, and recheck.•

3. Measure the resistance between the appropriate wheel sensor (+) and (-) circuit terminals (see table).

NO-Goto step 7. DTe 7. Disconnectthe harness 2P connectorfrom the appropriate wheel sensor, and check the resistance between the (+) and (-) terminals of the wheel sensor.

Is the resistance between 450- 2,000 Q ? YES-Repair open in the (+) or (-) circuit wire, or short beween the (+) circuit wire and the (-) circuit wire between the ABS/TCS control unit and the wheel sensor.• NO-Replace the wheel sensor.•

Appropriate Terminal (-) Side A11: FRW A10: FRW (+) Side

12 (Right-front)

(+)

(-)

14 (Left-front)

A9: FLW

A8: FLW

(+)

(-)

16 (Right-rear)

A23: RRW

A24: RRW

(+)

(-)

18 (Left-rear)

A21: RLW

A22:RLW

(+)

(-)

Is there less than 450 Q ? YES- Repair short to wire between the appropriate wheel sensor (+) and (-) circuits.• NO - Go to step 4.

(cont'd)

BACK

19-49

ABS/TCS Components DTe Troubleshooting (cont'd) 4. Check for continuity between the appropriate wheel sensor (+) circuit terminal and other wheel sensor (+) circuit terminals (see table). OTC

12

14

16

18

Appropriate Terminal A11 : FRW (+) A9: FLW(+)

Other Terminal

A9: FLW(+)

A23: RRW (+) A21: RLW(+)

A11 : FRW (+) A11 : FRW (+) A11 : FRW(+)

A23: RRW (+) A23: RRW (+) A9: FLW(+) A9: FLW (+)

A21 : RLW (+) A21: RLW (+) A21 : RLW (+) A23: RRW(+)

ABS OTe 21, 22, 23, 24: Pulser 1. Clear the OTC. 2. Test-drive the vehicle at 19 mph (30 km/h) or more. Does the ABS indicator come on and are DTCs 21, 22, 23, or 24 indicated? YES-Go to step 3. NO- The system is OK at this time .• 3. Check the appropriate pulser gear for a chipped tooth (see table).

Is there continuity? YES-Repair short to wire between the appropriate wheel sensor and the other wheel sensor.•

OTC

Appropriate Pulser

21 22 23 24

Right-front Left-front Right-rear Left-rear

Is the pulser OK? NO- Clear the OTC, and test-drive the vehicle. If the ABS indicator comes on and the same OTC is indicated, replace the ABS/TCS control unit .•

YES-Check for loose ABS/TCS control unit connectors. If necessary, substitute a known-good ABS/TCS control unit, and recheck .• NO- Replace the driveshaft or the hub unit. (Chipped pulser gear).

19-50

BACK

~ ~ ABS DTC 31, 32, 33, 34, 35, 36, 37, 38: Solenoid

5. Connect the modulator unit 24P connector. 6. Check for continuity between the appropriate ABS/ TCS control unit connector C (12P) solenoid circuit terminal and body ground (see table).

1. Verify the DTC.

Is DTC 54 indicated? YES - Do the appropriate troubleshooting for DTC 54 .• NO-Go to step 2. 2. Turn the ignition switch OFF. 3. Disconnect the modulator unit 24P connector and the ABS/TCS control unit connector C (12P). 4. Check for continuity between the appropriate ABS/ TCS control unit connector C (12P) solenoid circuit terminal and body ground (see table).

31: 32: 33: 34: 35: 36: 37: 38:

OTC FR-IN FR-OUT FL-IN FL-OUT RR-IN RR-OUT RL-IN RL-OUT

Appropriate Terminal C11 C6 C9 C4 C8 C3 C10 C5

31: 32: 33: 34: 35: 36: 37: 38:



ABS/TCS CONTROL UNIT CONNECTOR C (12P)


Is there continuity? YES- Replace the modulator unit.• NO-Go to step 7. 7. Disconnect the modulator unit 24P connector.


Is there continuity? YES- Repair short to body ground in the appropriate solenoid circuit wire between the ABS/TCS control unit and the modulator unit.• NO-Go to step 5.

(cont'd)

BACK

19-51

ABS/TCS Components DTC Troubleshooting (cont'd) 8. Connect the appropriate modulator unit 24P connector solenoid circuit terminal to body ground with a jumper wire (see table).

31: 32: 33: 34: 35: 36: 37: 38:


9. Check for continuity between the appropriate ABS/TCS control unit connector C (12P) solenoid circuit terminal and body ground (see table).

Appropriate Terminal No.11 No. 19 No. 14 No. 22 No. 13 No.21 No. 12 No. 20

31: 32: 33: 34: 35: 36: 37: 38:



MODULATOR UNIT 24P CONNECTOR



Is there continuity? YES-Go to step 10. NO- Repair open in the appropriate solenoid circuit wire between the ABS/TCS control unit and the modulator unit.• 10. Remove the jumper wire from the modulator unit 24P connector. 11. Connect the modulator unit 24P connector.

~

!

19-52

BACK

~ ~ 12. Connect the ABS fail-safe relay 4P connector terminal No.2 to body ground with a jumper wire. NOTE: The wire colors of the ABS fail-safe relay connector are WHT/GRN, BRN/BLK, BLK, and YELlGRN.

31: 32: 33: 34: 35: 36: 37: 38:

ABS FAil-SAFE RELAY 4P CONNECTOR

SOlEN[&ID (BRN/BlK) ; JUMPER WIRE

3

15. Check for continuity between the appropriate ABS/TCS control unit connector C (12P) terminal and all other ABS and TCS solenoid circuit terminals (see table).

4


OTe FR-IN FR-OUT FL-IN FL-OUT RR-IN RR-OUT RL-IN RL-OUT

Tes Solenoid Wire side of female terminals

13. Check the resistance between the appropriate ABS/ TCS control unit connector C (12P) terminal and body ground (see table). IN: 8-10 Q (at 20°C, 68°F) OUT: 3-5 Q (at 20°C, 68°F)

31: 32: 33: 34: 35: 36: 37: 38:

OTe FR-IN FR-OUT FL-IN FL-OUT RR-IN RR-OUT RL-IN RL-OUT

NOR NCR NOL NCL

ABS/TCS Control Unit Connector A (26P) Terminal A16 A15 A3 A2


Appropriate Terminal C11 C6 C9 C4 C8 C3 C10 C5 Wire side of female terminals

ABS/TCS CONTROL UNIT CONNECTOR c (12P)


RED/GRN


lTBLU


Is the resistance OK? YES-Gotostep 14.


NO- Replace the modulator unit.•

VES- Repair short in the appropriate wires between the ABS/TCS control unit and the modulator unit.•

14. Disconnect the modulator unit 24P connector, and remove the jumper wire from the ABS fail-safe relay 4P connector.

NO-Go to step 16. (cont'd)

BACK

19-53

ABS/TCS Components OTC Troubleshooting (cont'd) 16. Connect the modulator unit 24P connector. 17. Check for continuity between the appropriate ABSrrCS control unit connector C (12P) terminal and all other ABS and TCS solenoid circuit terminals (see table).

ABS DTC 41, 42, 43, 44: Wheel Lock 1. Check for brake drag.

Do the brakes drag? YES-Repair the brake drag .•

31: 32: 33: 34: 35: 36: 37: 38:


DTC FR-IN FR-OUT FL-IN FL-OUT RR-IN RR-OUT RL-IN RL-OUT

TCS Solenoid NOR NCR NOL NCL

ASS/TCS Control Unit Connector A (26P) Terminal A16 A15 A3 A2

NO - Go to step 2. 2. Check the installation of the appropriate wheel sensor (see table). DTC 41 42 43 44


Is it correct? YES-Go to step 3.• NO- Reinstall the wheel sensor correctly.•


3. Check the modulator using the Honda PGM Tester.

Is kick-back felt in the pedal? YES - The probable cause was the vehicle spun during cornering. If the problem recurs, check for loose connectors, or try a known-good ABSrrCS control unit.• Wire side of female terminals

NO-Check for loose modulator unit connectors. If necessary, replace the modulator unit..


RED/GRN

LTBLU


Is there less than 3 Q ? YES-Replace the modulator unit.. NO-Check for loose ABSrrCS control unit connectors. If necessary, substitute a known-good ABSrrCS control unit, and recheck.•

19-54

BACK

~

~

ABS OTC 51: Motor Lock

ABS OTC 52: Motor Stuck OFF

1. Clear the DTC. 2. Test-drive the vehicle at 6 mph (10 km/h) or more.

Does the ABS indicator come on and is DTe 51 indicated?

1. Check the ASS MOTOR (30 A) fuse in the under-hood fuse/relay box, and reinstall the fuse if it is OK.

Is the fuse OK? YES- Go to step 3.

YES- Replace the modulator unit.. NO- Replace the fuse, and go to step 2. NO- The system is OK at this time .• 2. Remove the pump motor relay, and connect the pump motor relay 5P connector terminal No.4 to No.5 with a jumper wire for a moment, and check the fuse.

PUMP MOTOR RELAY 5P CONNECTOR

{1 4

MOTOR (WHT/BLU)

3 5

+B (WHT}


Is the fuse blown? YES-Check for a short to body ground in the motor power source circuit.• NO - Go to step 3. 3. Check the ASS MTR CK (7.5 A) fuse in the passenger's under-dash fuse/relay box, and reinstall the fuse if it is OK.

Is the fuse OK? YES-Go to step 5. NO- Replace the fuse, and go to step 4.

(cont'd}

BACK

19-55

ABS/TCS Components OTe Troubleshooting (cont'd) 4. Connect the pump motor relay 5P connector terminal No.4 to No.5 with a jumper wire for a moment, and check the fuse.

9. Measure the voltage between the modulator unit 24P connector terminal No.1 and body ground. MODULATOR UNIT 24P CONNECTOR MOTOR (WHT/BLU)

PUMP MOTOR RELAY 5P CONNECTOR

MOTOR (WHT/BLU)

+B(WHT)



Is there battery voltage? YES-Go to step 10. NO-Repair open in the wire between the underhood ABS relay box and the pump motor..

Is the fuse blown? YES-Check for a short to body ground in the GRN wire between the passenger's under-dash fuse/ relay box and the ABS/TCS control unit .•

10. Measure the voltage between the modulator unit 24P connectorterminal No.1 and No. 16. MODULATOR UNIT 24P CONNECTOR MOTOR (WHT/BLU)

NO-Go to step 5. 5. Check the pump motor relay in the under-hood ABS relay box. Refer to the '98- 02 Accord Service Manual (P/N 61S8400) (see page 22-52).

MOTOR GND (BlK) Wire side of female terminals

Is the relay OK? Is there battery voltage? YES-Go to step 6. NO - Replace the pump motor relay .• 6. Connect the pump motor relay 5P connector terminal No.4 to No.5 with a jumper wire for a moment.


YES- Replace the modulator unit.• NO- Repair open in the wire between the pump motor and body ground (G203) .• 11. Disconnect the ABS/TCS control unit connector B (16P). 12. Connect the pump motor relay 5P connector terminal No.1 to No.5 with a jumper wire.

YES-Gotostep 11. PUMP MOTOR RELA V 5P CONNECTOR

NO-Go to step 7.

~ JUMPER WIRE

7. Disconnect the modulator unit 24P connector.

PMP (VEL/RED)

8. Connect the pump motor relay 5P connector terminal No.4 to No.5 with a jumper wire.

1

3

4

5

+B(WHT)


19-56

BACK

~ ~

13. Measure the voltage between the ABS(TCS control unit connector B (16P) terminal B15 and body ground.

ABS DTC 53: Motor Stuck ON 1. Check that the pump motor operates with the ignition switch OFF.


ABS/TCS CONTROL UNIT CONNECTOR B (16PI

YES-Replace the pump motor relay. (pump motor relay stuck ON.). NO- Go to step 2. 2. Remove the ABS MTR CK (7.5 A) fuse in the passenger's under-dash fuse/relay box.


Is the fuse OK? Is there battery voltage? YES- Leave the fuse removed, and go to step 3. YES-Go to step 14. NO - Replace the fuse, and recheck .• NO- Repair open in the wire between the underhood ABS relay box and the ABS(TCS control unit.

•

14. Remove the jumper wire from the pump motor relay 5P connector, and reinstall the pump motor relay. 15. Start the engine.

3. Turn the ignition switch ON (II) . 4. Measure the voltage between the passenger's under-dash fuse/relay box connector I (16P) terminal 15 and body ground.

PASSENGER'S UNDER·DASH FUSE/RELAY BOX CONNECTOR I (16P) MCK(GRN)

16. Measure the voltage between the ABS(TCS control unit connector B (16P) terminal B15 and body ground.

ABS/TCS CONTROL UNIT CONNECTOR B (16PI


Is there about 10 V? YES-Go to step 5. NO- Repair open in the wire between the passenger's under-dash fuse/relay box and the ABS(TCS control unit.•


Is there battery voltage? YES- Repair short to power in the wire between the under-hood ABS relay box and the ABS(TCS control unit.•

5. Reinstall the ABS MTR CK (7.5 A) fuse in the passenger's under-dash fuse/relay box.

NO -If the problem recurs, replace the ABS(TCS control unit.• (cont'd)

BACK

19-57

ABS/TCS Components DTe Troubleshooting (cont'd) 6. Disconnect the modulator unit 24P connector. 7. Measure the voltage between terminal No.1 and body ground.

9. Remove the pump motor relay, then connect relay terminals No.4 and No.5 together with a jumper wire.

Does the pump motor run? MODULATOR UNIT 24P CONNECTOR MOTOR (WHT /BLU)

YES-Go to step 10. NO- Replace the pump motor.• 10. Disconnect the ABS/TCS control unit connector B (16P). 11. Check for continuity between terminal B15 and body ground.


ABS/TCS CONTROL UNIT CONNECTOR B (16P)

Is there about 10 V? YES-Go to step 8.

PMR (VEL/RED)

NO-Repair open in the wire between the underhood ABS relay box and the pump motor.•

Q =

8. Measure the voltage between the modulator unit 24P connector terminal No.1 and No. 16.


MOTOR (WHT/BLU)


Is there continuity? YES- Repair short to body ground in the wire between the under-hood ABS relay box and the ABS/TCS control unit.• NO-If the problem recurs, replace the ABS/TCS control unit.•

MOTOR GND (BLK)


Is there about 10 V? YES-Go to step 9. NO-Repair open in the wire between the pump motor and body ground (G203) .•

19·58

BACK

~ ~ ABS DTC 54: ABS Fail-safe Relay

5. Connect the ASS fail-safe relay 4P connector terminal No.1 to No.2 with a jumper wire.

1. Check the ASS F/S (20 A) fuse in the under-hood fuse/relay box, and reinstall the fuse if it is OK.

ABS FAIL-SAFE RELAY 4P CONNECTOR

15 the fuse OK? +B (WHT IGRN) .

YES- Go to step 2.

~ SOLEN~~ (BRN/BLK)

JUMPER WIRE

NO- Replace the fuse, and recheck .• 2. Turn the ignition switch ON (II).

Does the fuse blow? Wire side of female terminals

YES- Repair short to body ground in the wire between the ASS fail-safe relay, the TCS relay, the pump motor relay, and modulator unit.• NO-Go to step 3.

6. Disconnect the modulator unit 24P connector. 7. Measure the voltage between terminal No.2 and body ground.

3. Check the ASS fail-safe relay in the under-hood ASS relay box. Refer to the '98 - 02 Accord Service Manual (P/N 61 S8400) (see page 22-52). The wire colors of the ASS fail-safe relay connector are WHT/GRN, SRN/SLK, SLK, and YEL/GRN.

MODULATOR UNIT 24P CONNECTOR SOLENOID (BRN/BLK)

15 the relay OK? YES - Leave the ASS fail-safe relay removed, and go to step 4. NO- Replace the ASS fail-safe relay .•

=

4. Measure the voltage between the ASS fail-safe relay 4P connector terminal No.1 and body ground.


15 there battery voltage?

ABS FAIL-SAFE RELAY 4P CONNECTOR

YES - Go to step 8.

+B (WHT/GRF-ffi NO- Repair open in the wire between the ASS fail-safe relay and the modulator unit.•

~@Q$W

8. Remove the jumper wire from the ASS fail-safe relay connector.


15 there battery voltage? YES-Go to step 5. NO- Repair open in the wire between the underhood fuse/relay box and the ASS fail-safe relay .•

BACK

(cont'd)

19-59

ABS/TCS Components OTe Troubleshooting (cont'd) 9. Measure the voltage between the modulator unit 24P connector terminal No.2 and body ground.


13. Check for continuity between the ABS/TCS control unit connector A (26P) terminal A25 and body ground.


SOLENOID (BRN/BLK)

8

9

10 11

12 13

21

22 23 24 25 26

FSR (YEL/GRN)

= Wire side of female terminals Wire side of female terminals

=

Is there battery voltage? Is there continuity?

YES- Repair short to power in the wire between the ABS fail-safe relay, the TCS relay, the modulator unit, and the under-hood ABS relay box .•

YES- Repair short to body ground in the wire between the ABS/TCS control unit and the ABS fail-safe relay .•

NO-Gotostep 10.

NO-Go to step 14.


14. Check for continuity between the ABS fail-safe relay 4P connector terminal No.3 and body ground.

11. Turn the ignition switch ON (II). ABS FAIL-SAFE RELAY 4P CONNECTOR

12. Measure the voltage between terminal A25 and body ground.


8

9

10 11

12 13

21

22 23 24 25 26


FSR (YEL/GRN)



=


YES - Go to step 15. NO- Repair open in the wire between the ABS fail-safe relay and body ground, or a loose or poor connection at body ground (G202) .•

YES- Repair short to power in the wire between the ABS/TCS control unit and the ABS fail-safe relay .• NO- Goto step 13.

19-60

BACK

~,

~ ~ ABS DTC 61, 62: Ignition Voltage

15. Connect the ABS fail-safe relay 4P connector terminals No.3 and No.4 with a jumper wire.

1. Clear the DTC. ABS FAIL-SAFE RELAV 4P CONNECTOR

2. Test-drive the vehicle at 6 mph (10 km/h) or more.

Does the ABS indicator come on? YES- Go to step 3. GND (BLK)

FSR (VEL/GRN)

NO-The system is OK at this time .• JUMPER WIRE

3. Verify the DTC.

Is DTe 61 or 62 indicated?


YES-Check the charging system .• 16. Check for continuity between the ABS(TCS control unit connector A (26P) terminal A25 and body ground.

NO- Do the appropriate troubleshooting for the DTC . •


8

9

10 11

21

22 23

12 13

24 25 26

FSR (VEL/GRN)


=

Is there continuity? YES-Ifthe problem recurs, replace the ABS(TCS control unit.• NO-Repair open in the wire between the ABS(TCS control unit and the ABS fail-safe relay .•

BACK

19-61

ABS/TCS Components DTC Troubleshooting (cont'd) ABS DTC 71: Different Diameter Tire

ABS DTC 81: Central Processing Unit (CPU) Diagnosis, and ROM/RAM Diagnosis

1. Clear the DTC. 1. Clear the DTC. 2. Test-drive the vehicle. 2. Test-drive the vehicle.

Does the ABS indicator come on and is DTC 71 indicated?

Does the ABS indicator come on and is DTC 81 indicated?

VES- Make sure all four tires are the specified size and are inflated to proper specification .•

VES- Replace the ABS/TCS control unit.•



19-62

BACK

~ ~ TCS DTC 24, 25, 26, 27: TCS Solenoid

6. Check for continuity between the appropriate ABS{TCS control unit connector A (26P) solenoid circuit terminal and body ground (see table).

1. Verify the TCS DTC. Is

rcs orc 28 indicated? 24: 25: 26: 27:

YES - Do the appropriate troubleshooting for DTC28 .•

TeSOTe NOR NCR NOL NCL

A~roJ!l'iate

Terminal A16 A15 A3 A2

NO-Go to step 2. ABS/TCS CONTROL UNIT CONNECTOR A (26PI


NOL(GRYI

3. Disconnect the modulator unit 24P connector and the ABS{TCS control unit connector A (26P). 4. Check for continuity between the appropriate ABS{TCS control unit connector A (26P) TCS solenoid circuit terminal and body ground (see table).

24: 25: 26: 27:



Apprcmriate Terminal A16 A15 A3 A2

Is there continuity? YES- Replace the modulator unit.• NO-Go to step 7.

ABS/TCS CONTROL UNIT CONNECTOR A (26P) NOL(GRY)

7. Disconnect the modulator unit 24P connector. 8. Connect the appropriate modulator unit 24P connector TCS solenoid circuit terminals to body ground with jumper wires (see table).

24: 25: 26: 27:


Appropriate Terminal No.5 No.6 No.8 No.7

Wire side of female terminals MODULATOR UNIT 24P CONNECTOR


NCR (RED/GRNI

NCL (YEL/GRNI

YES-Repair short to body ground in the appropriate solenoid circuit wire between the ABS{TCS control unit and the modulator unit.• NO-Go to step 5.

JUMPER WIRE

5. Connect the modulator unit 24P connector.


(cont'd)

BACK

19-63

ABS/TCS Components OTe Troubleshooting (cont'd) 9. Check for continuity between the appropriate ABS/ TCS control unit connector A (26P) solenoid circuit terminal and body ground (see table).

24: 25: 26: 27:

TCSDTC NOR NCR NOl NCl

Appropriate Terminal A16 A15 A3 A2

12. Remove the TCS relay, and connect the TCS relay 4P connector terminal No.2 to body ground with a jumper wire. NOTE: The wire colors of the TCS relay 4P connector are BlU, RED/BlU, BRN/BlK, and GRN/yEL. TCS RELAY 4P CONNECTOR

TCS SOLENOID (RED/BLU)

ABS/TCS CONTROL UNIT CONNECTOR A (26P) NOL(GRY)

JUMPER WIRE



Is there continuity? YES-Go to step 10. NO-Repair open in the appropriate TCS solenoid circuit wire between the ABS/TCS control unit and the modulator unit.. 10. Remove the jumper wires from the modulator unit 24P connector. 11. Connect the modulator unit 24P connector.

19-64

BACK

~ ~

13. Check the resistance between the appropriate ABS/TCS control unit connector A (26P) terminal and body ground (see table). NOR, NOL, NCR, NCL: 8-10 Q (at 20°C, 68°F)

24: 25: 26: 27:

TCSDTC NOR NCR NOL NCL

15. Check for continuity between the appropriate ABS/TCS control unit connector A (26P) terminal and each of the other terminals listed (see table). TCSDTC NOR NCR NOL NCL


ABS Solenoid

ABS/TCS Control Unit Connector C (12P) Terminal C11 C6 C9 C4 C8 C3 C10 C5

24: 25: 26: 27:


ASS/TCS CONTROL UNIT CONNECTOR A (26P)

FR-IN FR-OUT FL-IN FL-OUT RR-IN RR-OUT RL-IN RL-OUT

NOL(GRV}

ABS/TCS CONTROL UNIT CONNECTOR A 126P) GRV


Is there resistance OK? YES-Goto step 14. NO- Replace the modulator unit.•

RED/GRN

LT BLU


14. Disconnect the modulator unit connector, and remove the jumper wire from the TCS relay 4P connector terminal.



Is there continuity? YES- Repair short in the appropriate wires between the ABS/TCS control unit and the modulator unit.• NO-Go to step 16.

(cont'd)

BACK

19-65

ABS/lCS Components DTC Troubleshooting (cont'd) 16. Connect the modulator unit 24P connector. 17. Check for continuity between the appropriate ABS/ TCS control unit connector A (26P) terminal and all other ABS and TCS solenoid circuit terminals (see table). TCSOTC NOR NCR NOl NCl


ABS Solenoid

ABS/TCS Control Unit Connector C (12P) Terminal C11 C6 C9 C4 C8 C3 C10 C5

24: 25: 26: 27:

FR-IN FR-OUT Fl-IN Fl-OUT RR-IN RR-OUT Rl-IN Rl-OUT

ABS/TCS CONTROL UNIT CONNECTOR A (26PI YEL/GRN

lCS DlC 28: res Relay 1. Check the BSC F/S (20 A) fuse in the under-hood fuse/relay box, and reinstall the fuse if it is OK.

Is the fuse OK? YES - Go to step 2. NO - Replace the fuse, and recheck.• 2. Turn the ignition switch ON (II).

Does the fuse blow? YES- Repair short to body ground in the wire between the TCS relay and the modulator unit.• NO - Go to step 3. 3. Check the TCS relay in the under-hood ABS relay box (see page 22-31). The wire colors of the TCS relay 4P connector are BlU, RED/BlU, BRN/BlK, and GRN/YEL.

Is the relay OK? YES-leave the TCS relay removed, and go to step 4. NO-Replace the TCS relay .•

RED/GRN

LTBLU


4. Measure the voltage between the TCS relay 4P connector terminal No.1 and body ground. TCS RELAY 4P CONNECTOR

ABS/TCS CONTROL UNIT CONNECTOR C (12PI

+B1BFm ~WlliJ Wire side of female terminals


Is there less than 3&2 ? YES - Replace the modulator unit.•


NO-Check for loose ABS/TCS control unit connectors. If necessary, substitute a known-good ABS/TCS control unit, and recheck.•

YES-Go to step 5.

19-66

NO-Repair open in the wire between the underhood fuse/relay box and the TCS relay .•

BACK

~ ~

5. Connect the TCS relay 4P connector terminal No.1 to No.2 with a jumper wire.

9. Measure the voltage between the modulator unit 24P connector terminal No. 17 and body ground.

TCS RELAY 4P CONNECTOR


+B(BLU) JUMPER WIRE

~

TCSSOLEN~ (RED/BLU)


'::I..



6. Disconnect the modulator unit 24P connector.


7. Measure the voltage between terminal No. 17 and body ground.

YES-Repair short to power in the wire between the TCS relay and the modulator unit.. NO-Go to step 10.


10. Disconnect the A8S/TCS control unit connector 8 (16P).


11. Measure the voltage between terminal 813 and body ground.

'::I.. ABS/TCS CONTROL UNIT CONNECTOR B (16P)


Is there battery voltage? YES - Go to step 8. NO- Repair open in the wire between the TCS relay and the modulator unit.•


8. Remove the jumper wire from the TCS relay 4P connector.

Is there battery voltage? YES-Repair short to power in the wire between the ABS/TCS control unit and the TCS relay.• NO-Go to step 12.

(cont'd)

BACK

19-67

ABS/TCS Components DTC Troubleshooting (cont'd) 12. Check for conti nuity between the ABS{fCS control unit connector B (16P) terminal B13 and body ground.

16. Measure the voltage between the TCS relay 4P connector terminal No.3 and body ground. TCS RELAY 4P CONNECTOR



Is there battery voltage? Is there continuity? YES-Go to step 17. YES- Repair short to body ground in the wire between the ABS{fCS control unit and the TCS relay .• NO-Gotostep 13.

NO- Repair open in the wire between the fail-safe relay and the TCS relay .• 17. Connect the TCS relay 4P connector No.3 and No.4 with a jumper wire.

13. Turn the ignition switch OFF. 14. Remove the ABS fail-safe relay. The wire colors of ABS fail-safe relay 4P connector are WHT/GRN, BRN/BLK, BLK, and YEL/GRN.

NOTE: Make sure the ABS{fCS control unit connector B (16P) is disconnected. TCS RELAY 4P CONNECTOR

15. Connect the ABS fail-safe relay 4P connector terminal No.1 and No.2 with a jumper wire. ABS FAil-SAFE RELAY 4P CONNECTOR

SOLENOID (BRN/BlK)

+B (WHT/GRN)

TCSR (GRN/YEl)

JUMPER WIRE

~ SOlEN9~ (BRN/BlK)

JUMPER WIRE



19-68

BACK

~ ~ 18. Measure the voltage between the ABS(TCS control unit connector B (16P) terminal B13 and body ground.

TCS DTC 31: Engine Retard Command (PFINH) signal NOTE: If the MIL or ABS indicator is ON, troubleshoot the PGM-FI or ABS first.


1. Disconnect the PCM connector A (32P) and the ABS(TCS control unit connector B (16P). 2. Check for continuity between the PCM connector A (32P) terminal A13 and body ground. PCM CONNECTOR A (32P)

5 6 7 8 9 10 11 1 1112 3 4 112113 14 15 16 17 18 19 20 21 22 23 24 1 25 26 27 28 29 30 31 ~


PFINH (BLU)


.Q YES -If the problem recurs, replace the ABS(TCS control unit..


NO- Repair open in the wire between the TCS relay and the ABS(TCS control unit.•

Is there continuity? YES- Repair short to body ground in the wire between the PCM and the ABS(TCS control unit.. NO-Goto step 3. 3. Connect the PCM connector A (32P). 4. Start the engine.

(cont'd)

BACK

19-69

ABS/TCS Components OTe Troubleshooting (cont'd) 5. Measure the voltage between the PCM connector A (32P) terminal A13 and body ground. NOTE: Use the 10 V range or similar range in an analog tester.

6. With an analog voltmeter set to the 10 V or similar range, measure the voltage between the ABS(TCS control unit connector B (16P) terminal B10 and body ground. ABS/TCS CONTROL UNIT CONNECTOR B (16PI

PCM CONNECTOR A (32PI

5 6 7 8 9 10 11 1 11 12 3 4 11211 314 15 16 17 18 19 20 21 22 23 24 1 25 26 27 28 29 30 31 ..lL

PFINH (BLUI

PFINH(BLUI

'Y.. Wire side of female terminals Wire side of female terminals

SV ........... .

sv ........... . About 2.SV _. About 2.SV _.

.

.

'-

.

.

.

._.

.

.

.

.

.-

.

.

.

._.

.

.

.-

.-

OV ...... . OV .......

Is there about 2.5 V? Is there about 2.5 V? YES-Check for loose ABS(TCS control unit connectors. If necessary, substitute a known-good ABS(TCS control unit, and recheck.•

YES - Go to step 6. NO-Check for loose PCM connectors. If necessary, substitute a known-good PCM, and recheck .•

19-70

NO- Repair open in the wire between the PCM and the ABS(TCS control unit.•

BACK

~ ~

TCS DTC 32: Engine speed (NEP) Signal NOTE: If the MIL or ABS indicator is ON, troubleshoot the PGM-FI or ABS first. 1. Disconnect PCM connector A (32P), ABS{TCS control unit connector B (16P) and gauge assembly connector A (30P).

5. With an analog voltmeter set to the 10 V or similar range, measure the voltage between the PCM connector A (32P) terminal A 19 and body ground.


2. Check for continuity between the PCM connector A (32P) terminal A 19 and body ground.

5 6 7 8 9 10 11 1 11 12 3 4 112j13 14 15 16 17 18 19 20 21 22 23 24 1 25 26 27 28 Il 30 31 ~ NEPIBLU)


'Y

5 6 7 8 9 10 11 1 11 12 3 4 112113 14 15 16 17 18 1920 21 22 23 24 1 25 26 27 28 I~ 30 31 ~


NEPIBLU)

Q = 12V············


About 6V _.

Is there continuity? YES- Repair short to body ground in the wire between the PCM and the ABS{TCS control unit.

.

.

.-

.

.

.

._.

.

.

.-

OV ...... .

NO - Go to step 3. 3. Connect the PCM connector A (32P).

Is there about 6 V? 4. Start the engine, warm it up to normal operating temperature, and let it idle.

YES - Go to step 6. NO-Check for loose PCM connectors. If necessary, substitute a known-good PCM, and recheck.•

(cont'd)

BACK

19-71

ABS/lCS Components DTe Troubleshooting (cont'd) 6. With the engine still idling, measure the voltage between the ABS{TCS control unit connector B (16P) terminal B11 and body ground with the analog voltmeter again.

TCS DTC 34: Reference Voltage (VREF) Signal NOTE: Ifthe MIL orthe ABS indicator is ON, troubleshoot the PGM-FI or the ABS first. 1. Disconnect the PCM connector A (32P) and the ABS{TCS control unit connector B (16P).


2. Check for continuity between the PCM connector A (32P) terminal A7 and body ground. PCM CONNECTOR A (32P) VREF (ORN/GRN)

I

5 6 7 8 9 10 11 1 11 12 3 4 112113 14 15 16 17 18 19 20 21 22 23 24 1 25 26 27 28 29 30 31 ~


Q Wire side offemale terminals

12V············

About 6V -'

.

.

.-

.

.

.

.-.

.

.

.-

OV ...... .

Is there continuity? YES-Repair short to body ground in the wire between the PCM and the ABS{TCS control unit.. NO-Goto step 3. 3. Connect the PCM connector A (32P).

Is there about 6 V?


YES - The system is OK at this time. If the problem recurs, replace the ABS{TCS control unit.. NO-Repair open in the wire between the PCM and the ABS{TCS control unit.•

19-72

BACK

~ ~ 5. Measure the voltage between the PCM connector A (32P) terminal A7 and body ground.

TCS DTC 36: Throttle Position Sensor Output

(THLOUT) Signal NOTE: If the MIL or the ABS indicator is ON, troubleshoot the PGM-FI or the ABS first.

PCM CONNECTOR A (32P) VREF (ORN/GRN)

I

1. Disconnect the PCM connector A (32P) and the ABS/TCS control unit connector B(16P).

5 6 7 8 9 10 111 11 12 3 4 112113 14 15 16 17 18 19 20 21 22 23 24 1 3225 26 27 28 29 30 31 ' -

2. Check for continuity between the PCM connector A (32P) terminal A31 and body gound.

':i.

=


5 6 7 8 9 10 11 1 11 12 3 4 112113 14 15 16 17 18 19 202122 23 24 1 25 26 27 28 29 3031 ...R


Is there about 5 V?

THLOUT (VEL/G RN)

YES-Go to step 6.

Q NO-Check for loose PCM connectors. If necessary, substitute a known-good PCM, and recheck.•


6. Measure the voltage between the ABS/TCS control unit connector B(16P) terminal B2 and body ground.

Is there continuity? ABS/TCS CONTROL UNIT CONNECTOR B (16P)

YES-Repair short to body ground in the wire between the PCM and the ABS/TCS control unit.•

VREF (ORN/GRN)

NO-Go to step 3. 3. Connect the PCM connector A (32P). 4. Start the engine.

=


Is there about 5 V? YES - The system is OK at this time. If the problem recurs, replace the ABS/TCS control unit.• NO- Repair open in the wire between the PCM and the ABS/TCS control unit.•

(cont'd)

BACK

19-73

ABS/TCS Components OTC Troubleshooting (cont'd) 5. Measure the voltage between the PCM connector A (32P) terminal A31 and body ground with the throttle fully opened and fully closed. There should be a smooth transition from approx. 0.5 V and 4.5 V. PCM CONNECTOR A (32P)

TCS DTC 61: AfT Shift Position (ATSFTP) Signal NOTE: If the MIL or the ABS indicator is ON, troubleshoot the PGM-FI or the ABS first. 1. Disconnect the PCM connector A (32P) and the ABS/TCS control unit connector B (16P).

8 9 10 11 I 5 6 7 11 12 3 4 l12113 14 15 16 17 18 19 20 2122 23 24 I 25 26 27 28 29 30 31 ~

2. Check for continuity between the PCM connector A (32P) terminal A 11 and body ground.

THLOUT (YEL/G RN)


':i

ATSFTP (LTGRN)

r-

=

5 6 7 8 9 10 11 J 1112 3 4 112113 14 15 16 17 18 19 20 21 22 23 24 ] 25 26 27 28 29 30 31 ~



Q

YES - Go to step 6.

= NO-Check for loose PCM connectors. If necessary, substitute a known-good PCM, and recheck.• 6. Measure the voltage between the ABS/TCS control unit connector B (16P) terminal B9 and body ground with the throttle fully closed. ABS/TCS CONTROL UNIT CONNECTOR B (16P)


Is there continuity? YES- Repair short to body ground in the wire between the PCM and the ABS/TCS control unit.• NO - Go to step 3. 3. Connect the PCM connector A (32P). 4. Shift the transmission to [f] position.

THLOUT (YEL/GRN)



Is there about 0.5 V? YES - The system is OK at this time. If the problem recurs, replace the ABS/TCS control unit.. NO- Repair open in the wire between the PCM and the ABS/TCS control unit..

19-74

BACK

~ ~ 6. With an analog voltmeter set to the 10 V or similar range, measure the voltage between the PCM connector A (32P) terminal A 11 and body ground. PCM CONNECTOR A (32P)

TCS DTC 81: Continuous TCS Operation NOTE: If the MIL or the ABS indicator is ON, troubleshoot the PGM-FI or the ABS first.

r-5 6 7 8 9 10 11 1 11 12 3 4 112113 14 15 16 17 18 19 20 21 22 23 24 1 25 26 27 28 29 30 31 -R.

1. Clear the DTC. 2. Test-drive the vehicle.

ATSFTP (VEL/GRN)

JJ] . JI;iiiJl :.:ii JI;i:i JI;::: iiii

Wire side of f ema Ie terml n als 5V 4V ..... - "TT:: n':: Tf;: About

OV .....

'rr::

':L =

Does the TCS indicator come on, and is DTC 81 indicated? YES- Replace the ABSrrCS control unit.•

TTT1


III: .11·111\11111111 : : :: :::: :::: :::: Ll..i..i

Is there about 4 V? YES-Go to step 7. NO- Check for loose PCM connectors. If necessary, substitute a known-good PCM, and recheck.• 7. With an analog voltmeter set to the 10 V or similar range, measure the voltage between the ABSrrCS control unit connector B (16P) terminal B7 and body ground. ABS/TCS CONTROL UNIT CONNECTOR B (16P) ATSFTP (LTGRN)

JJ] . 'JI:iiiJl i;ii JI;iiiJl i;ii iiii


=

5V 4V ..... - -:-:':: :-;':: .:-::: ':-,"",: ':-:-;', About

OV .....

!.!! !!!

!

111111111 III :::: ;::: :::: :::: Ll..i..i

Is there about 4 V? YES-Check for loose ABSrrCS control unit connectors. If necessary, substitute a known-good ABSrrCS control unit, and recheck .• NO- Repair open in the wire between the PCM and the ABSrrCS control unit.•

BACK

19-75

ABS/TCS Components ABS Indicator Circuit Troubleshooting 1. Turn the ignition switch ON (II), and watch the ABS indicator.

9. Check for continuity between the gauge assembly connector C (16PI terminal C10 and body ground.



YES -If the ABS indicator comes on and goes off, it's OK. Ifthe ABS indicator stays on, turn the ignition switch OFF, and go to step 13. ABS (BLU/WHT)

NO- Go to step 2. 2. Turn the ignition switch OFF then ON (II) again.

=

Does the brake system indicator come on?


YES - Go to step 3. NO- Repair open in the indicator power source circuit. • • Blown BACK UP LIGHT (7.5 A) fuse. • Open in the wire between the BACK UP LIGHT (7.5 A) fuse and the gauge assembly. • Open circuit inside the fuse box.

Is there continuity? YES-Repair short to body ground in the wire between the gauge assembly and the ABS/TCS control unit.• NO-Go to step 10.

3. Turn the ignition switch OFF. 10. Connect the gauge assembly connector C (16P). 4. Disconnect the ABS/TCS control unit connector A (26P).

11. Connect the gauge assembly connector B (22P) terminal B16 to body ground with a jumper wire.

5. Turn the ignition switch ON (II). GAUGE ASSEMBLY CONNECTOR B (22P)

Does the ABS indicator come on? YES-Check for loose ABS/TCS control unit connectors. If necessary, substitute a known-good ABS/TCS control unit, and recheck .•

GND (BLK)

NO - Go to step 6.

JUMPER WIRE

6. Check the ABS indicator bulb in the gauge assembly.


Is the bulb OK? YES-Go to step 7. NO- Replace the ABS indicator bulb .• 7. Turn the ignition switch OFF.


Does the ABS indicator come on? YES- Repair open in the wire between the gauge assembly and body ground (G501) .•

8. Disconnect the gauge assembly connector C (16P). NO-Replace the gauge assembly.•

19-76

BACK

~ ~ 13. Check the R/C MIRROR (7.5 A) fuse in the driver's under-dash fuse/relay box, and reinstall the fuse if it is OK.

17. Connect the ABS/TCS control unit connector A (26P) terminal A4 to body ground with a jumper wire.

Is the fuse OK?

ABS/TCS CONTROL CONNECTOR A (26P)

YES - Go to step 14. NO- Replace the fuse, and recheck .• 14. Connect the ABS/TCS control unit connector A (26P) terminal A 1 to body ground with a jumper wire.

=



Does the ABS indicator go off? YES-Check for loose ABS/TCS control unit connectors. If necessary, substitute a known-good ABS/TCS control unit, and recheck .•


NO-Go to step 18. 15. Turn the ignition switch ON (II). 18. Connect the gauge assembly connector C (16P) terminal C10 to body ground with a jumper wire.

Does the ABS indicator go off? YES-Repair open in the wire between the ABS/ TCS control unit and body ground (G403) .•


NO-Go to step 16. 16. Measure the voltage between the ABS/TCS control unit connector A (26P) terminal A13 and body ground.

ABS (BLU/WHT) JUMPER WIRE



Does the ABS indicator go off? YES-Repair open in the wire between the gauge assembly and the ABS/TCS control unit.•


NO- Replace the gauge assembly .•

Is there battery voltage? YES-Gotostep 17. NO- Repair open in the wire between the R/C MIRROR 0.5 A) fuse and the ABS/TCS control unit..

BACK

19-77

ABS/TCS Components TCS Indicator Circuit Troubleshooting 1. Start the engine, and watch the TCS indicator.

5. Remove the jumper wire at the gauge assembly, and connect the ABS/TCS control unit connector B (16P) terminal B16 and body ground with a jumper wire.

Does the TCS indicator come on? YES -If the TCS indicator comes on and goes off, it's OK. If the TCS indicator stays on, go to step 7.


NO-Go to step 2. 2. Turn the engine OFF, then restart it again. TCS2 (RED/WHT)

Does the brake system indicator come on? JUMPER WIRE

YES-Go to step 3. NO- Repair open in the indicator power source circuit.. • Blown BACK UP LIGHT (7.5 A) fuse. • Open in the wire between the BACK UP LIGHT (7.5 A) fuse and the gauge assembly. • Open circuit inside the fuse box.


Does the TCS indicator come on? YES-Goto step 6.

3. Turn the engine OFF, and check the TCS indicator bulb in the gauge assembly.

NO- Repair open in the wire between the gauge assembly and the ABS/TCS control unit..

Is the bulb OK? 6. Connect the ABS/TCS control unit connector C (12P) terminal C2 and body ground with a jumper wire.

YES-Go to step 4. NO- Replace the TCS indicator bulb.• 4. Connect the gauge assembly connector B (22P) terminal B18 and body ground with a jumper wire. Turn the ignition switch ON (II). GAUGE ASSEMBlV CONNECTOR B (22P)

ABS/TCS CONTROL UNIT CONNECTOR C (12P) lG (BRN/BlK)

JUMPER WIRE

...JII

1'5<1

/2 7 8

3 4 9

n....

5

6

10 11 12

_..... TCS (RED/WHT)


JUMPER WIRE

Does the TCS indicator come on? Wire side of female terminals

Does the TCS indicator come on? YES-Go to step 5.

YES- Repair open in the wire between the ABS/ TCS control unit and body ground (G101) .• NO-Check for loose ABS/TCS control unit connectors. If necessary, substitute a known-good ABS/TCS control unit, and recheck.•

NO-Replace the gauge assembly.•

19-78

BACK

~ ~ 7. Check the R/C MIRROR (7.5 A) fuse in the driver's under-dash fuse/relay box, and reinstall the fuse if itisOK.

9. Turn the ignition switch OFF. 10. Disconnect the ABS/TCS control unit connector A (26P) and connector B (16P).

Is the fuse OK? 11. Turn the ignition switch ON(lI). YES-Go to step 8.

Does the TCS indicator go off? NO- Replace the fuse, and recheck .• 8. Measure the voltage between the ABS/TCS control unit connector A (26P) terminal A13 and body ground.

YES-Check for loose ABS/TCS control unit connectors. If necessary, substitute a known-good ABS/TCS control unit, and recheck.• NO- Repair short to body ground in the wire between the gauge assembly and the ABS/TCS control unit..


IG2 (YEl/BlK)

2 3 15 16


Is there battery voltage? YES-Goto step 9. NO- Repair open in the wire between the driver's under-dash fuse/relay box and ABS/TCS control unit..

BACK

19-79

ABS/TCS Components Modulator Unit Removal and Installation NOTE: • Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. • Take care not to damage or deform the brake lines during removal and installation. • To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material.

Removal 1. Push the modulator unit connector lock (e), and turn the connector lever (D). 2. Disconnect the modulator unit connector (B). 3. Disconnect the brake lines, then remove the modulator unit (A).

c

o

6mmNUT 9.S N·m 11.0 kgf·m.

7.21~

~

SmmBOLT 22 N·m 12.2 kgf.m.16Ibf.ft)

Installation 1. Install the modulator unit in the reverse order of removal. 2. Bleed the brake system, starting with the front wheels. 3. Start the engine, and check that the ABS indicator and the TeS indicator go off. 4. Test-drive the vehicle, and check that the ABS indicator and the TeS indicator do not come on.

19-80

BACK

~ ~ Tes Switch Test 1. Remove the cruise control/TCS switch (A) from the switch panel.

2. Check for continuity between terminal No.5 and No.6. There should be continuity when the TCS switch is pushed. CRUISE CONTROl/TCS SWITCH CONNECTOR

4 IG2 (BlK/VEl)


BACK

19-81

ABS/TCS Components ABS/TCS Control Unit Replacement 1. Remove the passenger's kick panel.

Wheel Sensor Inspection 1. Inspect the front and rear pulsers for chipped or damaged teeth.

2. Remove the ABS/TCS control unit (A). A

2. Measure the air gap between the wheel sensor and pulser all the way around while rotating the pulser. Remove the rear brake disc to measure the gap on the rear wheel sensor. If the gap exceeds 1.0 mm (0.04 in), check for a bent suspension arm.

~~--~t

Standard: Front: 0.4 -1.05 mm (0.02 - 0.04 in) Rear: 0.19-1.14 mm (0.01-0.05 in) Front

t

3. Disconnect the ABS/TCS control unit connectors (B). 4. Install the ABS/TCS control unit in the reverse order of removal.

Rear

t

19-82

BACK

~ ~ Wheel Sensor Replacement Install the sensors carefully to avoid twisting wires. Front

/

6mmBOLT 9.8N·m (1.0 kgf.m, 7.2Ibf·ft)

WHEEL SENSOR

Rear

-----..

6mmBOLT

9.8 N·m (1.0 kgf·m, 7.2Ibf·ft)

WHEEL SENSOR

BACK

19-83

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If body maintenance is required) The Accord Sedan/Coupe (V6) SRS includes a driver's airbag located in the steering wheel hub, a passenger's airbag located in the dashboard above the glove box, and side airbags ('00-02 models) located in the front seat-backs. Information necessary to safely service the SRS is included in the '98-02 Accord Sedan/Coupe (L4) Service Manual, PIN 61S8400.ltems marked with an asterisk (* ) on the contents page include or are located near SRS components. Servicing, disassembling, or replacing these items will require special precautions and tools, and should therefore be done by and authorized Honda dealer.

• To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal co/fision, a/f SRS service work must be performed by an authorized Honda dealer. • Improper service procedures, including incorrect removal and installation ofthe SRS, could lead to personal injury caused by unintentional deployment of the frontal airbags (and side airbags on some '00-02 models). • Do not bump the SRS unit, Otherwise, the system may fail in case of a co/fision, or the airbags may deploy when the ignition switch is ON (/f). • SRS electrical connectors are indicated with ye/fow color coding. Related components are located in the steering column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats ('00-02 models) and around the floor ('00-02 models). Do not use electrical test equipment on these circuits.

BACK

Body Seats Front Seat Removal and Installation -4-Way Power-Sedan ........................................ Front Seat Disassembly/Reassembly -4-Way Power-Sedan ........................................ Front Seat Linkage Disassembly/Reassembly -4-Way Power-Sedan ........................................ Front Seat Wire Harness Installation -4-Way Power-Sedan ........................................

20-2 20-3 20-4 20-5

Bumper Rear Bumper Spoiler Replacement ..................... 20-6

Hood Replacement

20-7

Exterior Trim Emblem Replacement-Coupe Emblem Replacement-Sedan

20-8 20-8

Frame Sub-frame Replacement ....................................... 20-9 Frame Repair Chart ............................................... 20-12 NOTE: Refer to the 1998- 2002 Accord Service Manual (PIN 6158400) for the items not shown in this section.

Outline of V6 Model Changes 1998 model:

tfP""

• The Accord sedan and coupe V6 model has been added. - The V6 emblem has been added. - The hood replacement procedure is different. - The sub-frames are different. - The frame repair chart is different. 2001 model: • The following item has been added on Sedan or Coupe V6 model. - The passenger's 4 way power seat (sedan) - The rear bumper spoiler (coupe)

Seats Front Seat Removal/Installation - 4-Way Power - Sedan '01-02 models: SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service. Refer to '98-02 ACCORD Service Manual, PIN 61 S8400.

4. Lift up the front seat, then disconnect and detach the seat harness connector (A) and harness clip (8). A


B

A

B

A

2. Disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. 3. Remove the seat track end covers (A), and remove the bolts securing the front seat (8). When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Take care not to scratch the body or tear the seat covers. Fastener Locations

1>: Clip, 1

~: Bolt,4

N·m (3.5 kgf·m, ~ 34251bf.ftl

10x1.25mm

~

To body. To body.

5. With the help of an assistant, carefully remove the front seat through the front door opening. 6. Install the front seat in the reverse order of removal, and note these item: • Replace the damaged track and cover clip. • Make sure the seat harness connector is plugged in properly. • Enter the anti-there code for the radio, then enter the customer's radio station presets.

A

20-2

BACK

Front Seat DisassemblyIReassembly - 4-Way Power - Sedan '01-02 models: SRS components are located in this area. Review the SRS component locations (see page 23-23), and precautions and procedures (see page 23-28) in the SRS section before performing repairs or service. Refer to '98-02 ACCORD Service Manual, PIN 61S8400. Disassembly the front sent as shown. Reassemble the seat in the reverse order of disassembly, and note these items: • • • • •

Route the seat wire harness correctly (see page 20-5). Make sure the bushing and pivot washer are installed correctly. Apply mUltipurpose grease to the moving portion of the seat track. To prevent wrinkles in the seat-back cover, stretch the material evenly over the pad. If the seat-back pad or the OPDS unit is replaced, reinitialize the OPDS unit. Refer to '98-02 ACCORD Service Manual, PIN 61S8400 (see page 23-300).

n~HEADREST

~

HOOKS

SEAT-BACK /

PIVOT WASHER

WIRE TIE

10 x 1.25 mm 47 N·m (4.8 kgf·m, 35 Ibf·tt)

POWERSEAT~~~ ~

------..:'"~.

RECLINE COVER

~\)~

~~ ~'--~ ~

~~

~:~.. ~ -~' " ~';J~~WI" n.?~

/

~~ ~

IS< ' " "

~ SEAT LINKAGE

10x1.25mm 47 N·m (4.8 kgf·m, 35 Ibf·tt)

.. '(),

CAPS

10x1.25mm 47N·m (4.8 kgf.m, 35 Ibf·tt)

"",-"

SWITCH KNOBS

BACK

20-3

Seats Front Seat linkage Disassembly/Reassembly - 4-Way Power - Sedan '01·02 models:

NOTE: • Put on gloves to protect your hands. • To remove the slide motor and slide gearbox, slide the front seat backward fully. Disassemble the linkage as shown. Reassemble the linkage in the reverse order of disassembly, and note these items: • Before installing the slide motor and slide gearbox, align portion (AI as shown to align both slide gearbox positions. • Apply multipurpose grease to the sliding and pivot portions of the linkage. • Check operation of the recline and slide adjusters.

8x 1.2Smm 14N·m (1.4 kgf·m, 10 Ibf·ft)

OUTER SLIDE

7U7/END~P 6x 1.0mm 9N·m

]

kgf·m. 7Ibl·ft]

RIGHT SLIDE GEARBOX

\-

?t 6x1.0mm 9N.m

ff 6x1.0mm 8N·m

~:-

..

0 0

1O.9kgf·m. 71b~

3.7 N·m (0.38 kgf·m, 2.7 Ibf·ft)

20-4

SLIDE MOTOR! LEFT SLIDE GEARBOX

BACK

6x 1.0mm 9N·m (0.9 kgf·m, 7 Ibf·ft)

END CAP

~

r-'

Front Seat Wire Harness Installation - 4-Way Power - Sedan '01-02 models: When assembling the front seat, make sure the seat belt switch harness (A), seat harness (8), seat heater harnesses (e), side airbag harness (0), OPOS unit harness (E), connectors (F), clips (G) and wire tie (H) are fastened correctly.

F

F

G

G F

E G

~~

~.

[A][B]

To seat cushion heater. To recline motor.

[C]

L-----,


Y.

~

I~ ~~ B

G

F

BACK

20-5

Bumpers Rear Bumper Spoiler Replacement - Coupe '01-02 models: NOTE: Take care not to scratch the rear bumper. Remove the rear bumper spoiler as shown. Install the spoiler in the reverse order of removal, and replace any damaged clips. Fastener Locations

~~'BoIt.2

6xl.0mm 9.8N·m (1.0 kgf·m, 7.2Ibf·ft)

I>~.

I

REAR BUMPER

HOOKS

/1

REAR BUMPER SPOILER

20-6

BACK

l

Hood \

Replacement 1. Disconnect the windshield washer tubes (A) from the windshield washer nozzles (B), and release the windshield washer tube from the clips (C).

c

4. Install the hood in the reverse order of removal, and note these items: • Before reattaching the support struts, adjust the hood alignment. • Make sure the hood opens properly and locks securely. • Make sure the windshield washer tubes are connected properly. • When reattaching the support struts, set the clips (A) to the original position, then attach the support struts (B) on the pivot bolts (C) by pushing the support strut.

B

c A

2. With a flat-tip screwdriver, pry the clips (A) out of the support struts (B) on each hood side, then release both support struts from the pivot bolts (C) with the help of an assistant. Do not remove the clips from the support struts. If necessary, release the support strut from the pivot bolt on the body, then remove the support strut. Fastener Locations ~: Bolt, 4

6x1.0mm @an 9.8 N·m (1.0 kgf.m,

7.2Ibf·ft)

B

3. With the help of an assistant, remove the bolts, then remove the hood (D). Take care not to damage the hood and body.

BACK

20-7

Exterior Trim Emblem Replacement - Coupe

Emblem Replacement - Sedan

Apply the emblem where shown.

Apply the emblem where shown.

NOTE: • Before applying, clean the rear bumper surface with a sponge dampened in alcohol. • After cleaning, keep oil, grease and water from getting on the surface.

NOTE: • Before applying, clean the rear bumper surface with a sponge dampened in alcohol. • After cleaning, keep oil, grease and water from getting on the surface.

Attachment Point (Reference):

Attachment Point (Reference): V6EMBLEM

V6EMBLEM TRUNK LID

Edge of the Unit: mm (in.)

Unit: mm (in.)

rear bumper.

13.5 (0.53)

Edge ofthe

Edge ofthe

trunk lid.

20-8

rear bumper.

BACK

Frame

r""

Sub-frame Replacement After loosening the sub-frame mounting bolts, be sure to replace them with new ones. REAR BEAM


REAR BEAM STIFFENER

/

FRONT BEAM

~

.....

SPEt.AL BOLT

~

WASHER

~

~

~

""

14x1.5mm ~~~ N·m (10.5 kgf·m, 76lbf·ftl

~'.",

12x1.Z5mm 64 N·m (6.5 kgf·m, 47 Ibf·ftl SPECIAL BOLT

14x 1.5 mm 103 N·m (10.5 kgf·m, 76lbf·ftl Replace.

(cont'd)

BACK

20-9

Frame Sub-frame Replacement (cont'd) After loosening the sub-frame mounting bolts, be sure to replace them with new ones.

REAR SUSPENSION SUB-FRAME

To body.

1

REAR SUSPENSION

~

SU~E~tf

8x 1.25 mm 22 N·m (2.2 kgf·m, 16lbf·ft)

20-10

kJ - - - - - - - REAR SUSPENSION SUB-FRAME STAY

8x 1.25 mm 22 N·m (2.2 kgf·m, 16lbf·ft)

SPECIAL BOLTS

14x1.5mm 103 N·m (10.5 kgf·m, 76lbf·ft) Replace.

BACK

BACK

20-11

Frame Frame Repair Chart Top View

Unit: mm (in.) "': Inner diameter POINTh

POINT 9

~INTo

~

POINTd2

' ; ' : ; ,d3

POINTf POINTi POINTj POINTk POINTu

/

\'\\

POINT a

~~\QQ ~ J "1'1~~'

r-'-~

N. tlV1

l\

-

~~

~.

N ,... ;:: M

'"... ... 0 0

0 0

~ I)-

rf

.......

ol"~ •

;:: P;-iij

&~ ~

N 00

M

,...

en en

00

'"

.'"

P;..;

an an

CD

.",

~ b-.)

---

/

I~

I

!2

,..: !2

00

en

1/ M

11

. ..

...£ J

!2

0

..... : 1)5 t..t ~ ~D

/\

..;

\

I

~~

I

L...i

"',"

~

Y

r

...

0

o

i

~

J

I...J

.5

l/

130 ~IO.2) 77 (3.0) (5.12i 200 (7.9) 280 (11.0) 425 (16.7) 268 (10.6) 321 (12.6) 595 (23.4) 490 (19.3) 610 (24.0)

~

"'~w (J

wZ

>::::i

BACK

.

... 0

00 00

0

iD ..; !2

Gi

!2

1425 (56.10)

20-12

0

iii ,...

iD

C;

0 ,...

0

00

w;,( ~

\

I

~/

iii~ in

Gi Gi aO aO ..; an an ... !2 !2 !2 !2!2 0

CENTER LINE

~

L=

POINT I

00 00

0

I

~

POINT n

rolm,

POINT m~ \

~

r..;~ ~I!--

I I

0

POINT 5

\~[~~~~M

I I

@

POINTq

I JiJI •

\

-....;

I

Il;::~

0 00 ,.: :!.

-....

in I')

0

0 !e

:!.

~

N

C

C

....N N

~

..; It)

....."""c'"

'"

1\

\. tr

~

_l

I-- -

~~

.......

It)

It)

I')

It)C CUI

•ri

•ri

f\

'C

-

... ....... ..."""....

N ....

~~

0....

.........

C C

C C

'"

'"

N~

....-

~~ ~.

~ 0

I I

I---:~

@ ;:[l

I ""L..,

t"r,~ ..J

~.~ @)

r

~-.w.

r

~

I~\

\

~-....

,

0

([ .--

~\

I ~roWh

POINTw

POINTt

POINTp

2145 (84.45) 2236 (88.03) 2365 (93.11) 2750 (108.3) 2899 (114.11 2971 (117.0) 2998 (118.0) 3008 (118.4) 3200 (126.0) 3622 1142.6)

(cont'd)

BACK

20-13

Frame Frame Repair Chart (cont'd) Side View .11.5 (0.45) Unit: mm (In,) 2-811 (0.43)

111: Inner diameter .11.5 (0.45) POINTe POINTf

269(10.6/ SECTIONAA

SECTIONBB

POINTg Front Damper Center

POINTe Upper Arm Point M10x 1.25 .11 (0.43) Engine Mount Point M10x 1.25 M14x 1.5

... ii cD !: ~ ... ... ; ~

ii

~ ."

r.n

N POINTu .25 (1.0) Locate Hole POINTk .15 (0.59) Locate Hole

cl

IS

POINT I .25 (1.0) Locate Hole

,J

e( (J

tlw wZ

>:::::1

POINT I .17 (0.7) For Rear Beam

20-14

BACK


2 - .13 10.51

SECTION DD

Rear Damper Center

M8 x 1.25 POINTq 1125 11.01 Locate Hole POINTw

~&6§rt::~I~~=~b[:::J~J~1I20 10.81 Locate Hole i r:: :-------=i POINTn 1111.410.4491 For Rear Suspension Subframe

POINTt 119 10.35) For Rear Suspension Sub-frame Stay

M14x 1.5 111510.59) Locate Hole 118 10.311 For Rear POINTm

820 10.81 Locate .Iole

Suspension Subframe Stay

1111.4(0.449) For Rear Suspension Sub-frame

BACK

20-15

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If HVAC maintenance is required) The Accord Sedan/Coupe (V6) SRS includes a driver's airbag located in the steering wheel hub, a passenger's airbag located in the dashboard above the glove box, and side airbags ('00-02 models) located in the front seat-backs. Information necessary to safely service the SRS is included in the '98-02 Accord Sedan/Coupe (L4) Service Manual, PIN 61S8400.ltems marked with an asterisk (* ) on the contents page include or are located near SRS components. Servicing, disassembling, or replacing these items will require special precautions and tools, and should therefore be done by and authorized Honda dealer.

• To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all SRS service work must be performed by an authorized Honda dealer. • Improper service procedures,"including incorrect removal and installation of the SRS, could lead to personal injury caused by unintentional deployment ofthe frontal airbags (and side airbags on some '00-02 models). • Do not bump the SRS unit, Otherwise, the system may fail in case of a collision, or the airbags may deploy when the ignition switch is ON (II). • SRS electrical connectors are indicated with yellow color coding. Related components are located in the steering column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats ('00-02 models) and around the floor ('00-02 models). Do not use electrical test equipment on these circuits.

BACK

HVAC (Heating, Ventilation, and Air Conditioning) Air Conditioning Special Tools ........................ 21-2 Component Location Index .................................. 21-3 AlC Refrigerant Oil Replacement ..................... 21-6 Symptom Troubleshooting Index .................................. 21-7 Circuit Diagram .................... 21-8 Condenser Fan Circuit Troubleshooting ............... 21-10 Radiator and Condenser Fans Common Circuit Troubleshooting ............... 21-12 Heater Valve Cable Adjustment ....................... 21-13 AlC System Tests ................... 21-15 Compressor Replacement ('98-00 model) ................... 21-18 Compressor Clutch Check ('98-00 model) ................... 21-20 Compressor Clutch Overhaul ('98-00 model) ................... 21-21 Compressor Relief Valve Replacement ('98-00 model) ................... 21-22 Compressor Replacement ('01-02 model) ................... 21-23 Compressor Clutch Check ('01-02 model) ................... 21-25 Compressor Clutch Overhaul ('01-02 model) ................... 21-26 Compressor Relief Valve Replacement ('01-02 model) ................... 21-27 Condenser Replacement ..... 21-28 Refrigerant Leak Test ............. 21-29 System Charging .................... 21-30

Climate Control Component Location Index .................................. 21-32 General Troubleshooting Information ....................... 21-34 DTC Troubleshooting Index .................................. 21-35 Symptom Troubleshooting Index .................................. 21-36 System Description .............. 21-37 Circuit Diagram .................... 21-38 DTC Troubleshooting .......... 21-40 ECT Sensor Circuit Troubleshooting ............... 21-56 Climate Control Power and Ground Circuits Troubleshooting ............... 21-57 Recirculation Control Motor Circuit Troubleshooting ... 21-58 AlC Pressure Switch Circuit Troubleshooting ............... 21-59 In-car Temperature Sensor Replacement and Test ..... 21-61 Outside Air Temperature Sensor Replacement and Test ............................. 21-62 Sunlight Sensor Replacement and Test ............................. 21-63 Power Transistor Test .......... 21-64 Climate Control Unit Removal and Installation ................. 21-64 Climate Control Unit Disassembly and Reassembly ....................... 21-65

Refer to the 1998-2002 Accord Service Manual (PIN 61S8400) for items not shown in this section.

Outline of V6 Model Change The air conditioning and climate control has been changed to suit the Accord V6.

HVAC (Heating, Ventilation, and Air Conditioning) Special Tools Tool Number 07SAZ-001 OOOA

Descri tion

CD

21-2

BACK

Air Conditioning Component Location Index

SERVICE VALVE (LOW-PRESSURE SIDE) SERVICE VALVE (HIGH-PRESSURE SIDE)

EVAPORATOR

Removal and Installation, page 21-46 in the '98-02 Accord Service Manual COMPRESSOR EVAPORATOR COMPONENTS

Replacement, page 21-47 in the '98-02 Accord Service Manual

('98-00 models) Replacement, page 21-18 Clutch Check, page 21-20 Clutch Overhaul, page 21-21 Relief Valve Replacement, page 21-22 COMPRESSOR

('01-02 model) Replacement, page 21-23 Clutch Check, page 21-25 Clutch Overhaul, page 21-26 Relief Valve Replacement, page 21-27

(cont'd)

BACK

21-3

Air Conditioning Component Location Index (cont'd)

AlC PRESSURE SWITCH

RADIATOR FAN

CONDENSER FAN BLOWER MOTOR RELAY, RADIATOR FAN RELAY, CONDENSER FAN RELAY, COMPRESSOR CLUTCH RELAY (Located in the under-hood fuse/relay box) Test, page 22-52 in the '98-02 Accord Service Manual

21-4

BACK

HEATER VALVE CABLE Adjustment, page 21-13 HEATER UNIT/CORE Replacement, page 21-28 in the '98-02 Accord Service Manual EVAPORATOR Removal and Installation, page 21-46 in the '98-02 Accord Service Manual EVAPORATOR COMPONENTS Replacement, page 21-47 in the '98-02 Accord Service Manual RECIRCULATION CONTROL MOTOR Test, page 21-22 in the '98-02 Accord Service Manual Replacement, page 21-22 in the '98-02 Accord Service Manual

BLOWER UNIT ... /

d===~~

Removal and Installation, page 21-26 in the '98-02 Accord Service Manual

BLOWER UNIT COMPONENTS Replacement, page 21-27 in the '98-02 Accord Service Manual

BLOWER RESISTOR

%

~

-",,,,,r---.,.,,

MODE CONTROL MOTOR Test, page 21-21 in the '98-02 Accord Service Manual Replacement, page 21-21 in the '98-02 Accord Service Manual


Test, page 21-23 in the '98-02 Accord Service Manual

Q

Q

~DUST 0

AM> POLLEN FILTER Replacement, page 21-25 in the '98-02 Accord Service Manual

~HEATER CONTROL PANEL

Removal and Installation, page 21-24 in the '98-02 Accord Service Manual Disassembly and Reassembly, page 21-24 in the '98-02 Accord Service Manual

HEATER FAN SWITCH Test, page 21-23 in the '98-02 Accord Service Manual

AIR MIX CONTROL MOTOR Test, page 21-20 in the '98-02 Accord Service Manual Replacement, page 21-20 in the '98-02 Accord Service Manual

BACK

21-5

Air Conditioning Ale Refrigerant Oil Replacement EVAPORATOR SUCTION HOSE

~::i~~~~~~----RECEIVER/DRVER LINE wal~=-----CONDENSER LINE

® CD

COMPRESSOR BRACKET

®

CD Discharge hose to the compressor (6 x 1.0 mm) : 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft) ® Discharge hose to the condenser (6 x 1.0 mm) : 9.8 N·m (1.0 kgf.m, 7.2 Ibf.ft) ® Condenser line to the condenser (6 x 1.0 mm) : 9.8 N·m (1.0 kgf.m, 7.2 Ibf·ft) ® Condenser line to the receiver/dryer: 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft) ® Receiver line to the receiver/dryer: 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft) ® Receiver line to the evaporator: 13 N·m (1.3 kgf·m, 9.4Ibf·ft) (J) Suction hose to the evaporator: 31 N·m (3.2 kgf·m, 23 Ibf·ft) ® Suction hose to the compressor (6 x 1.0 mm): 9.8 N·m (1.0 kgf·m, 7.2Ibf·ft) ® Compressor to compressor bracket (8 x 1.25 mm) : 22 N·m (2.2 kgf·m, 16 Ibf·ft) @ Compressor bracket to engine block (10 x 1.25 mm) : 44 N·m (4.5 kgf.m, 33 Ibf·ft)

21-6

BACK

~ \

Symptom Troubleshooting Index Symptom

Recirculation control doors do not change between Fresh and Recirculate. Blower motor runs, but one or more speeds are inoperative.


Recirculation Control Motor Circuit Troubleshooting, refer to the '98-02 Accord Service Manual (see page 21-14) Blower Motor Circuit Troubleshooting, refer to the '98-02 Accord Service Manual (see page 21-15)

Blower motor does not run at all. Blower Motor Circuit Troubleshooting, refer to the '98-02 Accord Service Manual (see page 21-15)

Condenser fan does not run at all (but radiator fan runs with theAlC on).


Both fans do not run with the AlC on.


Compressor clutch does not engage.

Compressor Clutch Circuit Troubleshooting, refer to the '98-02 Accord Service Manual (see page 21-39)

AlC system does not come on (both fans and compressor).

AlC Pressure Switch Circuit Troubleshooting, refer to the '98-02 Accord Service Manual (see page 21-41 ) Heater Control Power and Ground Circuits Troubleshooting, refer to the '98-02 Accord Service Manual (see page 21-19)

Both heater and AlC do not work.

BACK

Also check for

• Blown fuse No.3 (7.5A) in the driver's under-dash fuse/relay box • Cleanliness and tightness of all connectors • Blown fuse No. 56 (40A) in the underhood fuse/relay box, and No.3 (7.5A) in the driver's under-dash fuse/relay box • Poor ground at G202 and G401 • Cleanliness and tightness of all connectors • Blown fuse No. 56 (40A) in the underhood fuse/relay box, and No.3 (7.5A) in the driver's under-dash fuse/relay box • Poor ground at G202 and G401 • Cleanliness and tightness of all connectors • Blown fuse No. 58 (20A) in the underhood fuse/relay box, and No.3 (7.5A) in the driver's under-dash fuse/relay box • Poor ground at G201 • Cleanliness and tightness of all connectors • Blown fuse No. 57 (20A) and No. 58 (20A) in the under-hood fuse/relay box, and No.3 (7.5A) in the driver's underdash fuse/relay box • Poor ground at G201 • Cleanliness and tightness of all connectors • Blown fuse No. 58 (20A) in the underhood fuse/relay box, and No.3 (7.5A) in the driver's under-dash fuse/relay box • Cleanliness and tightness of all connectors Cleanliness and tightness of all connectors

• Blown fuse No. 54 (40A) in the underhood fuse/relay box, No.3 (7.5A) in the driver's under-dash fuse/relay box, and No. 13 (7.5A) in the passenger's under-dash fuse/relay box • Poor ground at G202 and G401 • Cleanliness and tightness of all connectors

21-7

Air Conditioning Circuit Diagram DRIVER'S UNDER-DASH FUSEIRELAY BOX UNDER-HOOD FUSE/RELAY BOX

IGNITION SWITCH

No.42 (50A)

;-0'"'

IGI BAT IG2

WHT

No.6 (15A)
BlK/YEl VEL

BlKlYEl

L r--

BlKlYEl BlKlYEl

I

WHTIYEl

BATTERY No.41 (IOOA)

+

No.54 (40A)

I

VEL

No.13 (7.5A)

r:t"VJ


~(40A)

No.57 (20A)

NO.58 (20A)

"'V

RADIATOR FAN RELAY

I

1

3

~~----------~ GRN

r~

BlUlBlK

3

1

3

BlUIYEl

4

S ----------j~

2

RED

BLOWER MOTOR RELAY

1

~----------~~ 4

2

COMPRESSOR CLUTCH RELAY

4

~~----~-----~ 4

2

CONDENSER FAN RELAY

2

RED

~

3

~,

'~'~1

YEflK

CLUTCH

-

~ T.

GRN

GRN

-G202

ACC

5V

2

RADIATOR ~ FAN SWITCH A (Closed: Above) 1 199'F (93'C)

FANC -:-

AlC PRESSURE SWITCH ACS 27

r

-GRN

BlU/RED

27 2

2 RADIATOR FAN MOTOR

CONDENSER FAN MOTOR

M I

M

PCM

GI:

2

I BLK

BlK

BlK

21-8

GIOI

G201

3

1,

6

RADIATOR FAN CONTROL MODULE

Is

4

WHT/GRN

111 G201

BlKlYEl YEUWHT VEL WHT BlKlYEl

1

~

RADIATOR FAN SWITCHB 2 (Closed: Above) BlK 22S'F (107'C)

BlK

1

1

GIOI

G401

BACK

17

~

YEUGRN

YEUBLK

BLOWER MOTOR

~1 2 BLKlYEL

BLOWER RESISTOR BLUIRED JBLU/RED

BLU/YEL BLU

5V

BLUIBLK . . . - - - - BLUIRED

.....--+--GRN .....------~--BLK--~---------------------~__,

GRN EVAPORATOR TEMPERATURE SENSOR

.....- - - - WHTIYEL

BRN ~ ~ YEUGRN - - - . ,

- - - - - - - - - - YEUGRN

S5V AMD·P M·COOL M·HOT

S·COMo---t AIR MIX CONTROL MOTOR

M·VENT REAR WINDOW DEFOGGER RELAY

C>-

M·DEF MODEl

BRN/YEL

MODE2

S·COM MODE CONTROL MOTOR

MODE3 COMBINATION LIGHT SWITCH or TAILLIGHT RELAY MULTIPLEX CONTROL UNIT (DRIVER'S)

C>
MODE4 YEUGRN __--!:======~

RED/BLK

RED

FRS RECIRCULATION CONTROL MOTOR IG2

--(;!~--'

__J BLK BLKlYEL

I

BLK-----+i HEATER CONTROL PANEL

BACK

G401

21-9

Air Conditioning Condenser Fan Circuit Troubleshooting 1. Check the No. 58 (20 A) fuse in the under-hood fuse/relay box, and the No.3 (7.5 A) fuse in the driver's under-dash fuse/relay box.

4. Connect the No.1 and No.2 terminals of the condenser fan relay 4P socket with a jumper wire.

Are the fuses OK?

CONDENSER FAN RELAY 4P SOCKET

YES-Go to step 2. NO- Replace the fuse(s), and recheck .• JUMPER WIRE

2. Remove the condenser fan relay from the underhood fuse/relay box, and test it, refer to the '98-02 Accord Service Manual (see page 21-52).

2 4

3

BLU/YEL

Is the relay OK? YES-Go to step 3. Does the condenser fan run? NO- Replace the condenser fan relay .• YES-Go to step 5. 3. Measure the voltage between the No.1 terminal of the condenser fan relay 4P socket and body ground. CONDENSER FAN RELAY 4P SOCKET

NO-Go to step 9. 5. Disconnect the jumper wire. 6. Turn the ignition switch ON (II). 7. Measure the voltage between the No.3 terminal of the condenser fan relay 4P socket and body ground.

2

4 3


= 4 Is there battery voltage? YEL/WHT

YES - Go to step 4. NO-Replace the under-hood fuse/relay box .•

= Is there battery voltage? YES- Replace the under-hood fuse/relay box.• NO- Go to step 8.

21-10

BACK

B. Measure the voltage between the No.3 terminal of the radiator fan control module BP connector and body ground with the BP connector connected.

12. Check for continuity between the No.1 terminal of the condenser fan 2P connector and body ground. CONDENSER FAN 2P CONNECTOR

RADIATOR FAN CONTROL MODULE 8P CONNECTOR


Wire side of female terminals VEL/WHT

1

2

3

4

5

6

7

8

= = Is there continuity? Is there battery voltage? YES - Replace the condenser fan motor.• YES-Repair open in the wire between the condenser fan relay and the radiator fan control module .•

NO-Check for an open in the wire between the condenser fan and body ground. If the wire is OK, check for poor ground at G201 .•

NO-Perform the radiator fan control module input tests (see page 10-20) .• 9. Disconnect the jumper wire. 10. Disconnect the condenser fan 2P connector. 11. Check for continuity between the No.2 terminal of the condenser fan relay 4P socket and the No.2 terminal of the condenser fan 2P connector. CONDENSER FAN RELAY 4P SOCKET

CONDENSER FAN 2P CONNECTOR Wire side of female terminals


r

NO-Repair open in the wire between the condenser fan relay and the condenser fan .•

BACK

21-11

Air Conditioning Radiator and Condenser Fans Common Circuit Troubleshooting 1. Check the No. 57 (20 A) and No. 58 (20 A) fuses in the under-hood fuse/relay box, and the No.3 (7.5 A) fuse in the driver's under-dash fuse/relay box.

9. Using a 8ackprobe Set, measure the voltage between the No. 20 terminal of the PCM connector A (32P) and body ground with the PCM connectors connected.

Are the fuses OK? PCM CONNECTOR A (32P)

YES - Go to step 2.


NO - Replace the fuse(s), and recheck.• 8

2. Remove the condenser fan relay from the underhood fuse/relay box.

9

10

23

24

32

3. Turn the ignition switch ON (II). 4. Measure the voltage between the No.3 terminal of the condenser fan relay 4P socket and body ground.

=


Is there battery voltage? YES-Check for loose wires or poor connections at the PCM connector A(32P). If the connections are good, substitute a known-good PCM, and recheck. If the symptom/indication goes away, replace the original PCM .•

2 4

NO-Repair open in the wire between the radiator fan relay, the condenser fan relay and PCM .•

=


YES - Go to step 5. NO- Perform the radiator fan control module input tests (see page 10-20) .• 5. Turn the ignition switch OFF. 6. Reinstall the condenser fan relay. 7. Make sure the

AlC switch is OFF.


21-12

BACK

Heater Valve Cable Adjustment 1. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (8) from the heater valve arm (C). B

/r\

(,/',',I (:0) ',',,>-"/'~

I

,Ii ,

5. From under the hood, turn the heater valve arm (C) to the fully closed position as shown, and hold it. Attach the heater valve cable (8) to the heater valve arm, and gently pull on the heater valve cable housing to take up any slack, then install the heater valve cable housing into the cable clamp (A). B

~J':(i-:'-~

,~

,

-l~

!

><-.:::: " \,

(,,~,

c A

2. From under the dash, disconnect the heater valve cable housing from the cable clamp (A), and disconnect the heater valve cable (8) from the air mix control linkage (C).

A

c

A

o

c

B

3. Set the temperature control dial on Max Cool (60°F or 18°C) with the ignition switch ON (II). 4. Attach the heater valve cable (8) to the air mix control linkage (C) as shown above. Hold the end of the heater valve cable housing against the stop (D), then snap the heater valve cable housing into the cable clamp (A).

BACK

21-13

Air Conditioning

21-14

BACK

Ale System Tests Pressure Test Test results

Discharge (high) pressure abnormally high

Related symptoms

Air in system

Reduced or no air flow through condenser

• Clogged condenser or radiator fins • Condenser or radiator fan not workinc orooerlv Restricted flow of refrigerant in system • Faulty compressor discharge valve • Faultv comoressor seal • Faulty expansion valve • Moisture in system

Line to condenser is excessively hot. Discharge pressure abnormally low

Suction (low) pressure abnormally low

Suction pressure abnormally high

Suction and discharge pressures abnormally hiQh Suction and discharge pressure abnormally low Refrigerant leaks

Remedy

Probable cause

After stopping compressor, pressure drops to about 196 kPa (2.0 kgf/cm2, 28 psi) quickly, and then falls gradually.

High and low pressures are balanced soon after stopping compressor. Low side is hioherthan normal. Outlet of expansion valve is not frosted, low-pressure gauge indicates vacuum. Expansion valve is not frosted, and low-pressure line is not cold. Loworessure cauce indicates vacuum. Discharge temperature is low, and the air flow from vents is restricted. Exoansion valve is frosted. Receiver/dryer outlet is cool, and inlet is warm (should be warm during ooeration). Low-pressure hose and check joint are cooler than the temperature around evaoorator. Suction pressure is lowered when condenser is cooled by water. High and low-pressure are equalized as soon as the compressor is stopped, and both gauges fluctuate while runnino. Reduced air flow through condenser.

Low-pressure hose and metal end areas are cooler than evaoorator. Temperature around expansion valve is too low compared with that around receiver/dryer. Comoressor clutch is dirty. Comoressor bolt(s) are dirtv. Comoressor oasket is wet with oil.

• Frozen expansion valve (Moisture in system) • Faulty exoansion valve Frozen evaporator Clo~ged eXDansion valve Clogged receiver/dryer

Recover, evacuate, refer to the '98-02 Accord Service Manual (see page 21-55), and recharge with specified amount (see page 21-30) • Clean • Check voltage and fan rpm. • Check fan direction. Restricted lines Replace the compressor.

• Replace • Recover, evacuate, and recharge with soecified amount. • Recover, evacuate, and recharge with specified amount. • Reolace the exoansion valve. Run the fan with compressor off, then check evaoorator temoerature sensor. Clean or reolace. Replace

• Expansion valve open too long • Loose expansion capillary tube

Repair or replace.

Excessive refrigerant in system

Recover, evacuate, and recharge with soecified amount. Replace the compressor.

• Faulty gasket • Faulty high-pressure valve • Foreign particle stuck in highDressure valve • Clogged condenser or radiator fins • Condenser or radiator fan not workinc orooerlv Clogged or kinked low-pressure hose oarts Clogged high-pressure line

Repair or replace.

Comoressor shaft sealleakinQ Leaki!)Q around bolt(s) Gasket leaking_

Reolace the comoressor. Tichten bolt(s) or reolace comoressor. Reolace the comoressor.

• Clean • Check voltage and fan rpm. • Check fan direction. Repair or replace.

r (cont'd)

BACK

21-15

Air Conditioning Ale System Tests (cont'd) Performance Test

3. Insert a thermometer in the center air vent.

I AWARNING • Compressed air mixed with R-134a forms a combustible vapor. • The vapor can burn or explode causing serious injury. • Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning systems.

I ACAUTION • Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. • Be careful when connecting service equipment. • Do not breathe refrigerant or vapor.

The performance test will help determine if the air conditioner system is operating within specifications. Use only service equipment that is U.L.-listed and is certified to meetthe requirements of SAE J2210 to remove HFC-134a (R-134al from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air.

4. Test conditions: • • • •

Avoid direct sunlight. Open the hood. Open the front doors. Set the temperature control dial on Max Cool, the mode control switch on Vent and the recirculation control switch on Recirculate. • Turn the AlC switch on and the fan switch on Max. • Run the engine at 1,500 rpm. • No driver or passengers in vehicle.

5. After running the air conditioning for 10 minutes under the above test conditions, read the delivery temperature from the thermometer in the dash vent, the intake temperature near the blower unit behind the glove box and the high and low system pressure from the AlC gauges.

Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recover/recycling/ charging station to the high-pressure service port and the low-pressure service port, following the equipment manufacturer's instructions. 2. Determine the relative humidity and air temperature.

21-16

BACK

6. To complete the charts: • • • • • • • •

Mark the delivery temperature along the vertical line. Mark the intake temperature (ambient air temperature) along the bottom line. Draw a line straight up from the air temperature to the humidity. Mark a point 10 % above and 10 % below the humidity level. From each point, draw a horizontal line across the delivery temperature. The delivery temperature should fall between the two lines. Complete the low-side pressure test and high-side pressure test in the same way. Any measurements outside the line may indicate the need for further inspection. Showatype

Calsonic type

Calsonic:

Show.: kPa

kPa (kgf/cm')

(k~f/cm')

[psi]

psi]

2900 (30) [430]

800/0

2500 (25) [360] 2000 (20) [280] 1500 (15) [210]

DELIVERY PRESSURE

of (OC)

400 86 (4) (30) [57]

DELIVERY 200 PRESSURE (~k8]

68 (20)

100 (1) [14]

59 (15)

0

50 (10)

800/0 HUMIDITY 800/0 LEVEL

300/0

kP.

1500 (15) [210]

400 (4) [57]

86 (30)

980 110) [140]

300 (3) [43

77

800/0 r~Sl1~ITY

(25)

30%

200 (2) [28

68

100 11) [14

59 (15)

(k~f/cm')

psi]

HUMIDITY LEVEL DELIVERY PRESSURE

o

INTAKE PRESSURE

of 1°C) 800/0

HUMIDITY LEVEL

(20)

300/0

50 (10)

INTAKE PRESSURE


41 (5)

300/0

2000 120) [280]

300/0


HUMIDITY LEVEL

300/0

kPa (kgf/cm')

[psi]

800/0

HUMIDITY 2500 LEVEL (25) [360]

300 980 77 (3) (25) (10) [43] [140]

41 (5)

I

68 120)

r

2900 (30) [430]

I 77 (25)

I

86 (30)


I 95 (35)

I

68

(20)

INTAKE TEMPERATURE

77

(25)

86 (30)

95 (35)

INTAKE TEMPERATURE

BACK

21-17

Air Conditioning Compressor Replacement ('98-00 model) 1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons.

7. Remove the bolt and the nut, then disconnect the suction (A) and discharge (8) lines from the compressor. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

3. Disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station, refer to the '98-02 Accord Service Manual (see page 21-54). 5. Remove the alternator (see page 4-31). 6. Remove the compressor clutch connector (A) from the condenser fan shroud (8), then disconnect the compressor clutch connector. Disconnect the condenser fan connector (e), then remove the wire harness clips (D) from the condenser fan shroud. Remove the cruise control actuator cable (E) from the clamp. Loosen the lower mounting bolt. then remove the upper mounting bolts and the condenser fan shroud. 8e careful not to damage the radiator fins when removing the condenser fan shroud.

d;.~ ~'!ni~o kgf.m. 7.20bf·ttl

6x 1.0 mm

9.a N·m (1.0 kgf·m, 7.2Ibf·ft)

~

I

8. Remove the mounting bolts and the compressor. 8e careful not to damage the radiator fins when removing the compressor.

~c E

A

ax 1.25 mm 22 N·m (2.2 kgf·m, 16Ibf·ft)

6x1.0 mm

9.a N·m (1.0 kgf·m, 7.2Ibf·ft)

21-18

B

BACK

9. Remove the bolts, the suction service valve (A) and the O-ring (B) from the compressor.

B

10. If necessary, remove the mounting bolts and the compressor bracket.

11. Install the compressor in the reverse order of removal, and note these items: • If you're installing a new compressor, you must calculate the amount of refrigerant oil to be removed from it, refer to the '98-02 Accord Service Manual (see page 21-32). • Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for HFC-134a (R-134a) to avoid leakage. • Use refrigerant oil (DENSO NO-OIL 8) for HFC134a DENSO piston type compressor only. • To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. • Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. • Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. • Be careful not to damage the radiator fins when installing the compressor and the condenser fan shroud. • Charge the system (see page 21-30). • Enter the anti-theft code for the radio, then enter the customer's radio station presets.

10 x 1.25 mm 44 N·m 14.5 kgf·m, 33 Ibf·ftl

BACK

21-19

Air Conditioning Compressor Clutch Check ('98-00 model) 1. Check the plated parts of the pressure plate for color changes, peeling or other damage. If there is damage, replace the clutch set (see page 21-21). 2. Check the pulley bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag (see page 21-21).

4. Check resistance of the field coil. If resistance is not within specifications, replace the field coil (see page21-21). Field Coil Resistance:

3. Measure the clearance betweenn the pulley (A) and the pressure plate (8) with a dial indicator. Zero out the indicator, then apply battery voltage to the compressor clutch. Measure the movement of the pressure plate when the voltage is applied. If the clearance is not within the specified limits, the pressure plate must be reshimed (see page 21-21). Clearance: O.5±O.15 mm (O.020±O.006 in)

e

® 12V

21-20

BACK

3.4-3.8 ohms at 68°F (20°C)

Compressor Clutch Overhaul ('98-00 model) Special Tool Required

Ale clutch holder, Robinair 10204, Kent-Moore J37872, or Honda Tool and Equipment KMT-J33939, commercially available


1. Remove the center bolt while holding the pressure plate with a commercially available Ale clutch holder. 13.2 N·m (1.35 kgf·m, 9.76Ibf·ft)

~


4. Remove the screw from the field coil ground terminal (A). Remove the snap ring (B) with snap ring pliers, then remove the field coil (e). Be careful not to damage the field coil and compressor.

B

NOTE: The shims are available in four thicknesses: 0.1 mm, 0.3 mm, 0.5 mm, and 1.5 mm.

c~

(cont'd)

BACK

21-21

Air Conditioning Compressor Clutch Overhaul ('98-00 model) (cont'd)

Compressor Relief Valve Replacement ('98-00 model) 1. Recover the refrigerant with a recovery/recycling/ charging station, refer to the '98-02 Accord Service Manual (see page 21-54).

5. Reassemble the clutch in the reverse order of disassembly, and note these items: • Install the field coil with the wire side facing down, and align the boss on the field coil with the hole in the compressor. • Clean the pulley and compressor sliding surfaces with contact cleaner or other non-petroleum solvent. • Install new snap rings, note the installation direction, and make sure they are fully seated in the groove. • Make sure that the pulley turns smoothly after it's reassembled. • Route and clamp the wires properly or they can be damaged by the pulley.

2. Remove the relief valve (A) and the O-ring (8). Plug

the opening to keep foreign matter from entering the system and the compressor oil from running out. A 13.2 N·m 11.35

kg/·7.7.,bf.ftJ

~~~/~

B

3. Clean the mating surfaces. 4. Replace the O-ring with a new one at the relief valve, and apply a thin coat of refrigerant oil before installing it. 5. Remove the plug, and install and tighten the relief valve. 6. Charge the system (see page 21-30).

21-22

BACK

Compressor Replacement ('01-02 model) 1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons.

7. Remove the bolt and the nut, then disconnect the suction line (A) and discharge line (B) from the compressor. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

3. Disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station, refer to '98-02 Accord Service Manual (see page 21-54). 5. Remove the alternator (see page 4-31). 6. Remove the compressor clutch connector (A) from the condenser fan shroud (B), then disconnect the compressor clutch connector. Disconnect the condenser fan connector (e), then remove the wire harness clips (D) from the condenser fan shroud. Remove the cruise control actuator cable (E) from the clamp. Loosen the lower mounting bolt, then remove the upper mounting bolts and the condenser fan shroud. Be careful not to damage the radiator fins when removing the condenser fan shroud.

6x 1.0 mm 9.8N·m (1.0 kgf·m, 7.2Ibf·ft)

8. Remove the mounting bolts and the compressor. Be careful not to damage the radiator fins when removing the compressor.

8x1.2Smm 22 N·m (2.2 kgf·m, 16 Ibf.ft)

(cont'd)

BACK

21-23

Air Conditioning Compressor Replacement ('01-02 model) (cont'd) 9. If necessary, remove the mounting bolts and the compressor brecket.

10 x 1.25 mm 44 N·m 14.5 kgf·m, 33 Ibf·ft)

21-24

10. Install the compressor in the reverse order of removal, and note these items: • If you're installing a new compressor, you must calculate the amount of refrigerant oil to be removed from it, refer to '98-02 Accord Service Manual (see page 21-32). • Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for HFC-134a (R-134a) to avoid leakage. • Use refrigerant oil (DENSO NO-OIL 8) for HFC134a DENSO piston type compressor only. • To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. • Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. • Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. • Be careful not to damage the radiator fins when installing the compressor and the condenser fan shroud. • Charge the system (see page 21-30). • Enter the anti-theft code for the radio, then enter the customer's radio station presets.

BACK

Compressor Clutch Check ('01-02 model) 1. Check the plated parts of the pressure plate for color changes, peeling or other damage. If there is damage, replace the clutch set (see page 21-26). 2. Check the pulley bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag (see page 21-26).

4. Check resistance of the field coil. If resistance is not within specifications, replace the field coil (see page 21-26).

Field Coil Resistance:

3.4-3.8 ohms at 68°F (20°C)

3. Measure the clearance between the pulley (A) and the pressure plate (B) with a dial indicator. Zero out the indicator, then apply battery voltage to the compressor clutch. Measure the movement of the pressure plate when the voltage is applied. If the clearance is not within the specified limits, the pressure plate must be reshimed (see page 21-26).

Clearance: 0.5 ± 0.15 mm (0.020 ± 0.006 in.)

BACK

21-25

Air Conditioning Compressor Clutch Overhaul ('01-02 model) Special Tool Required

Ale clutch holder, Robinair 10204, Kent-Moore J37872, or Honda Tool and Equipment KMT-J33939, commercially available


1. Remove the center bolt (A) while holding the pressure plate with a commercially available Ale clutch holder (B). A 13.2N·m (1.35 kgf.m,

9.76Ibf·ft)


B

4. Remove the screw from the field coil ground terminal (A). Remove the snap ring (B) with snap ring pliers, then remove the field coil (e). Be careful notto damage the field coil and compressor.

NOTE: The shims are available in four thicknesses: 0.1 mm, 0.3 mm, 0.5 mm, and 1.5 mm. A

B

21-26

BACK

Compressor Relief Valve Replacement ('01-02 model) 5. Reassemble the clutch in the reverse order of disassembly, and note these items: • Install the field coil with the wire side facing down, and align the boss on the field coil with the hole in the compressor. • Clean the pulley and compressor sliding surfaces with contact cleaner or other non-petroleum solvent. • Install new snap rings, note the installation direction, and make sure they are fully seated in the groove. • Make sure that the pulley turns smoothly after it's reassembled. • Route and clamp the wires properly or they can be damaged by the pulley.

1. Recover the refrigerant with a recovery/recycling/ charging station, refer to '98-02 Accord Service Manual (see page 21-54). 2. Remove the relief valve (A) and the O-ring (8). Plug the opening to keep foreign matter from entering the system and the compressor oil from running out.

B

A 13.2 N·m 11.35 kgf·m, 9.76Ibf·ft)

3. Clean the mating surfaces. 4. Replace the O-ring with a new one at the relief valve, and apply a thin coat of refrigerant oil before installing it. 5. Remove the plug, and install and tighten the relief valve. 6. Charge the system (see page 21-30).

r BACK

21-27

Air Conditioning Condenser Replacement 1. Recover the refrigerant with a recovery!recycling! charging station, refer to the '98-02 Accord Service Manual (see page 21-54). 2. Remove the coolant reservoir, but do not disconnect the reservoir hose from the coolant reservoir and the radiator.

5. Remove the bolts and the upper mount brackets (A), then remove the condenser (B) by lifting it up. Be careful not to damage the radiator and condenser fins when removing the condenser. A

~

3. Remove the bolts, then remove the upper mount brackets from the radiator. 6x 1.0mm 9.S N·m 11.0 kgf.m, 7.2Ibf·ft)

4. Remove each bolt, then disconnect the discharge line (A) and condenser (B) line from the condenser. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination. A

B

21-28

6x1.0mm 9.S N·m (1.0 kgf·m, 7.2Ibf·ft)

6. Install the condenser in the reverse order of removal, and note these items: • If you're installing a new condenser, add refrigerant oil (DEN SO NO-OIL 8), refer to the '9802 Accord Service Manual (see page 21-32). • Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for HFC-134a (R-134a) to avoid leakage. • Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. • Do not spill the refrigerant oil on the vehicle; it may damage the paint; ifthe refrigerant oil contacts the paint, wash it off immediately. • Be careful not to damage the radiator and condenser fins when installing the condenser. • Charge the system (see page 21-30).

BACK

Refrigerant Leak Test Special Tool Required Leak detector, Honda Tool and Equipment YGK-H-10PM, commercially available

AWARNING

1. Connect a R-134a refrigerant recovery/recycling/ charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions.

• Compressed air mixed with R-134a froms a combustible vapor. • The vapor can burn or explode causing serious injury. • Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning system.


Use only service equipment that is U.L.-listed and is certiified to meet the requirements of SAl; J2210 to remove HFC-134a (R-134a) from the air conditioning system.

If accidental system discharge occurs, ventilate work area before resuming service. R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air.

Additional health and safety information may be obtained from the refrigerant and lulbricant manufacturers.

2. Open high pressure valve to charge the system to the specified capacity, then close the supply valve, and remove the charging system couplers. Select the appropriate units of measure for your refrigerant charging station.

Refrigerant capacity with Showa condenser: SOOtoS50 g O.SO to 0.S5 kg 1.3 to 1.41bs 21.2 to 22.9 oz Refrigerant capacity with Calsonic condenser: 450to500g 0.45 to 0.50 kg 1.0to 1.11bs 15.9 to 17.Soz 3. Check the system for leaks using a R-134a refrigerant leak detector with an accuracy of 14 g (0.5 oz) per year or better. 4. If you find leaks that require the system to be opened (to repair or replace hoses, fittings, etc.), recover the system. 5. After checking and repairing leaks, the system must be evacuated.

BACK

21-29

Air Conditioning System Charging

: ACAUTION • Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. • Be careful when connecting service equipment. • Do not breathe refrigerant or vapor.

Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recovery/recycling/ charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions.

2. Evacuate the system, refer to the '98-02 Accord Service Manual (see page 21-55). 3. Add the same amount of new refrigerant oil to the system that was removed during recovery. Use only OENSO NO-OIL 8 refrigerant oil. 4. Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system; the compressor will be damaged. Select the appropriate units of measure for your refrigerant charging station.

Refrigerant capacity with Showa condenser: 600t0650g 0.60 to 0.65 kg 1.3 to 1.41bs 21.2 to 22.9 oz Refrigerant capacity with Calsonic condenser: 450 to 500 g 0.45 to 0.50 kg 1.0to 1.11bs 15.9 to 17.6 oz 5. Check for refrigerant leaks (see page 21-29). 6. Check for system performance (see page 21-16).

!

i i

I

-

i

./

/, .. .. .....-

/

\..

21-30

'-...

BACK

BACK

21-31

Climate Control Component Location Index

AIC PRESSURE SWITCH

BLOWER MOTOR RELAY, RADIATOR FAN RELAY, CONDENSER FAN RELAY, COMPRESSOR CLUTCH RELAY (Located in the under-hood fuse/relay box) Test, page 22-52 in the '98-02 Accord Service Manual

21-32

OUTSIDE AIR TEMPERATURE SENSOR Replacement, page 21-62 Test, page 21-62 CONDENSER FAN

BACK

TER VALVE CABLE Adjustment, page 21-13 SUNLIGHT SENSOR RePlacement, page 21-63 Test, page 21-63

/

HEATER UNIT/CORE Replacement, page 21-28 in the '98-02 Accord Service Manual

~

~~

CONTROL MOTOR Test, page 21-22 in the '98-02 Accord Service Manual Replacement, page 21-22 in the '98-02 Accord Service Manual

MOTOR HIGH RELAY Test, page 22-52 in the '98-02 Accord Service Manual

DUST AND POLLEN FILTER Replacement, page 21-25 in the '98-02 Accord Service Manual EVAPORATOR Removal and Installation, page 21-46 in the '98-02 Accord Service Manual EVAPORATOR COMPONENTS Replacement, page 21-47 in the '98-02 Accord Service Manual AIR MIX CONTROL MOTOR Test, page 21-20 in the '98-02 Accord Service Manual Replacement, page 21-20 in the '98-02 Accord Service Manual

CLIMATE CONTROL UNIT Removal and Installation, page 21-64 Disassembly and Reassembly, page 21-65

EVAPORATOR TEMPERATURE SENSOR Test, page 21-23 in the '98-02 Accord Service Manual IN-CAR TEMPERATURE SENSOR Replacement, page 21-61 Test, page 21-61 MODE CONTROL MOTOR Test, page 21-21 in the '98-02 Accord Service Manual Replacement, page 21-21 in the '98-02 Accord Service Manual

BACK

21-33

Climate Control General Troubleshooting Information How to Retrieve a DTC The climate control unit has a self-diagnosis function. Running the Self-diagnosis Function 1. Turn the ignition switch ON (II). TEMPERATURE CONTROL DIAL

TEMPERATURE INDICATOR

OFF BUTTON C" E

B,D

A-~a*o:-F

GJIfD~J K

I

H 'N

2. Set the temperature control dial on Max Cool, then slowly to Max Hot. 3. After 1 minute, press the AUTO button and then the OFF button. Continue to hold both buttons down. If there is any abnormality in the system when both buttons are pressed, the temperature indicator will light up the segment (A to N) corresponding to the error. The temperature indicator will then alternate every second between displaying "88" (all segments lit) and the error segment. Ifthere is no abnormality, the segments will not light up. Resetting the Self-diagnosis Function Turning the ignition switch OFF will cancel the self-diagnosis function. After completing repair work, run the selfdiagnosis function again to make sure that there are no other malfunctions.

21-34

BACK

I""" \

DTC Troubleshooting Index To retrieve the DTC, you must run the self-diagnosis function (see page 21-34). In the case of multiple problems, the respective indicator segments will come on. If indicator segments A, C, E, G, I, and L come on at the same time, there may be an open in the common ground wire of the sensors.

TEMPERATURE INDICATOR

C E

B

D

~Lt

A

--Q -0 QB--F

G~O#JatFJ K I

DTe (Temperature Indicator segment) A B

C D E

F G H I

J K

L M N

H N

Page

Detection Item

An open in the in-car temperature sensor circuit A short in the in-car temperature sensor circuit An open in the outside air temperature sensor circuit A short in the outside air temperature sensor circuit An open in the sunlight sensor circuit A short in the sunlight sensor circuit An open in the evaporator temperature sensor circuit A short in the evaporator temperature sensor circuit An open in the air mix control motor circuit A short in the air mix control motor circuit A problem in the air mix control linkage, door, or motor An open or short in the mode control motor circuit A problem in the mode control linkage, doors, or motor A problem in the blower motor circuit

(see (see (see (see (see (see (see (see (see (see (see (see (see (see

page 21-40) page 21-41) page 21-41) page 21-43) page 21-43) page 21-44) page 21-45) page 21-46) page 21-47) page 21-47) page 21-48) page 21-49) page 21-50) page 21-51)

r BACK

21-35

Climate Control Symptom Troubleshooting Index Symptom


The blower motor does not run immediately even through the engine is fully warmed up NOTE: The temperature control dial or button must be set between 64°F (18°C) and 90°F (32°C) Recirculation control doors do not change between Fresh and Recirculate.

ECT Sensor Circuit Troubleshooting (see page 21-56)

Cleanliness and tightness of all connectors

Recirculation Control Motor Circuit Troubleshooting (see page 21-58)

• Blown fuse No.3 (7.5A) in the driver's under-dash fuse/relay box • Cleanliness and tightness of all connectors • Blown fuse No. 58 (20A) in the underhood fuse/relay box, and No.3 (7.5A) in the driver's under-dash fuse/relay box • Poor ground at G201 • Cleanliness and tightness of all connectors • Blown fuse No. 57 (20A) and No. 58 (20A) in the under-hood fuse/relay box, and No.3 (7.5A) in the driver's underdash fuse/relay box • Poor ground at G201 • Cleanliness and tightness of all connectors • Blown fuse No. 58 (20A) in the underhood fuse/relay box, and No.3 (7.5A) in the driver's under-dash fuse/relay box • Cleanliness and tightness of all connectors Cleanliness and tightness of all connectors • Blown fuse No. 54 (40A) in the underhood fuse/relay box, No.3 (7.5A) in the driver's under-dash fuse/relay box, and No. 13 (7.5A) in the passenger's under-dash fuse/relay box • Poor ground at G202 and G401 • Cleanliness and tightness of all connectors

Condenser fan does not run at all (but radiator fan runs with the AlC on).


Both fans do not run with the AlC on.


Compressor clutch does not engage.

Compressor Clutch Circuit Troubleshooting, refer to the '98-02 Accord Service Manual (see page 21-39)

AlC system does not come on (both fans and compressor). Both heater and AlC do not work.

AlC Pressure Switch Circuit Troubleshooting (see page 21-59) Climate Control Power and Ground Circuits Troubleshooting (see page 21-57)

21-36

BACK

Also check for

System Description Climate Control Unit Inputs and Outputs CLIMATE CONTROL UNIT CONNECTORS


20P CONNECTOR

8P CONNECTOR

~ 4

8P CON ECTOR

6

}8

5

6

7

9

11

12 13 14 15 16 17 18 19 20

3

4

8

2

10

(0 on Circuit Diagram)

Cavity 1 2 3 4 5 6 7 8

Wire color BLK/YEL WHT/yEL RED/WHT BLU/ORN ORN/BLK BLU/RED BRN/YEL BLK

20P CONECTOR Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

5

rs <'1 1

Signal IG2 (Power) +B (Power) ENGINE COOLANT TEMPERATURE (ECT) SENSOR BLOWER MOTOR HIGH RELAY POWER TRANSISTOR BLOWER FEEDBACK REAR WINDOW DEFOGGER RELAY GROUND

INPUT INPUT OUTPUT INPUT OUTPUT INPUT INPUT OUTPUT

(0 on Circuit Diagram)

Wire color PNK/BLK YEL/GRN GRN/RED GRN/WHT BLU/BLK BLU/WHT RED/YEL RED/BLK RED/WHT RED YEL/GRN WHT/RED GRY BRN BRN/WHT YEL/RED BLU/GRN LT GRN/BLK GRN/YEL GRN/BLK

Signal AIR MIX POTENTIAL AlC PRESSURE SWITCH FRESH RECIRCULATE MODE DEF MODE VENT AIR MIX HOT COMBINATION LIGHT SWITCH or TAILLIGHT RELAY AIR MIXCOOL MULTIPLEX CONTROL UNIT (DRIVER'S) SENSOR COMMON GROUND SUNLIGHT SENSOR AIR MIX POTENTIAL +5V EVAPORATOR TEMPERATURE SENSOR OUTSIDE AIR TEMPERATURE SENSOR IN-CAR TEMPERATURE SENSOR MODE4 MODE3 MODE 2 MODE 1

BACK

OUTPUT INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT INPUT OUTPUT OUTPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT

21-37

Climate Control ~

I

Circuit Diagram DRIVER'S UNDER-DASH FUSE/RELAY BOX UNDER-HOOD FUSE/RELAY BOX

IGNITION SWITCH No.S(lSA)

No.42 (SOA) --<:J"'\ BATTERY

No.4l (100A)

+

IGl BAT IG2

WHT

-..

BlKiYEl

BlKiYEL

NO.3 (7_SA) VEL

L

No.S4(40A)

~

BLKiYEl BlKiYEl

VEL No.SS(40A) -.0"'\ No_58 (20A)

No.S7(20A)

--..

RADIATOR FAN RELAY

1

1

3

~~----------~

2

t--

COMPRESSOR CLUTCH RELAY

4

4

3

RED

BLOWER MOTOR RELAY

1

2

RED

3

1

~'~,~~ ~ CLUTCH

G1N

--

,

AlC PRESSURE SWITCH ACS

,,7

BlUiRED

~

ECT

?'

REDIWHT

REDIWHT

GD'''~

COOLANT TEMPERATURE (ECT) SENSOR

<

CONDENSER FAN MOTOR

M

SG2

2

2

-!--

M

Gl: BlK

BlK

BLK

2

3

1

I

1s 4

WHT/GRN

~

G201

21-38

Gl01

G20l

1

GRNlBlK _

PCM

1

1

YELlGRN

FANC

~GRN

1<

RADIATOR FAN MOTOR

K

G202

ACC.

2 RADIATOR ~ FAN SWITCH A (Closed: Above) 1 199'F (93'C)

YEr

-

-

. T ~ r? cT

4

~----------~~

2

GRN

GRN

1

~----------~~

BlUIYEl

GRN

BlUlBlK

3

~~----------~ 4

2

CONDENSER FAN RELAY

RADIATOR FAN SWITCHB 2 Closed: Above (107'C) , BlK

BlK

1

1

Gl01

G401

~2S'F

BACK

BlKiYEl YELlWHT VEL WHT BlKiYEl 17

I

1

YEUBlK

BLOWER MOTOR

~1

2 BLUIRED

f

Ba~KlYEl BlUIR:D

BLUIRED BLOWER

---------_-IJ ~I~~OR

1

No.13 (7.5A)

3 PASSENGER'S UNDER-DASH FUSEIRELAY BOX

BLUIORN BlUIORN _ _ _""","",,"_.....J BLUIRED r-~~--

RELAY

5 BLK

POWER TRANSISTOR

----+-------t--j-''YYIrt

ORN~lK--------+-------------~~--1r--_t

BLKlYEL

' - - - - - - WHTIYEL

BRN---~~~-~

- - - - - - - YEUGRN

....----.C

- - - - - - - REDIWHT -f31-----4~

A: IN-CAR TEMPERATURE SENSOR B : OUTSIDE AIR TEMPERATURE SENSOR C : SUNLIGHT SENSOR 0: EVAPORATOR TEMPERATURE SENSOR

~....-K1-1H-~- YEUGRN

S-COMo--.... AIR MIX CONTROL MOTOR

REAR

~~~~ER [>-

BRNIYEL

RELAY

S.COM 0-.;.7_-t

COMBINATION LIGHT SWITCH or TAILLIGHT RELAY MULTIPLEX CONTROL UNIT (DRIVER'S)

[>-

MODE CONTROL MOTOR REDIBlK

--'=---

YEUGRN

RED

_...!=======-_--J

GRNIRED ~

GRNIWHT BLK

FRS RECIRCULATION CONTROL MOTOR IG2

----y REC

o: o:

8P CONNECTOR 20P CONNECTOR

CLIMATE CONTROL UNIT

BACK

BlK BlKIYEL

1 G401

21-39

Climate Control OTe Troubleshooting OTC indicator light A: An open in the in-car temperature sensor circuit 1. Remove the in-car temperature sensor (see page 21-61).

4. Check for continuity between the No. 16 terminal of the climate control unit 20P connector and the No. 2 terminal of the in-car temperature sensor 2P connector. CLIMATE CONTROL UNIT 20P CONNECTOR


2. Measure the resistance between the No.1 and No. 2 terminals of the in-car temperature sensor. *Check for a change in resistance by heating or cooling the sensor with a hair drier. IN-CAR TEMPERATURE SENSOR

IN-CAR TEMPERATURE SENSOR 2P CONNECTOR



12 11 10

\

9 8 RESISTANCE

kQ

7

6

NO-Repair open in the wire between the climate control unit and the in-car temperature sensor.•

\

\

\.

5

5. Check for continuity between the No. 11 terminal of the climate control unit 20P connector and the No. 1 terminal ofthe in-cartemperature sensor 2P connector.

\

4 3 2

'"

."",

"-...... -......

1 14 -10

32 0

50 10

68 20

---

86 30

~

CLIMATE CONTROL UNIT 20P CONNECTOR Wire side offemale terminals

104 of 40°C

TEMPERATURE

* Is the resistance within the specifications shown on the graph? IN-CAR TEMPERATURE SENSOR 2P CONNECTOR Wire side of female terminals

YES-Go to step 3. NO- Replace the in-car temperature sensor.•

Is there continuity? 3. Disconnect the climate control unit 20P connector. YES-Check for loose wires or poor connections at the climate control unit 20P connector and at the incar temperature sensor 2P connector. If the connections are good, substitute a known-good climate control unit, and recheck. If the symptom/ indication goes away, replace the original climate control unit.• NO-Repair open in the wire between the climate control unit and the in-car temperature sensor.•

21-40

BACK

l

DTC indicator light B: A short in the in-car temperature sensor circuit

DTC indicator light C: An open in the outside air temperature sensor circuit

1. Remove the in-car temperature sensor (see page 21-61 ).

1. Remove the outside air temperature sensor (see page 21-62).

2. Test the in-car temperature sensor (see page 21-61).

2. Measure the resistance between the No.1 and No. 2 terminals of the outside air temperature sensor. *Dip the sensor in ice water the and measure the resistance. Then pour hot water on the sensor, and check for a change in resistance.

Is the resistance within the specifications shown on the graph? YES-Go to step 3.

OUTSIDE AIR TEMPERATURE SENSOR

NO- Replace the in-car temperature sensor.• 3. Disconnect the climate control unit 20P connector. 4. Check for continuity between the No. 16 terminal of the climate control unit 20P connector and body ground. CLIMATE CONTROL UNIT 20P CONNECTOR Wire side of female terminals

,lflii' \

12 11 10

15<1

1

2

3

4

5

6

7

8

9

10

1\

\

9 8

11 12 13 14 15 16 17 18 19 20

4~WRED

RESISTANCE

7

kQ

6

\

'"'"

5 4 3 2 1


14 -10

YES-Repair short to body ground in the wire between the climate control unit and the in-car temperature sensor..

\

32 0

"'"

50 10

"",

.......

68 20

r---.

86 30

104"F 40"C

TEMPERATURE

* Is the resistance within the specifications shown NO-Substitute a known-good climate control unit. and recheck. If the symptom/indication goes away, replace the original climate control unit.•

on the graph? YES-Go to step 3. NO- Replace the outside air temperature sensor.• 3. Disconnect the climate control unit 20P connector.

(cont'd)

BACK

21-41

Climate Control DTC Troubleshooting (cont'd) 4. Check for continuity between the No. 15 terminal of the climate control unit 20P connector and the No. 1 terminal ofthe outside airtemperature sensor 2P connector.

5. Check for continuity between the No. 11 terminal of the climate control unit 20P connector and the No. 2 terminal of the outside air temperature sensor 2P connector.

CLIMATE CONTROL UNIT 20P CONNECTOR




OUTSIDE AIR TEMPERATURE SENSOR 2P CONNECTOR

OUTSIDE AIR TEMPERATURE SENSOR 2P CONNECTOR





YES-Go to step 5.

YES-Check for loose wires or poor connections at the climate control unit 20P connector and at the outside air temperature sensor 2P connector. If the connections are good, substitute a known-good climate control unit, and recheck. If the symptom/ indication goes away, replace the original climate control unit..

NO-Repair open in the wire between the climate control unit and the outside air temperature sensor .•

NO-Repair open in the wire between the climate control unit and the outside air temperature sensor.•

21-42

BACK

DTC indicator light 0: A short in the outside air temperature sensor circuit 1. Remove the outside air temperature sensor (see page 21-62).

DTC indicator light E: An open in the sunlight sensor circuit 1. Disconnect the sunlight sensor 2P connector. 2. Disconnect the climate control unit 20P connector.

2. Test the outside air temperature sensor (see page 21-62).

Is the resistance within the specifications shown on the graph?

3. Check for continuity between the No. 12 terminal of the climate control unit 20P connector and the No. 1 terminal of the sunlight sensor 2P connector. CLIMATE CONTROL UNIT 20P CONNECTOR

YES-Go to step 3.


NO- Replace the outside air temperature sensor .• 3. Disconnect the climate control unit 20P connector.

11

2

3

4

5

6

7

8

9

10

12

13

14

15

16

17

18

19

20

4. Check for continuity between the No. 15 terminal of the climate control unit 20P connector and body ground. CLIMATE CONTROL UNIT 20P CONNECTOR

Wire side of female terminals SUNLIGHT SENSOR 2P CONNECTOR

I>

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20


?RN/W~

YES-Go to step 4. NO-Repair open in the wire between the climate control unit and the sunlight sensor.•

= Is there continuity? YES- Repair short to body ground in the wire between the climate control unit and the outside air temperature sensor.. NO-Substitute a known-good climate control unit, and recheck. If the symptom/indication goes away, replace the original climate control unit.•

(cont'd)

BACK

21-43

Climate Control DTC Troubleshooting (cont'd) 4. Check for continuity between the No. 11 terminal of the climate control unit 20P connector and the No. 2 terminal of the sunlight sensor 2P connector.

DTC indicator light F: A short in the sunlight sensor circuit 1. Disconnect the sunlight sensor 2P connector.


2. Disconnect the climate control unit 20P connector.


11

2

3

4

5

6

7

8

9

10

12

13

14

15

16

17

18

19

20

3. Check for continuity between the No. 12 terminal of the climate control unit 20P connector and body ground.



SUNLIGHT SENSOR 2P CONNECTOR Wire side of female terminals

1><1 6

1

2

3

4

5

11

12

13

14

15

16

7

8

9

10

17

18

19

20

f~/~D


=

NO-Repair open in the wire between the climate control unit and the outside air temperature sensor. II

Is there continuity? YES- Repair short to body ground in the wire between the climate control unit and the sunlight sensor..

5. Reconnect the sunlight sensor 2P connector. 6. Reconnect the climate control unit 20P connector.

NO-Go to step 4. 7. Test the sunlight sensor (see page 21-63). 4. Reconnect the sunlight sensor 2P connector.

Is the sunlight sensor OK? 5. Reconnect the climate control unit 20P connector. YES-Check for loose wires or poor connections at the climate control unit 20P connector and at the sunlight sensor 2P connector. If the connections are good, substitute a known-good climate control unit, and recheck. If the symptom/indication goes away, replace the original climate control unit.. NO- Replace the sunlight sensor..

6. Test the sunlight sensor (see page 21-63).

Is the sunlight sensor OK? YES-Substitute a known-good climate control unit, and recheck. If the symptom/indication goes away, replace the original climate control unit.• NO - Replace the sunlight sensor.•

21-44

BACK

DTC indicator light G: An open in the evaporator temperature sensor circuit 1. Disconnect the evaporator temperature sensor 2P connector.

4. Check for continuity between the No. 14 terminal of the climate control unit 20P connector and the No. 2 terminal of the evaporator temperature sensor 2P connector. CLIMATE CONTROL UNIT 20P CONNECTOR

2. Measure the resistance between the No.1 and No. 2 terminals of the evaporator temperature sensor.




EVAPORATOR TEMPERATURE SENSOR 2P CONNECTOR Wire side of female terminals

40


I I 30 RESISTANCE

kQ

20

~

10

YES-Go to step 5.

I I

i

NO- Repair open in the wire between the climate control unit and the evaporator temperature sensor.•

I

~i

i'--

50 10

68 20

~

86 of 30°C

TEMPERATURE

Is the resistance within the specifications shown on the graph? YES - Go to step 3. NO- Replace the evaporator temperature sensor.. 3. Disconnect the climate control unit 20P connector.

(cont'd)

BACK

21-45

Climate Control OTe Troubleshooting (cont'd) 5. Check for continuity between the No. 11 terminal of the climate control unit 2ap connector and the No. 1 terminal of the evaporator temperature sensor 2P connector.

DTC indicator light H: A short ill the evaporator temperature sensor circuit 1. Disconnect the evaporator temperature sensor 2P connector.



2. Test the evaporator temperature sensor (see step 2 on page 21-45). Is the resistance within the specifications shown on the graph? YES- Go to step 3. NO- Replace the evaporator temperature sensor.•

EVAPORATOR TEMPERATURE SENSOR 2P CONNECTOR Wire side of female terminals


3. Disconnect the climate control unit 2ap connector. 4. Check for continuity between the No. 14 terminal of the climate control unit 2ap connector and body ground.

YES-Check for loose wires or poor connections at the climate control unit 2ap connector and at the evaporator temperature sensor 2P connector. If the connections are good, substitute a known-good climate control unit, and recheck. Ifthe symptom/ indication goes away, replace the original climate control unit.•



1

2

3

4

1'5<1 6

5

7

8

9 10

11 12 13 14 15 16 17 18 19 20

~MN

NO-Repair open in the wire between the climate control unit and the evaporator temperature sensor. II

Is there continuity? YES- Repair short to body ground in the wire between the climate control unit and the evaporator temperature sensor.• NO-Substitute a known-good climate control unit, and recheck. If the symptom/indication goes away, replace the original climate control unit..

21-46

BACK

OTC indicator light I: An open in the air mix control motor circuit

OTC indicator light J: A short in the air mix

control motor circuit





3. Check for continuity between following terminals of the climate control unit 20P connector and the air mix control motor 7P connector. 20P: 7P: No.1 No.3 No.7 No.2 No.9 No.1 No.11 No.5 No.7 No. 13

3. Check for continuity between body ground and the climate control unit 20P connector terminals No.1, 7,9,11 and 13 individually.





PNK/BLK

RED/WHT

2

3

4

5

6

7

8

9

10

=

11 12 13 14 15 16 17 18 19 20 YELl GRN

GRY


Q

Q Q

YES- Repair any short to body ground in the wire(s) between the climate control unit and the air mix control motor..

NO - Go to step 4. RED/WHT

AIR MIX CONTROL MOTOR 7P CONNECTOR


Is there continuity? YES - Check for loose wires or poor connections at the climate control unit 20P connector and at the air mix control motor 7P connector. If the connections are good, substitute a known-good climate control unit, and recheck. If the symptom/indication goes away, replace the original climate control unit.•

r

NO- Repair any open in the wire(s) between the climate control unit and the air mix control motor .•

(cont'd)

BACK

21-47

Climate Control OTe Troubleshooting (cont'd) 4. Turn the ignition switch ON (11), and check the same terminals for voltage.

DTC indicator light K: A problem in the air mix control linkage, door and motor 1. Test the ai r mix control motor, refer to the '98-02 Accord Service Manual (see page 21-20).

CLIMATE CONTROL UNIT 20P CONNECTOR Wire side of female terminals

Is the air mix control motor OK? YES-Substitute a known-good climate control unit, and recheck. Ifthe symptom/indication goes away, replace the original climate control unit.• NO-Go to step 2. 2. Remove the ai r mix control motor, refer to the '98-02 Accord Service Manual (see page 21-20).

3. Check the air mix control linkage and door for smooth movement.

Is there any voltage?

Do the air mix control linkage and door move smoothly?

YES-Repair any short to power in the wire(s) between the climate control unit and the air mix control motor. This short also damages the climate control unit. Repair the short to power before replacing the climate control unit.•

YES-Replace the air mix control motor.• NO- Repair the air mix control linkage or door.•

NO-Substitute a known-good climate control unit, and recheck. Ifthe symptom/indication goes away, replace the original climate control unit..

21-48

BACK

DTC indicator light L: An open or short in the

mode control motor circuit 1. Disconnect the mode control motor 7P connector.

4. Turn the ignition switch ON (II), and check the same terminals for voltage. CLIMATE CONTROL UNIT 20P CONNECTOR Wire side of female terminals

2. Disconnect the climate control unit 20P connector. 3. Check for continuity between body ground and the climate control unit 20P connector terminals No.5, 6,11,17,18,19 and 20 individually. CLIMATE CONTROL UNIT 20P CONNECTOR Wire side of female terminals

=

=

=

=

/s there any voltage?

YES- Repair any short to power in the wire(s) between the climate control unit and the mode control motor. This short also damages the climate control unit. Repair the short to power before replacing the climate control unit.• /s there continuity?

NO- Go to step 5.

YES-Repair any short to body ground in the wire (s) between the climate control unit and the mode control motor.• NO-Go to step 4.

(cont'd)

BACK

21-49

Climate Control DTC Troubleshooting (cont'd) 5. Turn the ignition switch OFF, and check for continuity between following terminals of the climate control unit 20P connector and the mode control motor 7P connector. 20P: 7P: No.1 No.5 No.2 No.6 No.7 No.11 No.17 No.3 No. 18 No.4 No.5 No.19 No. 20 No.6

OTC indicator light M: A problem in the mode control linkage, doors and motor 1. Test the mode control motor, refer to the '98-02 Accord Service Manual (see page 21-20).

Is the mode control motor OK? YES-Substitute a known-good climate control unit, and recheck. Ifthe symptom/indication goes away, replace the original climate control unit.. NO-Go to step 2.


2. Remove the mode control motor, refer to the '98-02 Accord Service Manual (see page 21-20).


3. Check the mode control linkage and doors for smooth movement.

VEL/GRN 1--I----I--+--+-+---1-t--I----I--I

Do the mode control linkage and doors move smoothly? YES- Replace the air mix control motor.•

Q

Q

Q

NO- Repair the mode control linkage or doors .•

MODE CONTROL MOTOR 7P CONNECTOR


Is there continuity? YES-Check for loose wires or poor connections at the climate control unit 20P connector and at the mode control motor 7P connector. If the connections are good, substitute a known-good climate control unit, and recheck. If the symptom/ indication goes away, replace the original climate control unit.• NO- Repair any open in the wire(s) between the climate control unit and the mode control motor..

21-50

BACK

DTC indicator light N: A problem in the

4. Connect the No.4 and No.5 terminals of the power transistor 5P connector with a jumper wire.

blower motor circuit 1. Turn the ignition switch ON (II) and turn the blower fan speed knob to HIGH.

POWER TRANSISTOR 5P CONNECTOR Wire side offemale terminals

Does the blower motor run? YES-Go to step 2. NO- Go to step 15. 2. Turn the ignition switch OFF, then disconnect the power transistor 5P connector. 3. Check for continuity between the No.5 terminal of the power transistor 5P connector and body ground.

POWER TRANSISTOR 5P CONNECTOR Wire side of female terminals

JUMPER WIRE


Does the blower motor run at high speed? YES-Go to step 6. NO- Repair open in the wire between the power transistor and the blower motor.. 6. Turn the ignition switch OFF. 7. Disconnect the jumper wire.

=


Is there continuity? YES-Go to step 4. NO-Check for an open in the wire between the power transistor and body ground. If the wire is OK, check for poor ground at G401 .•

(cont'd)

BACK

21-51

Climate Control OTe Troubleshooting (cont'd) 9. Check for continuity between the No.5 terminal of the climate control unit 8P connector and the No.3 terminal of the power transistor 5P connector.

11. Check for continuity between the No.6 terminal of the climate control unit 8P connector and the No.1 terminal of the power transistor 5P connector.





POWER TRANSISTOR 5P CONNECTOR Wire side of female terminals

POWER TRANSISTOR 5P CONNECTOR Wire side offemale terminals


Is there continuity? YES- Go to step 12. YES-Go to step 10. NO-Repair open in the wire between the climate control unit and the power transistor.• 10. Check for continuity between the No.5 terminal of the climate control unit 8P connector and body ground.

NO- Repair open in the wire between the climate control unit and the power transistor.• 12. Check for continuity between the No.6 terminal of the climate control unit 8P connector and body ground. CLIMATE CONTROL UNIT 8P CONNECTOR




4 4

= = Is there continuity? Is there continuity? YES- Repair short to body ground in the wire between the climate control unit and the power transistor.•

YES- Repair short to body ground in the wire between the climate control unit and the power transistor.• NO-Go to step 13.

NO-Go to step 11.

21-52

BACK

13. Reconnect the climate control unit 8P connector.


14. Testthe power transistor (see page 21-64).

19. Discor.nect the jumper wire.

Is the power transistor OK? YES- Check for loose wires or poor connections at the climate control unit 8P connector and at the power transistor 5P connector. If the connections are good, substitute a known-good climate control unit, and recheck. Ifthe symptom/indication goes away, replace the original climate control unit..

20. Remove the blower motor high relay, and test it, refer to the '98-02 Accord Service Manual (see page 22-52).

Is the relay OK? YES-Go to step 21. NO- Replace the blower motor high relay .•

NO - Replace the power transistor .• 15. Turn the ignition switch OFF, and check the No. 56 (40 A) fuse in the under-hood fuse/relay box, and No.3 (7.5 A) fuse in the driver's under-dash fuse/ relay box.

21. Connect the No.4 terminal ofthe blower motor high relay 5P connector to body ground with a jumper wire. BLOWER MOTOR HIGH RELAY 5P CONNECTOR


Are the fuses OK? YES- Go to step 16. NO- Replace the fuse(s), and recheck .• 16. Connect the No.2 terminal ofthe blower motor 2P connector to body ground with a jumper wire.

BLU/RED JUMPER WIRE

=

BLOWER MOTOR 2P CONNECTOR



Does the blower motor run? BLU/RED

JUMPER WIRE

YES - Go to step 23. NO- Repair open in the wire between the blower motor high relay and the blower motor..

=

23. Turn the ignition switch OFF. 17. Turn the ignition switch ON (II). 24. Disconnect the jumper wire.

Does the blower motor run? 25. Turn the ignition switch ON (II). YES - Go to step 18. NO- Go to step 31.

(cont'd)

BACK

21-53

Climate Control OTe Troubleshooting (cont'd) 26. Measure the voltage between the No.1 terminal of the blower motor high relay 5P connector and body ground. BLOWER MOTOR HIGH RELAY 5P CONNECTOR


29. Disconnect the climate control unit 8P connector. 30. Check for continuity between the No.4 terminal of the climate control unit 8P connector and the No.3 terminal of the blower motor high relay 5P connector. CLIMATE CONTROL UNIT 8P CONNECTOR


= Is there battery voltage? YES - Go to step 27. NO- Repair open in the wire between the blower motor high relay and the No.3 fuse in the driver's under-dash fuse/relay box .•

BLOWER MOTOR HIGH RELAY 5P CONNECTOR


27. Turn the ignition switch OFF. 28. Check for continuity between the No.5 terminal of the blower motor high relay 5P connector and body ground. BLOWER MOTOR HIGH RELAY 5P CONNECTOR


Is there continuity? YES- Check for loose wires or poor connections at the climate control unit 8P connector and at the blower motor high relay 5P connector. If the connections are good, substitute a known-good climate control unit, and recheck. If the symptom/ indication goes away, replace the original climate control unit.• NO-Repair open in the wire between the climate control unit and the blower motor high relay .•

= Is there continuity? YES-Go to step 29. NO-Check for an open in the wire between the blower motor high relay and body ground. Ifthe wire is OK, check for poor ground at G401 .•

21-54

BACK

31. Disconnect the jumper wire.

36. Measure the voltage between the No.4 terminal of the blower motor relay 4P socket and body ground.

32. Disconnect the blower motor 2P connector. 33. Measure the voltage between the No.1 terminal of the blower motor 2P connector and body ground.

BLOWER MOTOR RELA V 4P SOCKET

BLOWER MOTOR 2P CONNECTOR



=

NO - Replace the under-hood fuse/relay box .•

Is there battery voltage? 37. Turn the ignition switch ON (II). YES - Replace the blower motor.• 38. Measure the voltage between the No.1 terminal of the blower motor relay 4P socket and body ground.


BLOWER MOTOR RELAV 4P SOCKET

35. Remove the blower motor relay from the underhood fuse/relay box, and test it, refer to the '98-02 Accord Service Manual (see page 22-52).

Is the relay OK? YES-Go to step 36. NO - Replace the blower motor relay .•

= Is there battery voltage? YES - Go to step 39. NO- Repair open in the wire between the No.3 fuse in the driver's under-dash fuse/relay box and the blower motor relay .•

(cont'd)

BACK

21-55

Climate Control OTC Troubleshooting (cont'd) 39. Turn the ignition switch OFF. 40. Check for continuity between the No.2 terminal of the blower motor relay 4P socket and body ground. BLOWER MOTOR RELAY 4P SOCKET

ECT Sensor Circuit Troubleshooting 1. Check the malfunction indicator lamp (MIL).

Does the malfunction indicator lamp come on? YES-Read the DTC and perform the appropriate troubleshooting for that code. Refer to the fuel and emissions section ofthe '98-02 Accord Service Manual (see page 11-3) .• NO-Go to step 2. 2. Turn the ignition switch OFF. 3. Disconnect the ECT sensor 2P connector. 4. Disconnect the climate control unit 8P connector.

= Is there continuity? YES- Repair open in the wire between the blower motor relay and the blower motor..

5. Turn the ignition switch ON (II). 6. Measure the voltage between the No.3 terminal of the climate control unit 8P connector and body ground. CLIMATE CONTROL UNIT 8P CONNECTOR


NO-Check for an open in the wire between the blower motor relay and body ground. If the wire is OK, check for poor ground at G202 .•

2

3

RED/WHT

1---+-'''9"'-1-+--I

4

7

8

=

Is there about 5 volts? YES-Check for loose wires or poor connections at the climate control unit 8P connector and at the ECT sensor 2P connector. If the connections are good, substitute a known-good climate control unit, and recheck. If the symptom/indication goes away, replace the original climate control unit.• NO- Repair open in the wire between the climate control unit and the ECT sensor..

21-56

BACK

Climate Control Power and Ground Circuits Troubleshooting 1. Check the No. 54 (40A) fuse in the under-hood fuse/relay box, the No.3 (7.5A) fuse in the driver's under-dash fuse/relay box, and the No. 13 (7.5A) fuse in the passenger's under-dash fuse/relay box.

6. Measure the voltage between the No.2 terminal of the climate control unit 8P connector and body ground. CLIMATE CONTROL UNIT 8P CONNECTOR Wire side of female terminals

Are the fuses OK? YES-Go to step 2. NO- Replace the fuse(s), and recheck .• 2. Disconnect the climate control unit 8P connector. 3. Turn the ignition switch ON (II). 4. Measure the voltage between the No.1 terminal of the climate control unit 8P connector and body ground. CLIMATE CONTROL UNIT 8P CONNECTOR

= Is there battery voltage? YES-Go to step 7.


NO-Repair open in the wire between the No. 13 fuse in the passenger's under-dash fuse/relay box and the climate control unit.•

BlK/VEl

7. Check for continuity between the No.8 terminal of the climate control unit 8P connector and body ground.

4


= Is there battery voltage? YES - Go to step 5. NO-Repair open in the wire between the No.3 fuse in the driver's under-dash fuse/relay box and the climate control unit.• 5. Turn the ignition switch OFF.

Is there continuity? YES-Check for loose wires or poor connections at the climate control unit 8P connector. If the connections are good,substitute a known-good climate control unit, and recheck. Ifthe symptom/ indication goes away, replace the original climate control unit.• NO-Check for an open in the wire between the blower motor high relay and body ground. Ifthe wire is OK, check for poor ground at G401 .•

BACK

21-57

Climate Control Recirculation Control Motor Circuit Troubleshooting 1. Check the No.3 (7.5A) fuse in the driver's underdash fuse/relay box.

8. Check for continuity between the No.3 and No.4 terminals of the climate control unit 20P conector and body ground individually.

Is the fuses OK? CLIMATE CONTROL UNIT 20P CONNECTOR

YES-Go to step 2.


NO-Replace the fuse, and recheck .• 2. Disconnect the recirculation control motor 7P connector.

GRN/RED

1


2

I 3

I

GR:HT

4

5

6

7

8

9

10

11 12 13 14 15 16 17 18 19 20

4. Measure the voltage between the No.1 terminal of the recirculation control motor 7P connector and body ground.

Q

Q




YES- Repair any short to body ground in the wire (s) between the climate control unit and the recirculation control motor.• NO-Go to step 9. 9. Turn the ignition switch ON(II), and check the same wires for voltage.

=



GRN/RED

NO-Repair open in the wire between the recirculation control motor and the No.3 fuse in the driver's under-dash fuse/relay box .•

I I GR~HT 3

4

5

6

7

8

9

10

1

2

11

12 13 14 15 16 17 18 19 20


'Y.

'Y. 6. Test the recirculation control motor, refer to the '98-02 Accord Service Manual (see page 21-22).

=

Is the recirculation control motor OK?

Is there any voltage?

YES-Go to step 7.

YES- Repair any short to power in the wire(s) between the climate control unit and the recirculation control motor. This short also damages the climate control unit. Repair the short to power before replacing the climate control unit.

NO-Goto step 11. 7. Disconnect the climate control unit 20P connector.

•

NO- Go to step 10.

21-58

BACK

AIC Pressure Switch Circuit Troubleshooting 10. Turn the ignition switch OFF, and check for continuity between the following terminals of the climate control unit 20P connector and the reci rculation control motor 7P connector. 20P: 7P: No.3 No.5 No.4 No.7 CLIMATE CONTROL UNIT 20P CONNECTOR


1. Disconnect the NC pressure switch 2P connector. 2. Turn the ignition switch ON (II). 3. Measure the voltage between the No.2 terminal of the NC presure switch 2P connector and body ground. AIC PRESSURE SWITCH 2P CONNECTOR Wire side of female terminals

= RECIRCULATION CONTROL MOTOR 7P CONNECTOR

Is there about 5 volts?



YES-Go to step 4.

YES-Check for loose wires or poor connections at the climate control unit 20P connector and at recirculation control motor 7P connector. If the connections are good, substitute a known-good climate control unit, and recheck. If the symptom/ indication goes away, replace the original climate control unit.•

NO-Go to step 10.

NO-Repair any open in the wire(s) between the climate control unit and the recirculation control motor..

4. Turn the ignition switch OFF. 5. Check for continuity between the No.1 and No.2 terminals of the NC pressure switch.

AIC PRESSURE SWITCH

11. Remove the recirculation contol motor, refer to the '98-02 Accord Service Manual (see page 21-22). 12. Check the recirculation control linkage and doors for smooth movement.

'---~

Do the recirculation control linkage and doors move smoothly?


YES - Replace the recirculation control motor .•

YES-Go to step 6.

NO- Repair the recirculation control linkage or doors .•

NO-Goto step 11.

Qf----'

(cont'd)

BACK

21-59

Climate Control AIC Pressure Switch Circuit Troubleshooting (cont'd) 6. Reconnect the AlC pressure switch 2P connector. 7. Disconnect the climate control unit 20P connector.

10. Using a 8ackprobe Set, measure the voltage between the No. 27 terminal ofthe PCM connector A (32P) and body ground with the PCM connectors connected.



9. Measure the voltage between the No.2 terminal of the climate control unit 20P connector and body ground. CLIMATE CONTROL UNIT 20P CONNECTOR Wire side of female terminals

IVEL/GRN 1

2

3

4


V

V

5 6 2 3 4 8 9 12 13 14 15 y" 17 18 19 20 21 28 29 30 25 26 27

/

1/

10 23

/ 24

fLU IRED r>
5

6

7

8

9

10

=

11 12 13 14 15 16 17 18 19 20

Is there about 5 volts?

':i.

= Is there about 5 volts? YES-Check for loose wires or poor connections at the climate control unit 20P connector and at the AlC pressure switch 2P connector. If the connections are good, substitute a known-good climate control unit, and recheck. If the symptom/ indication goes away, replace the original climate control unit.•

NO- Repair open in the wire between the climate control unit and the AlC pressure switch .•

YES- Repair open in the wire between the PCM and the AlC pressure switch .• NO-Check for loose wires or poor connections at the PCM connector A (32P). If the connections are good, substitute a known-good PCM, and recheck. Ifthe symptom/indication goes away, replace the original PCM .• 11. Check for proper AlC system pressure. Is the pressure within specifications?

YES- Replace the AlC pressure switch .• NO- Repair the AlC pressure problem .•

21-60

BACK

In-car Temperature Sensor Replacement

In-car Temperature Sensor Test Check for a change in resistance by heating or cooling the sensor with a hair drier.

1. Remove the in-car temperature sensor (A) from the dashboard, then disconnect the 2P connector (B) and the air hose (C). Be careful not to damage the sensor and the dashboard. B

Compare the resistance reading between the No.1 and No.2 terminals of the in-car temperature sensor with the specifications shown in the graph; the resistance should be within the specifications. IN-CAR TEMPERATURE SENSOR

'----{Ql-----'

2. Install the sensor in the reverse order of removal. Be sure to connect the air hose securely.

RESISTANCE (kQ)

12 11 10 9 8 7 6 5 4 3 2 1

1\

\

\

\

"-

14 -10

32 0

""'" 50 10

"I'-..

........

68 20

b-

86 30

104 of 40°C

TEMPERATURE

BACK

21-61

Climate Control Outside Air Temperature Sensor Replacement

Outside Air Temperature Sensor Test

1. Disconnect the 2P connector from the outside air temperature sensor. Release the lock, and remove the outside air temperature sensor.

Dip the sensor in ice water, and measure the resistance. Then pour hot water on the sensor, and check for a change in resistance.

~Zn

Compare the resistance reading between the No.1 and No.2 terminals of the outside air temperature sensor with the specifications shown in the graph; the resistance should be within the specifications.

,

....

.

OUTSIDE AIR TEMPERATURE SENSOR

I

Q

2. Install the sensor in the reverse order of removal.

12 11 10

RESISTANCE (kQ)

9 8 7 6 5 4 3 2 1

1\

\

\

\

""'"1"14 -10

32 0

50 10

"- r-.....

.........

68 20

TEMPERATURE

21-62

BACK

r--

86 30

104 OF 40°C

Sunlight Sensor Replacement

Sunlight Sensor Test

1. Remove the sunlight sensor from the dashboard, then disconnect the 2P connector. Be careful not to damage the sensor and the dashboard.

Turn the ignition switch ON (II). Measure the voltage between the terminals with the (+) probe on the No.1 terminal and the (-) probe on the No.2 terminal with the 2P connector connected. The voltage will not change under the light of a flashlight or a fluorescent lamp. Voltage should be: • 3.6-3.7 V or more with the sensor out of direct sunlight . • 3.3-3.5 V or less with the sensor in direct sunlight.

WHT/RED

VEL/GRN

2. Install the sensor in the reverse order of removal.

BACK

21-63

Climate Control Power Transistor Test

Climate Control Unit Removal and Installation

1. Disconnect the 5P connector from the power transistor. 1. Remove the center panel together with the climate control unit, refer to the '98-02 Accord Service Manual (see page 20-86).

2. Measure the resistance between the No.1 and No. 4 terminals of the power transistor. If should be approximately 1.4 -1.5 k Q .

2. Remove the self-tapping screws and the climate control unit (A) from the center pagnel (B) .

• If the resistance is within the specifications, go to step 3. • If the resistance is not within the specifications, replace the power transistor.

~

POWER TRANSISTOR

3. Carefully release the lock tab on the No.3 terminal (ORN/BLK) (A) in the 5P connector, then remove the terminal and insulate it from body ground.

3. Install the control unit in the reverse order of removal. After installation, operate the control unit controls to see whether it works properly.

B

4. Run the self-diagnosis function to comfirm that there are no problems in the system (see page 21-34).

o

A

4. Connect a 1.2-3.4 W bulb (B) between the No.3 and the No.4 cavity on the 5P connector. ~;

Reconnect the 5P connector to the power transistor.

6. Turn the ignition switch ON (II), and check that the blower motor runs . • If the blower motor does not run, replace the power transistor. • Ifthe blower motor runs, replace the climate control unit.

21-64

BACK

Climate Control Unit Disassembly and Reassembly 1. Remove the fan switch (A) and temperature control (8) dials, then remove the front (C), temperature control (D) and fan switch (E) panels. Remove AlC switch (F), MODE control switch (G), AUTO switch (H), OFF switch (I), recirculation. control switch (J), front defroster switch (K) and rear defogger switch (L) buttons. D

E G

J

A

2. Reassemble the control unit in the reverse order of removal.

BACK

21-65

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If electrical maintenance is required) The Accord Sedan/Coupe (V6) SRS includes a driver's airbag located in the steering wheel hub, a passenger's airbag located in the dashboard above the glove box, and side airbags ('00-01 models) located in the front seat-backs. Information necessary to safely service the SRS is included in the '98-02 Accord Sedan/Coupe (L4) Service Manual, PIN 61S8400. Items marked with an asterisk (*) on the contents page include or are located near SRS components. Servicing, disassembling or replacing these items will require special precautions and tools, and should therefore be done by and authorized Honda dealer.

• To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all SRS service work must be performed by an authorized Honda dealer. • Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury caused by unintentional deployment of the frontal airbags (and/or side airbags on some '00-02 models). • Do not bump the SRS unit, Otherwise, the system may fail in case of a collision, or the airbags may deploy when the ignition switch is ON (II). • SRS electrical wiring harnesses are indicated with yellow color coding. Related components are located in the steering column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats ('00-02 models) and around the floor ('00-02 models). Do not use electrical test equipment on these circuits.

BACK

Body Electrical Relay and Control Unit Locations ................ Connectors and Harnesses ...................... ..... Fuse/Relay Boxes .............. .................... ........ Power Distribution ........................................ Ground Distribution .............. ................ ........ Battery ......................... ........................... ........ Relays

22-2 22-4 22-23 22-26 22-29 22-30

Power Relay Test ...................................................... 22-31

* Gauges Gauge Bulb Replacement ........................................ 22-32 Circuit Diagram ......................................................... 22-33

Safety Indicator System Circuit Diagram ......................................................... 22-38

* Stereo Sound System

Component Location Index ..................................... Circuit Diagram ......................................................... Audio Unit Connector Replacement ....................... Radio Remote Switch Test .......................................

22-40 22-41 22-42 22-42

Homelink Remote Control System Circuit Diagram ......................................................... 22-43 Test ............................................................................. 22-43

Power Seat ('01-02 Sedan) Component Location Index ..................................... Circuit Diagram ......................................................... Motor Test ................................................................. Switch Test/Replacement ........................................

22-44 22-45 22-46 22-47

Seat Heaters-Canada Component Location Index ..................................... 22-48 Circuit Diagram ......................................................... 22-49 NOTE: Refer to the '98-02 Accord Service Manual, PIN 61S8400, for the items not shown in this section.

Outline of V6 Model Changes 1998 model: · The ASS control unit location has been changed; related component locations are included. · A blower motor high relay and a radiator fan control module have been added; related component locations are included. · The wire harness and ground locations have been changed. · The bulb locations in the gauges have been changed. · The stereo sound system has been changed. · Homelink remote control system has been added; related information is included. · Circuit diagrams which differ from those in the '98 Accord Service Manual have been included. 1999 model: · There are no changes to the 1998 model. 2000 model: · There side airbag system has been added; related information is included. · The engine wire harness has been changed. · Circuit diagrams which differ from theose in the '98-99 Accord Service Manual have been included. 2001 model: · The seat heater relay location has been changed · The ASS/TCS control unit, TCS relay, and TCS indicator have been added. · The wire harness and ground locations have been changed. · The passenger's power seat has been added in the sedan. · Circuit diagrams which differ from those in the '98-01 Accord Service Manual have been included. 2002 model: · There are no changes to the 2001 model.

r--:'I L:.I

Relay and Control Unit Locations Engine Compartment

SEAT HEATER RELAV (Canada) '98-00 models) Wire colors: BlK/VEL, BlK, WHT /BlK and WHT/GRN TCSRElAV '01-02 models) Wire colors: GRN/VEl, BRN/BlK, RED/BLU and BLU

t t

HORNRELAV

J )

CONDENSER FAN RElAV

RADIATOR FANRELAV

ElD UNIT ABS FAil-SAFE RElAV (Wire colors: VEl/GRN, BlK, lBRN/BlK and WHT/GRN ABS PUMP MOTOR RELAV (Wire colors: VEL/RED, ) l BRN/BlK, WHT/BlU and WHT

22-2

INTERMITTENT WIPERRELAV Wire colors: GRN/BlK, [ WHT, BlK, GRN/RED, and BlU/WHT

BACK

J

~

I..!!:..I Dashboard

BLOWER MOTOR HIGH RELAV (Wire colors: BlK/VEl, lBlU/ORN, BLU/RED and BlK

CLIMATE CONTROL UNIT

J

SEAT HEATER RELAV (Canada) ('01-02 models)

(Wire colors: BlK/VEl, BlK, lWHT/BlK, and WHT/GRN

J RADIATOR FAN CONTROL MODULE

ABS CONTROL UNIT ('98-00 models)

ABS/TCS CONTROL UNIT ('01-02 models)

BACK

22-3

Connectors and Harnesses Connector Index Identification numbers have been assigned to in-line connectors. The number is preceded by the letter "C" for connectors, "G" for ground terminals or "T" for non-ground terminals.

Harness Engine Compartment Starter cable Battery ground cable Engine ground cable Engine wire harness

Right engine compartment wire harness Left engine compartment wire harness Dashboard wire harness B (left branch) Dashboard wire harness B (right branch) Dashboard wire harness A

T1 T2 and (+) T3 G1 and (-) T4 G2 C103 through C108 T101 and T102 G101 and G102 G201 through G20S G301 and G302

Dashboard

Location Others IFloor, Door, Trunk and Roof)

(see Dace 22-5) (see page 22-5) (see page 22-5) (see page 22-6)

C201 through C204

Isee page 22-12)

C103 and C104 C301 and C304 C301, C401 and C402 G401 C201 through C203 and C403 C204, C302 and C401 GS01 and GS02

(see page 22-14)

Left side wire harness

Right side wire harness

Rear wire harness

Isee page 22-16) (see page 22-16) CS01 through CSOS and CS82 GS03 and GS04 CS01 and CSS1 through CSS7 GSS1 and GSS2 CS81 through CS86 and C8S1 GS81 CSS4 and C601 G601 CS02

Moon roof wire harness

Roof wire harness

Driver's power seat wire harness

CSS1

Passenger's power seat wire harness ('01 Sedan) Driver's door wire harness

C701 C631 and C632

Passenger's door wire harness

Left rear door wire harness

CSS3

Right rear door wire harness

CS81

Ignition switch harness

C404

SRS main harness

CS03

SRS floor harness (Sedan)

CSS6, CSS7, CS83 and CS84 G801 CSOS and C8S1

C8S1

OPDS wire harness (with side airbags) Rear window defogger wi re harness

22-4

Notes

BACK

(see page 22-18)

Refer to the '98-02 Accord Service Manual (see page 22-24) (see page 22-20)

Refer to the '98-02 Accord Service Manual isee pjlge 22-26) Refer to the '98-02 Accord Service Manual (see page 22-30) Refer to the '98-02 Accord Service Manual (see page 22-30) Refer to the '98-02 Accord Service Manual Isee p_age 22-31) (see page 22-22) Refer to the '98-02 Accord Service Manual (see page 22-32) Refer to the '98-02 Accord Service Manual (see page 22-34) Refer to the '98-02 Accord Service Manual (see paoe 22-36) Refer to the '98-02 Accord Service Manual (see Dace 22-37) Refer to the '98-02 Accord Service Manual (see Dace 22-38) Refer to the '98-02 Accord Service Manual (see page 22-38) Refer to the '98-02 Accord Service Manual (see Dace 22-39) Refer to the '98-02 Accord Service Manual (see page 22-42) Refer to the '98-02 Accord Service Manual (see paoe 22-42)

r:'I I.!>!.I Connector to Harness Index Starter Cable Connector or Terminal T1 T2

. Ref 1 2

Cavities

Ref 6 5

Cavities

(+1

Location Right side of engine compartment Left side of enQine compartment Battery

Connects to

Notes

Under-hood fuse/relay box Starter motor Battery positive terminal

Battery Ground Cable Connector or Terminal T3 G1

(-I

Location Left side of enQine compartment Left side of engine compartment Battery

Connects to

Notes

Transmission housinQ Body ground via battery Qround cables Batterv neQative terminal

Engine Ground Cable ('99 mode\) Connector or Terminal T4 G2

Ref 8 7

Cavities

Location Middle of engine compartment Right side of engine compartment

Connects to

Notes

Valve cover Body ground via engine Qround cable

Engine Ground Cable ('00-02 models) Connector or Terminal T4 G2

Ref 4 3

Cavities

Location Left side of enQine compartment Left side of engine compartment

Connects to

Notes

Transmission housinQ Body ground via engine ground cable

STARTER CABLE

~'----J---4

8

BACK

22-5

Connectors and Harnesses Connector to Harness Index (cont'd) Engine Wirre Harness ('98-99 models) Connector or Terminal

Ref

Cavities

42 27 28 15

4 2 2 10

Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment

4 16 41

2 2 1

Right side of engine compartment Right side of engine compartment Middle of engine compartment

39

2

Middle of engine compartment

45 40

2 6

Right side of engine compartment Middle of engine compartment

35 18 14 13 32

3 3 3 2 3

Right side of engine compartment Right side of engine compartment Right side of engine compartment Middle of engine compartment Right side of engine compartment

29 38 7 9 12 6 8 10 2 19 20 21 11

2 3 2 2 2 2 2 2 1 25 31 16 4

Right side of engine compartment Right side of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Right side of engine compartment Under middle of dash Under middle of dash Under middle of dash Middle of engine compartment

25 33 36 34 31 44 30 37 1 5 23

2 1 2 2 1 4 1 3 2 1 14

Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment

C104

24

10


C105 (Junction connector) C106 (Junction connector) T101 T102 G101

22 17 3 43 26

20

Right side of engine compartment Riqht side of enqine compartment Under-hood fuse/relay box Alternator Right side of engine compartment

Alternator AfT clutch pressure control valve A AfT clutch pressure control valve B Transmission range switch (AfT gear position switch) CKPsensor Countershaft speed sensor Coolant temperature gauge sending unit Engine coolant temperature (ECT) sensor Radiator fan switch B Exhaust gas recircuration (EGR) control solenoid valve Idle air control (lAC) valve Ignition coil Ignition control module (lCM) Intake air temperature (IAT) sensor Lock-up control solenoid valve and shift control solenoid valve A Mainshaft speed sensor MAP sensor No.1 fuel injector No.2 fuel injector No.3 fuel injector No.4 fuel injector No.5 fuel injector No.6 fuel injector Oil pressure switch PCM connector B PCM connector C PCM connector D Primary heated oxygen sensor (Primary H02S) Radiator fan switch A Second. clutch pressure switch Shift control solenoid valve B Shift control solenoid valve C Starter solenoid TDCsensor Third clutch pressure switch Throttle position (TP) sensor VTEC pressure switch VTEC solenoid valve C103

22-6

8

Location

BACK

Connects to

Left engine compartment wire harness (see page 22-14) Left engine compartment wire harness (see page 22-14)

Engine ground via engine wire harness

Notes

r--:'I

~

8 9 10 11

45

27

44

28 ENGINE WIRE HARNESS

29 30 31

43

42

41

40 39

38 37

36 35 34 33 32

(cont'd)

BACK

22-'1

Connectors and Harnesses Connector to Harness Index (cont'd) Engine Wire Harness ('00-02 models) Connector or Terminal

Alternator AfT clutch pressure control valve A AfT clutch pressure control valve B Transmission range (TR) switch (AfT gear position switch) CKP sensor Countershaft speed sensor Engine coolant temperature (ECT) sensor Exhaust gas recircuration (EGR) control solenoid valve Idle air control (lAC) valve Intake air temperature (lAT) sensor Lock-up control solenoid valve and shift control solenoid valve A Mainshaft speed sensor MAP sensor No.1 fuel injector No.2 fuel injector No.3 fuel injector No.4 fuel injector No.5 fuel injector No.6 fuel injector No.1 ignition coil No.2 ignition coil NO.3 ignition coil No.4 ignition coil No.5 ignition coil No.6 ignition coil Oil pressure switch PCM connector B PCM connector C PCM connector D

22-8

Ref

Cavities

46 28 29 15

4 2 2 10

Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment

Location

4 16 41

2 2 2

Right side of engine compartment Right side of engine compartment Middle of engine compartment

40

6


36 14 33

3 2 3

Right side of engine compartment Middle of engine compartment Right side of engine compartment

30 39 7 10 13 49 45 43 8 9 11 48 44 42 2 19 20 21

2 3 2 2 2 2 2 2 3 3 3 3 3 3 1 25 31 16

Right side of engine compartment Right side of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Middle of engine compartment Right side of engine compartment Under middle of dash Under middle of dash Under middle of dash

BACK

Connects to

Notes

r--:'I I.!:..I

51

28 29

]~~~~==~~~tt--t-----30

~~-;;;;;;'~E¥f,,"ml"~I--I----\t-l.=:-H+-AI--- 31

50

45

43 41

37

35

33

(cont'd)

BACK

22-9

Connectors and Harnesses Connector to Harness Index (cont'd) Engine Wire Harness ('00-02 models) (cont'd) Connector or Terminal Primary H02S Radiator fan switch A Radiator fan switch B Secondary clutch switch pressure switch Shift control solenoid valve B Shift control solenoid valve C Starter solenoid TDCsensor Third clutch pressure switch Throttle position (TP) sensor VTEC pressure switch VTEC solenoid valve C103

Ref 12 26 51 34

Cavities 4 2 2 1

Location Middle of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment

37 35 32 50 31 38 1 5 24

2 2 1 4 1 3 2 1 14

Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment

C104

25

10


C105 (Junction connector) C106 (Junction connector) C107 (Junction connector) C108 (Junction connector) T101 T102 G101

22 17 18 23 3 47 27

20 8 14 20

Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Under-hood fuse/relay box Alternator Right side of engine compartment

G102

6

22-10


BACK

Connects to

Left engine compartment wire harness (see page 22-14) Left engine compartment wire harness (see page 22-14)

Body ground via engine wire harness Body ground via engine wire harness

Notes

r:-:'I I..:!:..I

78 91011

51

28 29

~~~~~==~r--ttr-t-----30 ~;;t.-;;;t.~'rIf,,"'tft \'\'E11----tt--'-=::::ttt---flf--- 31

\il~~fhpL-+I-J---32 50

49

34 45

43 41

39

37

35

BACK

33

22-11

Connectors and Harnesses Connector to Harness Index (cont'd) Rialht Enaine ComDartment Wire Harness Connector or Terminal ABS control unit connector A ABS control unit connector B ABS fail-safe relay ABS modulator unit ABS pump motor ABS pump motor relay ABS rightfront wheel sensor ABSrrCS control unit connector A ABSrrCS control unit connector B ABSrrCS control unit connector C ABSrrCS modulator unit AlC compressor clutch AlC pressure switch Condenserfan motor Cruise control actuator Diode (Lighting) ELD unit High beam cut relay Left horn Outside air temperature sensor Passenger's under-dash fuse/relay box connector D (see page 22-25) Passenger's under-dash fuse/relay box connector C (see page 22-25) Power steering pressure (PSP) switch Radiator fan motor Right front parking light Right front side marker light Right headlight (High beam) Right headlight (Low beam) Right horn Seat heater relay Secondary heated oxygen sensor (Secondary H02S) Security hood switch Taillight relay rcs relay Under-hood fuse/relay box connector D (see page 22-23) Under-hood fuse/relay box connector C (see page 22-23) Under-hood fuse/relay box connector B (see page 22-23) Under-hood fuse/relay box connector A (see page 22-23) Washer level switch Windshild washer motor C201

Ref 1 2 6 22 23 5 20 45 1 2 22 31 25 30 21 40 12 42 26 28 4

Cavities 12 22 4 10 2 4 2 26 16 12 23 1 2 2 4 2 3 4 1 2 3

3

18


19 24 33 39 32 34 29 7 18

2 2 2 3 2 2 1 4 4

Middle of engine compartment Middle of engine compartment Behind right headlight Behind right of front bumper Behind right headlight Behind right headlight Behind middle of front bumper Right side of engine compartment Right side of engine compartment

27 41 7 8

2 4 4 16

Behind middle offront bumper Behind right kick panel Right side of engine compartment Right side of engine compartment

9

3


10

7


11

18


38 37 13

2 2 16

Behind right offront bumper Behind right of front bumper Under right side of dash

C202

14

7


C203

15

5


C204

16

22


G201

35


G202

17


G203

36


G204

43


G205

44


* 1: * 2:

Location Behind right kick panel Behind right kick panel Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Right side of engine compartment Behind right kick panel Behind right kick panel Behind right kick panel Right side of engine compartment Right side of engine compartment Behind condenser fan motor Middle of engine compartment Right side of engine compartment Behind right kick panel Inside under-hood fuse/relay box Behind right kick panel Behind middle offront bumper Behind middle offront bumper Behind right kick panel

'98-00 models '01-02 models

22-12

BACK

Connects to

Notes *1 *1 * 1 *1

*2 *2 *2 *2

Canada Canada

* 1

*2

Canada Dashboard wire harness B (see page 22-16) Dashboard wire harness B (see page 22-16) Dashboard wire harness B (see page 22-16) Dashboard wire harness A (see page 22-18) Body ground Via right engine compartment wire harness Body ground Via right engine compartment wire harness Body ground Via right engine compartment wire harness Body ground Via right engine compartment wire harness Body ground Via right engine compartment wire harness

r--:'I

~

8

9

10 11/

UNDER-HOOD FUSE/RELA

V

BOX

17

cY~~::::::4=:::DC~

ABS RELA V BOX

24 25

44

27

29

36

35

BACK

22-13

Connectors and Harnesses Connector to Harness Index (cont'd) Left Engine Compartment Wire Harness Connector or Terminal

ABS left front wheel sensor Brake fluid level switch connector A

Ref

Cavities

17 6

2 1

Left side of engine compartment Left side of engine compartment

Location

7

1


13

20


Connects to

Notes

(+)

Brake fluid level switch connector B (-)

Driver's under-dash fuse/relay box connector E (see page 22-24) Driver's under-dash fuse/relay box connector C (see page 22-24) Engine mount control solenoid valve EVAP purge control solenoid valve Intermittent wiper relay Left front parking light Left front side marker light Left headlight (High beam) Left headlight (Low beam) Seat heater relay Test tachometer connector Windshield wiper motor C103

12

5


4 3 15 22 19 23 21 14 1 8 2

2 2 6 2 3 2 2 4 2 5 14

Left side of engine compartment Left side of engine compartment Left side of engine compartment Behind left headlight Behind left of front bumper Behind left headlight Behind left headlight Behind left kick panel Left side of engine compartment Left rear of engine compartment Left side of engine compartment

C104

16

10


C301

9

20


C302

10

16


C303 C304 G301

11 18 20

1 1

Above left kick panel Left side of enaine compertment Left side of engine compartment

5

G302

*:


,

01-02 models

22-14

BACK

* Engine wire harness (see page 22-6) Engine wire harness (see page 22-6) Dashboard wire harness B (see page 22-16) Dashboard wire harness A (see page 22-18) Coupe Coupe Body ground via left engine compartment wire harness Body ground via left engine compartment wire harness

r--:'I

~

5


14

LEFT ENGINE COMPARTMENT WIRE HARNESS

18

23

BACK

22-15

Connectors and Harnesses Connector to Harness Index (cont'd) Dashboard Wire Harness B (Left Branch) Connector or Terminal Brake switch Cable reel Combinaion light switch Data link connector (DLC) Daytime running lights control unit Driver's under-dash fuse/relay box connector (see page 22-24) Driver's under-dash fuse/relay box connector P (see page 22-24) Driver's under-dash fuse/relay box connector Q (see page 22-24) Ignition switch Immobilizer control unit Intermittent dwell time controller PGM-FI main relay Windshield wiper/washer switch C301

Ref 5 13 12 16 14 1

Cavities 4 4 14 16 14 20

3

7


2

22


11 10 8 7 6

7 5 2 7 8 20

Under left side of dash Under left side of dash Under left side of dash Under left side of dash In steering column covers Under left side of dash

C401

15

22


C402

4

8


C402

4

4


G401

17

a

9

Location Under left side of dash Under left side of dash Under left side of dash Under left side of dash Under left side of dash Behind left kick panel


Connects to

Left engine compartment wire harness (see page 22-14) Dashboard wire harness A (see page 22-18) Security system wire harness (Optiona/) Security system wire harness (Ootiona/) Body ground via dashboard wire harness B

Notes

Canada USA

DASHBOARD WIRE HARNESS B lIeft branch) Continues to Right Branch


5

9

10

11

13

\~ 16

17

22-16

BACK

r--:'I

~

Dashboard Wire Harness B (Right Branch) Connector or Terminal

Ref

Air mix control motor Blower motor Blower motor high relay Blower resister Climate control unit connector A Climate control unit connector B Evaporator temperature sensor Heater control panel Heater fan switch Mode control motor Passenger's under-dash fuse/relay box connector J (see page 22-25) Passenger's under-dash fuse/relay box connector K (see page 22-25) Power transistor Radiator fan control module Recirculation control motor C201

16 12 11 13 3 1 4 3 1 2

Cavities 7

8

16

9

16


10

4

17

8 7

2 4 5 20

8 2 22

7 7

Connects to

Location Under right side of dash Under right side of dash Under right side of dash Under right side of dash Under middle of dash Under middle of dash Under middle of dash Under middle of dash Under middle of dash Under middle of dash Behind right kick panel

5 6

16

Under right side of dash Under middle of dash Under middle of dash Under right side of dash

C202

15

7


C203

14

5


C403

7

2


Notes AUTOA/C MAN.A/C AUTOA/C AUTOA/C MAN.AlC MAN.A/C

AUTOA/C Right engine compartment wire harness (see page 22-12) Right engine compartment wire harness (see page 22-12) Right engine compartment wire harness (see page 22-12) Security system wire harness (OotionaU

DASHBOARD WIRE HARNESS B (right branch) Continues to Left Branch

2

~-+-_--8

9

12

BACK

22-17

Connectors and Harnesses Connector to Harness Index (cont'd) Dashboard Wire Harness A Ref 29 32

Cavities

Location

2 4

17 16 37 7 7 31 2

20 5 14 5 8 6 18

Behind middle of dash Middle of floor between front seats Behind audio unit Behind middle of dash Behind left side of dash Behind instrument panel Behind instrument panel Behind middle of dash Behind left kick panel

3

18


11 10 12 27 14 38 9 8 5

14 22 16 2 10 2 2 6 22

Behind gauges Behind gauges Behind gauges Behind glove box Behind middle of dash Behind left side of dash Behind instrument panel Behind instrument panel Behind left kick panel

23

22


36

1

Passenger's seat heater switch Passenger's under-dash fuse/relay box connector H (see page 22-25) Passenger's under-dash fuse/relay box connector I (see page 22-25) PCM connector A Right tweeter Shift lock solenoid

30 21

6 18

Middle offloor between front seats Behind middle of dash Behind right kick panel

22

18


28 20 34

32 2 2

Sunlight sensor SRS memory erase signal (MES) SRS unit C204

15 4 33 26

2 2 8 22

Behind middle of dash Behind instrument panel Middle offloor between front seats Behind middle of dash Behind left kick panel Middle offloor Behind right side of dash

C302

39

16


C401

40

22


C501

42

18


C502

6

7

Behind instrument panel

C503

13

3


C503

13

2


C503

13

8


C504

41

2


C505

35

6

Middle offloor

C582

25

16

Behind right side of dash


Accessory socket NT gear position console lighVparking pin switch Audio unit Clock Cruise control unit Cruise main switch Cruise main {TCS switch Driver's seat heater switch Driver's under-dash fuse/relay box connector I (see page 22-24) Driver's under-dash fuse/relay box connector K (see page 22-24) Gauge assembly connector A Gauge assembly connector B Gauge assembly connector C Glove box light Hazard warning switch In-car temperature sensor Left tweete r Moonroof switch Multiplex control unit (driver's) connector B Multiplex control unit (passenger's) connector B Parking brake switch

22-18

BACK

Connects to

Notes

* 1 *2

*2 *3 Right engine compartment wire harness (see page 22-12) Left engine compartment wire harness (see page 22-14) Dashboard wire harness B (see page 22-16) Left side wire hareness, refer to the '98-02 Accord Service Manual (see page 22-24) Moonroof wire harness, refer to the '98-02 Accord Service Manual (see page 22-30) SRS main harness, refer to the '9802 Accord Service Manual (see page 22-39) SRS main harness, refer to the '9802 Accord Service Manual (see page 22-39) SRS main harness, refer to the '9802 Accord Service Manual (see page 22-39) Security system wire harness (Optional) SRS floor harness, referto the '9802 Accord Service Manual (see page 22-39) Right side wire harness (see page 22-21)

* 1 '00 Sedan '00 Coupe

USA '00 Sedan with side airbags '00 Coupe

r--:'I

~

Ref

Cavities

C582


25

6

G501

18


G502

19


G503

1


G504

24


* 1:

* 2: * 3:

.

Location

Behind right side of dash

Connects to Right side wire harness (see page 22-20) Body ground via dashboard wire harness A Body ground via dashboard wire harness A Body ground via dashboard wire harness A Body ground via dashboard wire harness A

Notes

*2

98-00 models '01-02 models '00-02 Sedan. '01-02 Coupe

19

24

BACK

22-19

Connectors and Harnesses Connector to Harness Index (cont'd) Right Side Wire Harness (Sedan) Connector or Terminal ABS right rear wheel sensor Front passenger's side airbag inflator Passenger's door switch Passenger's seat belt switch Passenger's seat heater Passenger's seat heater Passenger's side impact sensor Passenger's under-dash fuse/relay box connector A (see page 22-25) Passenger's under-dash fuse/relay box connector G (see page 22-25) Right rear door switch Right rear speaker Right side seat belt tensioner Window antenna coil connector A C581

Ref 16 2 13 4 3 3 11 7

Cavities 2 2 1 3 3 4 2 20

8

3


15 14 18 1

1 2 2 1 10

Right quarter panel Right quarter panel Right B-pillar Middle of rear shelf Right side of floor

C582

9

6


C583

5

4

C584

6

4

C701

3

10

C851

12

4

G581

10

* * * *

1: 2: 3: 4:

17

Location Under right side of rear seat Under passenger's seat Right B-pillar Under passenger's seat Under passenger's seat Under passenger's seat Under passenger's seat Behind right kick panel



'00 model wIthout seat heater '98-99 models '00 model with seat heater '01-02 models

22-20

BACK

Connects to

Notes

*4 *1 *2 *3 *4 Canada

*4 Right rear door wire harness, refer to the '98-02 Accord Service Manual (see page 2237) Dashboard wire harness A, refer to the '98-02 Accord Service Manual (see page 2218) SRS main harness, refer to the '98-02 Accord Service Manual (see page 22-39) SRS main harness, refer to the '98-02 Accord Service Manual (see page 22-39) Passenger's seat wire harness (see page 22-22), OPDS wire harness, refer to the '98-02 Accord Service Manual (see paae 22-421 Body ground via right side wire harness

*4

*4

*4

*2 *4

r--:'I I.!:..I Right Side Wire Harness (Coupe) Connector or Terminal ABS right rear wheel sensor Passenger's door switch Passenger's seat belt switch Passenger's seat heater Passenger's seat heater Passenger's side airbag inflator Passenger's side impact sensor Passenger's under-dash fuse/relay box connector A (see page 22-25) Passenger's under-dash fuse/relay box connector G (see page 22-25) Right rear speaker Right side seat belttensioner Window antenna coil connector A C582

Ref 16 13 12 10 10 15 14 5

Cavities 2 1 3 3 4 2 2 20

6

3


Canada

17 9 18 7

2 2 1 16

Right quarter panel Right B-piller Middle of rear shelf Behind right kick panel

*5

C582

7

6


C583

2

4

C584

3

4

C585 (Connects to C586) C586 (Connects to C585) C851

4 8 11

1 1 4

G581

1

* * * * * *

1: 2: 3: 4: 5: 6:

Location Under right side of rear seat Right B-pillar Under passenger's seat Under passenger's seat Under passenger's seat Under passenger's seat Under passenger's seat Behind right kick panel

Connects to

* 1 *2 *3 *5

Dashboard wire harnessA (see page 22-18) Dashboard wire harnessA (see page 22-18) SRS main harness, refer to the '98-02 Accord Service Manual (see page 22-39) SRS main harness, refer to the '98-02 Accord Service Manual (see page 22-39)

Under passenger's seat Under passenger's seat


,

Notes

OPDS wire harness, refer to the '98-02 Accord Service Manual (see page 22-42) Body ground via right side wire harness

*4 *5 *6 *6 *6 *6 *6

00-02 model without seat heater '98-99 models '00-02 model with seat heater '00 model '01-02 models '00-02 models

18

17

16

15 14

BACK

22-21

Connectors and Harnesses Connector to Harness Index (cont'd) Passenger's Seat Wire Harness (4-way Adjustable) ('01-02 models) Connector or Terminal Passenger's power seat adjustment switch connector A Passenger's power seat adjustment switch connector B Passenger's seat belt switch Passenger's seat heater Recline motor Slide motor C701

Ref

Cavities

4

6

Location Right side of passenger's seat

2

6

Right side of passenger's seat

7

3 4

Under passenger's seat Under passenger's seat Under passenger's seat Under passenger's seat Right side of passenger's seat

5 1

6 3

2 2 10

Connects to

Right side wire harness (see paqe 22-20)

PASSENGER'S SEAT WIRE HARNESS /4-way Adjustable)

7

2

6 3 5

22-22

BACK

Notes

r--:'I I.!!!.I

Fuse/Relay Boxes Connector to Fuse/Relay Box Index Under-hood Fuse/Relay Box Ref 15 3 14 11 13 1 12 9 4 10

Socket A AlC compressor clutch relay B Blower motor relay C Condenser fan relay D Diode ELD unit Horn relay Headlight relay 1 Headlight relay 2 Radiator fan relay T1 T101

1

2

7 8 2 6 5

Terminal 18 4

Connects to Right engine compartment wire harness (see page 22-12)

7

Right engine compartment wire harness (see page 22-12)

4 3 4 16 2 3 4 4 4 4

Right engine compartment wire harness (see page 22-12) Right engine compartment wire harness (see page 22-12) Not used

Battery positive cable (see paae 22-5) Enaine wire harness (see oaoe 22-6)

3

('" ,.

4 11

5

0

13

{]

14

~

12

6

O [JO 0

[eJ [eJ

9 8

n

~§]

0

n n n 464748 LJ LJ LJ

n n n 43 44 45 LJ LJ LJ

7

BACK

15

22-23

Fuse/Relay Boxes Connector to Fuse/Relay Box Index (cont'd) Driver's Under-dash Fuse/Relay Box

A

Ref 11

Terminal 10

B

3

14

C D Diode Diode

5

F

10 7 1 2 4 9

20 6

G

8

18

H I

5 13 12 14 23 15

6 18 2 18

6

24

22

2

21 16 17 26 19 27 18 24 20 25

20 7 22 1 4 1 4 1 4 1

Socket

E

J K L M Multiplex control unit connector A N

0 p Q R Reverse relay S Starter cut relay T Turn signal/hazard relay

U

6

Connects to Left side wire harness, refer to the '98-02 Accord Service Manual (see page 22-24) Left side wire harness, refer to the '98-02 Accord Service Manual (see page 22-24) Left engine compartment wire harness (see page 22-14) Not used

Left engine compartment wire harness (see page 22-14) Driver's door wire harness, refer to the '98-02 Accord Service Manual (see page 22-32) Driver's door wire harness, refer to the '98-02 Accord Service Manual (see page 22-32) No used Dashboard wi re harness A (see page 22-18) Service check connector Dashboard wire harness A (see page 22-18) Not used Ignition switch harness, refer to the '98-02 Accord Service Manual (see page 22-38) (Plugs directly into the fuse box) SRS wire harness, refer to the '98-02 Accord Service Manual (see page 22-39) Dashboard wire harness B (see page 22-16) Dashboard wire harness B (see page 22-16) Dashboard wire harness B (see page 22-16) Optional connector Optional connector Optional connector

o

tional connector

23

21

........_ _~~ -1-ft----17

2o--t-Door~19

18

22-24

BACK

~I

r--:'I l=!..I Passenger's Under-dash Fuse/Relay Box Socket A Accessory relay B

Ref 10 15 4

Terminal 20 4 4

C 0 Diode Diode Diode E

9 5 1 2 3 8

18 3

----

F

7

20

G H I

6 18 12 17 13 11

3 18 18 16 16 24

14 16

4 4

J K Multiplex control unit connector A Power window relay Rear window defogger relay

Connects to Right side wire harness (see page 22-20) Roof wire harness, refer to the '98-02 Accord Service Manual (see page 22-30) Right engine compartment wire harness (see page 22-12) Right engine compartment wire harness (see page 22-12) Not used

2

Passenger's door wire harness, refer to the '98-02 Accord Service Manual (see page 22-34) Passenger's door wire harness, refer to the '98-02 Accord Service Manual (see page 22-34) Right side wire harness (see page 22-20) Dashboard wire harness A (see page 22-18) Dashboard wire harness A (see page 22-18) Dashboard wire harness B (see page 22-16) Dashboard wire harness B (see page 22-16) (Plugs directly into the fuse box)

1 2 3 11 4

18

12

5

9 13 6

8

16

7

BACK

15

14 .

22-25

Power Distribution Fuse to Components Index Under-hood Fuse/Relay Box Fuse Number 41 42 43 44 45 46 47

Amps

Wire color

100A 50A 20A

-WHT RED/GRN

20A

RED/YEL

15A 20A

WHT/GRN WHT/YEL

--

48 49 50 51 52 53 54 55 56 57 58

20A 15A 30A 40A 20A 40A 40A 40A 40A 20A 20A

59

20A

--

Component(s) or Circuit(s) Protected Battery, Power distribution Ignition switch (BAT) Right headlight, Daytime running Ii!::jhts control unit (Canada) Not used Left headlight, Daytime running lights control unit (Canada) Hight beam indicator, Hight beam cut relay (Canada) PGM-FI main relay, Data link connector (DLC) Ignition key light and key interlock solenoid, ABS control unit (BLS) Cruise control unit, PCM, Horn relay High mount brake light, Brake failure sensor, Trailer lighting connector Multiplex control unit (driver's)

Fuse/relay box socket WHT/GRN ABS-TCS control unit WHT/GRN Turn signal/hazard relay ABSpum~motor, No. 14 fuse (in~assenger's under-dash fuse/relay box) WHT WHT/BLU No.1 fuse (in passenger's under-dash fuse/relay box), Power window relay TCS fail-safe relay BLU WHT/GRN Rear window defogger relay No.9, 10, 11, 12 and 13 fuses (in passenger's under-dash fuse/rela,{box) YEL YEL/GRN No.2, 4, 5 and 6 fuses (in passenger's under-dash fuse/relay box) Blower motor YEL/BLK BLU/BLK Radiator fan motor BLU/YEL Condenser fan motor Fan control module (Radiator fan control module) WHT RED AlC compressor clutch WHT/GRN Driver's and front passenger's seat heaters (Canada)

4 11

5

1

6

9

1""11""11""1

46 47 48

L.I L.I L.I

8

1""11""11""1

43 44 45

L.I L.I L.I

7

22-26

BACK

~

t=:.I Driver's Under-dash Fuse/Relay Box Fuse Number 1

Amps 15A

2 3

10A 7.5A

Wire Color RED/WHT RED/BLU (or GRN) BLK/WHT (or GRN) BLK/YEL

4

7.5A

YEL/BLK

5 6

7.5A 15A

Fuse/relay box socket YEL/RED BLK/YEL

7

7.5A

YEL/GRN

8

7.5A

9

7.5A

YEL/BLK Fuse/relay box socket YEL

10 11 12

7.5A 15A 30A

Fuse/relay box socket YEL/RED BLK/YEL GRN/BLK

13

7.5A

BLU/ORN

Component(s) or Circuit(s) Protected PGM-FI main relay SRS unit (VA) SRS unit (VB) Blower motor high relay, Climate control unit, Heater control panel, Fan control module (Radiator fan control module), Recirculation control motor, Rear window defogger relay, Seat heater relay (Canada) ABS control unit, Power mirror actuators, Power mirror defoggers (Canada), ABS/TCS control unit ('01-02 models) Optional connector Daytime running lights control unit (Canada) Alternator, Cruise control unit, Cruise control main switch indicator, ELD unit, Engine mount control solenoid valve, Evaporative emission bypass solenoid valve, Evaporative emission purge control solenoid valve, Gauge assembly, PCM, Primary and Secondary heated oxygen sensors, Vent shut solenoid valve, TCS switch ('01-02 models) Multiplex control unit (driver's) (All '98-99 models and '00 Sedan), Windshield washer motor (All '98-99 models and '00-02 Sedan), OPDS unit (with side airbags) Accessory socket relay Optional connector Back-up lights, Brake failure sensor, Clock, DRL indicator light (Canada), Gauge assembly, Multiplex control unit (passenger's), Security system (USA except EX), Shift lock solenoid, Trailer lighting connector Multiplex control unit (driver's) Turn signal/hazard relay Ignition coils Windshield wiper intermittent relay, Windshield wiper motor, Windshield washer motor ('00-02 Coupe), Multiplex control unit (driver's) ('00-02 Coupe) PCM, PGM-FI main relay

11 10 9

8

(cont'd)

BACK

22-27

Power Distribution Fuse to Components Index (cont'd) Passenger's Under-dash Fuse/Relay Box Fuse NllImber 1 2 3 4 5 6 7

Amps 30A 20A 20A 20A 20A 10A 20A

Wire Color GRN RED RED BLU WHT/RED RED/BLU WHTNEL

8 9

20A 20A

10

10A (Sedan) 15A (Coupe)

BLU/BLK WHT/GRN WHT/RED RED/GRN

11 12 13

7.5A 20A 7.5A

Fuse/relay box socket WHT/BLU Fuse/relay box socket WHTNEL

Fuse/relay box socket 14

7.5A

GRN

15 16

20A 20A

GRN/WHT WHT/BLK

Component(s) or Circuit(s) Protected Moonroof motor Power seat rear up-down motor, Recline motor Passenger's power seat Slide motor ('01-02 Sedan) Power seat front up-down motor, Slide motor Passenger's power seat, Recline motor ('01-02 Sedan) Daytime running lights control unit (Canada) Moonroof open relay, Moonroof close relay, Left rear power window motor (Sedan), Multiplex control unit (passenger's) Passen~er's Qower window motor Audio unit Audio unit, Accessory socket Heater control panel, AfT gear position console light, Driver's seat heater switch light (Canada), Audio unit, Gauge lights, Cruise main switch light, Moonroof switch light, Clock, Hazard warning switch light, Glove box light, Vanity mirror lights, Front parking lights, Front side marker lights, Rear side marker lights, License plate light(s), Taillights, Trailer lighting connector, Climate control unit Multiplex control unit (driver's) Courtesy lights, Trunk lillht, Ceilinlllillht, Spotlillhts Multiplex control unit (passenger's) PCM, Heater control panel, Security indicator, Multiplex control unit (door), Gauge assembly, Clock, Climate control unit Multiplex control unit (driver's) Multiplex control unit (passenger's) ABS control unit ('98-00 models), ABS-TCS control unit ('01-02 models) Multiplex control unit (door) Right rear power window motor (Sedan)

2 3 --i~_-4

L-JIn--- 5 9

8

22-28

6

BACK

r:-:'I ~

Ground Distribution Ground to Components Index NOTE: All ground wires are BLK unless otherwise noted. Ground G1 G2 G101 and G102 ('00-01 models)

G201

G202 G203 G204 G205 G301 G302 G401

G501

G502 G503 G504 G551

G552 G581

G601 G801

Component or circuit grounded Battery, Transmission housinR Engine block PCM (PG1 and PG2 are BLK; LG1 and LG2 are BRN/BLK), Idle air control solenoid valve, Radiator fan switch, PGM-FI main relay, EGR control solenoid valve, Shift control solenoid valve assembly, AfT~ear ~osition switch, Radiator fan switch A and B, Ignition coils ('00 model) Shielding between the PCM and these components (all have braided wires): CKP sensor, TDC sensor, Primary and secondary heated oxygen sensors, Mainshaft speed senser, Countershaft speed sensor, VTEC pressure switch, Data link connector (DLC), Immobilizer control unit Condenser fan motor, Radiator fan motor, Right headlight (low beam), Right front parking light, Right front side marker light, Right front turn signal light, Hood switch (security), Windshield washer motor Seat heater relay ('98-00 modelsHCanada), Blower motor relay, ELD unit, ABS fail-safe relay, Power steering pressure switch, Cruise control actuator ABS pump motor, ABS/TCS modulator unit ('01-02 models) ABS control unit (2 wires), ABS/TCS control unit ('01-02 models) ABS control unit (2 wires), ABS/TCS control unit (2 wires) ('01-02 models) Left headlight (low beam), Left front parking light, Left front side marker light, Left front turn signal light, Washer level sensor (Canada) Brake fluid level switch, Windshield wiper motor, Intermittent wiper relay, Seat heater relay ('01-02 modelsHCanada) Multiplex control unit (driver's), Turn signal/hazard relay, Power window master switch, Driver's door key cylinder switch, Driver'S door lock switch, Driver's door lock knob switch, Ignition key switch, Daytime running lights control unit (Canada), Data link connector (DLC), Combination light switch, Heater control panel (2 wires), Fan control module (Radiator fan control module), Blower motor high relay, Power transistor, Climate control unit, Windshield wiper/washer switch Moonroof switch, Moonroof open relay, Moonroof close relay, Driver's seat heater switch (Canada), Front passenger's seat heater switch (Canada), Glove box light, Transmission range switch (AfT gear position switch), Clock, Audio unit, Accessory socket, Gauge assembly, Cruise control unit, Cruise control main switch, OPDS unit ('00 Sedan with side airbags), Fuel gauge sending unit ('00-02 Coupe), Front passenger's seat belt switch ('00 model), Memory erase signal (MES) connector ('01-02 models), Cruise control main/TCS switch ('01-02 models) Audio unit Multiplex control unit (driver's) Multiplex control unit (passenger's) Power mirror switch, Left power mirror defogger (Canada), Driver'S power window motor, Power window master switch (2 wires), High mount brake light, Driver's seat belt switch, Left rear door lock knob switch, Driver's power seat switch (2 wires), Driver'S seat heater (Canada) Fuel pump (FP), Fuel gauge sending unit (All '98-99 models, '00 Sedan, and '01-02 models) Homelink unit, Multiplex control unit (passenger's), Power window relay, Accessory relay, Vanity mirror lights, Spotlights, Passenger's door key cylinder switch, Passenger's door lock switch, Passenger's door lock knob switch, Front passenger's seat heater (Canada), Right power mirror defogger (Canada), Right rear door lock knob switch, OPDS unit (Coupe with side airbags, '01-02 Sedan with side airbags) Front passenger's seat belt switch ('01-02 models), Front passenger's power seat switch (2 wires) ('01-02 models) Taillights (right, left), License plate light, Trunk latch switch, Trunk key cylinder switch (security), Trunk actuator (security), Brake light failure sensor, Trailer lighting connector SRS unit (2 wires), Memory erase signal (MES) connector ('00 model)

BACK

22-29

Battery Battery Test I

AWARNING

A battery can explode if you do not follow the proper procedure, causing serious injury to anyone nearby. Follow all procedures carefully and keep sparks and open flames away from the battery. Use either a JCI or Bear ARBST tester, and follow the manufacturer's procedures. If you don't have one of these computerized tester, follow this conventional test procedure: 1. Be sure the temperature of the electrolyte is between 70°F (21°C) and 100°F (38°C). 2. Inspect the battery case for cracks or leaks. • If the case is damaged, replace the battery.• • If the case looks OK, go to step 3. 3. Check the indicator EYE. • If the EYE indicates the battery is charged, go to step 4. • If the EYE indicates a low charge, go to step 7. 4. Apply a 300 amp load for 15 seconds to remove the surface charge. 5. Wait 15 seconds, then apply a test load of 280 amps for 15 seconds. 6. Record battery voltage. • If voltage is above 9.6 volts, the battery is OK.• • If voltage is below 9.6 volts, go to step 7. 7. Charge the battery on High (40 amps) until the EYE shows the battery is charged, plus an additional 30 minutes. If the battery charge is very low, it may be necessary to bypass the charger's polarity protection circuitry. • If the EYE indicates the battery is charged within 3 hours, the battery is OK.• • Ifthe EYE indicates the battery is not charged within 3 hours, replace the battery.•

22-30

BACK

r:-:'I l.!!:..I

Relays Power Relay Test Identify the relay, then do the test listed for it.

Normally-open type A:

NOTE: Refer to the '98-02 Accord Service Manual for the relay input test except that it is mentioned in this manual (see page 22-52)

Check for continuity between the terminals.

I

Rela~

I

Test Normally-open type A

• There should be continuity between the No.1 and No. 2 terminals when power and ground are connected to the No.3 and No.4 terminals. • There should be no continuity between the No.1 and No.2 terminals when power is disconnected. - TCS relay ('01-02 models)

2

H

BACK

3

4

22-31

Gauges Gauge Bulb Replacement Bulb Location

ABS INDICATOR LIGHT (1.26 W) HIGH BEAM RIGHT TURN SIGNAL INDICATOR INDICATOR LIGHT (1.26 W) LIGHT (1.26 W)

IMMOBILIZER INDICATOR LIGHT (1.26 W) WASHER LEVEL INDICATOR LIGHT (1.26 W) (Canada)

CRUISE INDICATOR LlGHT(1.26 W)

SIDE AIR BAG INDICATOR LIGHT (1.26W) ('00-01 models)

DRL INDICATOR LIGHT (1.26 W) (Canada) TCS INDICATOR LIGHT (1.26 W) ('01 model! LEFT TURN SIGNAL INIDICATOR LIGHT (1.26W)

o

GAUGE LIGHT (3.78W)

GAUGE LIGHTS (3.78W)

GAUGE LIGHT (3.78W) LCD BACK LIGHT (1.26 W) LOW FUEL INDICATOR LIGHT (3.78 W) GAUGE LIGHT (3.78W)

22-32

MAINTENANCE REQUIRED INDICATOR LIGHT (1.26W)

BACK

MALFUNCTION INDICATOR LIGHT (1.26W)

r--:'I t=!..I Circuit Diagram IGNITION SWITCH

UNDER-HOOD FUSEIRELAY BOX BATIERY

(±)+

~ No.41 (100A) No.42 (SOA) BAT -'-_ _ BlK ~-Cf"'u:>-....-a"""",o---I--WHT---foi"T BlKlYEl - - - - - - - - . No.54 (40A) IGl

NO.13

(7.SA)

~

""~ DAYTIME RUNNING • LIGHTS

.

""j

I.~~I

1"~EDNEl

•

(Canada)



No.9 (7.SA)

NO.6 (lSA)

BOX

VEL

BlKlYEl

I

--t::> (~~~J +---------------+------------------.-W~NEl~ ~

WHTNEl

YEL

(Canada)

I":'

WHTNEl

B9 GAUGE ASSEMBLY :

B20

A4

•

SAFETY INDICATOR CIRCUIT


IMMOBILIZER INDICATOR

LlG~

BRAKE

(1.26W)

Flher Circun

E~~\EM

DRl INDICATOR LIGHT (1.26W)

:

(lED)

A12 Blu/RED

ORNIW~

11

BlK

PNK

C14

AS

WHT/BlU GRNlRED

V V

, COMBINATION LIGHT SWITCH (USA) 'DAYTIME RUNNING LIGHTS CONTROL UNIT (Canada)

4

B8

B19

BlUIW~

V

PCM

V g~~TROl J

ALTERNATOR

• MULTIPLEX CONTROL UNIT (Driver's) (USA) • ASS CONTROL UNIT

UNIT

(Canada)

~GR_D G?RNIREDBRAKE


FLUID lEVEL SWITCH ( ON : Floal down ) OFF: Floal up

1

G401

G302

--II

GRN/RED

(USA)

~

DAYTIME RUNNING

' ' 'NO

LlG~S

1 ,

BRAKE " SWITCH ' .;LI\. ( ON : lever up ) '\r-V OFF: lever down

.•

BlK

1

I

---~

CONTROL UNIT

GRNlWHT •

~

PARKING BRAKE

U_S~_IT_CH_---I (cont'd)

BACK

22-33

Gauges Circuit Diagram (cont'd) PCM

I BLU

BLU B21

B11

GAUGE ASSEMBLY


B1

MICRO CONTROLLER and SUB SYSTEM CIRCUIT

C11

C2

B2

YEUBLU

YEUGRN

B3 (SCS)

BLUIWHT

~ PCM

2

c;~

FUEL GAUGE UNIT


ENGINE COOLANT TEMPERATURE

~ECT6 EN INGUNIT

1

1

22-34

PCM ('00·02 models)

BLK

G552

¢)~-.

('98-99 models)

BACK

B13 (RXD)

B14 (TXD)

~

r--:'I

~

~ \

COMBINATION LIGHT SWITCH or TAilLIGHT RELAY

I

REDlBlK GAUGE ASSEMBLY

wAsHER! lEVEL I

INDICATOR I LIGHT (1.26W)

MICRO CONTROlLER and SUB SYSTEM CIRCUIT

AfT GEAR POSITION INDICATOR DIMMING CIRCUIT B12

B16

PNK

Bl0

BlK

MULTIPLEX CONTROL UNIT (Driver's) WASHER LEVEL SENSOR

I G301

I_

I

__

---.J

G501

(Canada)

r (cont'd)

BACK

22-35

Gauges Circuit Diagram (cont'd) TURN SIGNAUHAZARD RELAY LEFT

RIGHT

11

GRN/BLU

GRNIYEL

SRS UNIT

I


BLU

C9

RIGHT TURN SIGNAL LIGHTS

GRNtBLU

GRNlYEL

A14

C8



GAUGE ASSEMBLY

ABS INDICATOR LIGHT (1.26W) TCS INDICATOR LIGHT (1.26W)

I I

B18

:'~' ABSCONTROL UNIT

r

LOW FUEL INDICATOR LIGHT (3.78W)

C1 LTGRNlRED

: ABsrrcs ONTROL UNIT

---

(,01-02 models)

LOW FUEL SENSOR

BLK

1 G552

22-36

BACK


~

l!!!:I

MULTIPLEX CONTROL UNIT (Orivefs)

I

REDIWHT GAUGE ASSEMBLY

--I,

l

~~

~ ~EATBELT REMINDER LIGHT (LED)

C3 MULTIPLEX CONTROL UNIT (Driver's)

(D

MALFUNCTION INDICATOR LA~MIL) (I.

B6

REDIBLU

y

GRNIORN

PCM

REDIBLU

REDIBLU

DRIVER'S SEAT BELT SWITCH ( ON : Unbuckled ) OFF: Buckled

(~RUISE

!'(

~

~OW

,,

A6

B7

,,

BLUIBLK

YEURED

INDICATOR LIGHT (1.26W)

~

ENGINE OIL PRESSURE INDICATOR LIGHT (LED)

MULTIPLEX CONTROL UNIT (DrIver's)

\lI

CRUISE CONTROL UNIT

,

D

SIDE AlRBAG INDICATOR LIGHT (1.26W)

~

,,

-;~ .!O-


,, 85

B17 GRN

:L2

YEURED

B4

WHT/RED

,,

UNIT - - ~___~ ('00-02 models)


YELJRED

ENGINE OIL PRESSURE SWITCH ( ON : !;nglne stopped ) OFF: engine runrung

I G551

BACK

22-37

Safety Indicator System Circuit Diagram UNDER-HOOD FUSE/RELAY BOX BATTERY

0-

No.41 (20A) WHTNEL----~D~R~IV~E~R·~S-------------------------

BLK

UNDER-DASH FUSE/RELAY BOX

IGNITION SWITCH No.41 (IOOA)

'-r\

No.42 (50A) WHT

--@-IGI

No.9 (I.SA)

rJ"'...D-+---....,---- YEL -

BLKNEL - -........

YEL

I

SAFETY INDICATOR (In Ihe gauge assembly)

BII

I MICRO CONTROLLER and SUB SYSTEM CIRCUIT

~ ~RIVER.S ~ ~RONT ILiNG HT

DOOR INDICATOR LIGHT (LED)

--l

~ ~EFT

PASSENGER'S DOOR INDICATOR LIGHT (LED)

REAR DOOR INDICATOR LIGHT (LED)

~ ~IGHT

REAR DOOR INDICATOR LIGHT (LED)

~ ~RUNK

INDICATOR LIGHT (LED)

~ ~RAKE

INDICATOR LIGHT (LED)

..

~

...:: :: ::

·

I·

HT

AIO

..

I·

I · :~ I J BLKlWHT


: (passenger·~_

( WithOUI keyless ) enlry syslem

,.

· ... ... · .. A2

Al

GRN/ORN

• MULTIPLEX CONTROL UNIT ~river's~

• OURT SY LIGHT

~r

GRN

• MULTIPLEX CONTROL UNIT ~assen~er's)

• OURT SY LIGHT

AI

• MULTIPLEX CONTROL UNIT ~river's~ • OURT SY LIGHT

"

A8

GRNNEL

A9

GRNIWHT

ORN

• OURT SY LIGHT

GRN


GRNNEL

,RONT PASSENGER'S DOOR SWITCH

GRNNEL

LEFT REAR DOOR SWITCH (Sedan)

TRUNK LIGHT

ORN

RIGHT REAR DOOR SWITCH (Sedan)

TRUNK LATCH SWITCH BLK

1 G601

22-38

WHTIBLU

ALTERNATOR

Y Y Y Y Y

GRN/ORN

B8

~

• MULTIPLEX CONTROL UNIT

~assen~er's)

All

BACK

[ ]: Coupe

I

I

:r-,

VEL

TSWITCH

WHTIBLK 5[6]

~

4[2] WHT/GRN

1--~~

-

BRAKE FAILURE SENSOR

WHTlBlK

~

• MULTIPLEX CONTROl. UNIT (Driver·s) •: CRUISE PCM CONTROL UNIT ASS CONTROL UNIT • TRAilER LIGHTING CONNECTOR

WHT/BLK

..... 2 [3]

3[5]

I

BlK

GRN

h

GRN

lEFT BRAKE LIGHT 21 W) 27Wx2]

RIGHT BRAKE LIGHT (21W) (27Wx2)

1 BlK

BLK

HIGHMOUNT BRAKE LIGHT (21W)

BLK

BlK

1 r

G601

G551

BACK

22-39

Stereo Sound System Component Location Index

TWEETERS Replacement, page 22-125 in the '98-02 Accord Service Manual

PASSENGER'S DOOR SPEAKER Replacement, page 22-125 in the '98-02 Accord Service Manual

AUDIO UNIT Removal, page 22-124 in the '98-02 Accord Service Manual Connector Replacement, page 22-42

DRIVER'S DOOR SPEAKER Replacement, page 22-125 in the '98-02 Accord Service Manual RADIO REMOTE SWITCH Test, page 22-42

REAR SPEAKERS Replacement, page 22-125 in the '98-02 Accord Service Manual

22-40

WINDOW ANTENNA Test, page 22-126 in the '98-02 Accord Service Manual Repair, page 22-126 in the '98-02 Accord Service Manual

BACK

~ ~ Circuit Diagram

IGNITION SWITCH

UNDER·HOOD FUSE/RELAY BOX BATIERY

No.41 (100A)

@-BlK


No.42 (SOA) WHT

"V

Q AT

WHT/BlK

~O'8(7'5A)

ACC YEL/BlK

No.54 (40A)

1......0--\

n.

VEL

~ NO.9 (20A) PASSENGER'S UNDER·DASH FUSE/RELAY BOX

~~---------

WINDOW ANTENNA


-1-

m

MUlTIPLE~-1 COMBINATION LIGHT SWITCH

WHT/RED

~T~'1

I

REDlBlK

ANTENNA lEAD

WHT/GRN

WHT/RED

ACCESSORY SOCKET

CONTROL UNIT (Passenger's)

BlK

1 I BlU

GS81

10

4 AUDIO UNIT

e o e o e 18 GRN/RED

GRYIWHT

BRNiWHT

17

8

GRYlBlK

REDIYEl

BlUIYEl

14

7

BRNlBlK

BlU/GRN

RED

BlK

BlK

RED/GRN

GRY/BlK lEFT REAR SPEAKER

('98-<10 models)

e

I

J

;ASSENGER'~

BRNLlK

RIGHT REAR DRIVER'S gLU/GRN gED/GRN MULTIPLEX SPEAKER DOOR SPEAKER DOOR SPEAKER CONTROL UNIT (Driver's)

RADIO REMOTE SWITCH lEFT TWEETER

RIGHT TWEETER

I

SEEK I (AUDIO/CH)

I

GS02

I I

I i ~~~J (With securrty alarm system)

BACK

22-41

Stereo Sound System Audio Unit Connector Replacement When replacing an audio unit connector, match the wires to the cavities listed in the following table. Cavities 1, 11, 12, and 13 are not used. Cavity 2

Wire WHT/RED

3 4 5 6 7

GEN/RED BLU RED/YEL BLU/YEL RED/GRN

Connect to

Radio Remote Switch Test 1. Remove the radio remote switch (A) from the steering wheel by removing the two screws, and disconnect the 2P connector (B). A

ACC (Main stereo power supply) Radio remote switch Security IN Right rear speaker (+) Left rear speaker (+) Front passenger's speaker (+)

8 9 10 14* 15 16 17

18 19 20 *:

Right tweeter (+) BLU/GRN Driver's door speaker (+) Left tweeter (+) RED/BLK Liahts-on sianal WHT/GRN Constant power Security OUT BLK BRN/WHT Right rear speaker (-) GRY/WHT Left rear speaker (- ) BRN/BLK Front passenger's door speaker (-) RiQht tweeter (-) GRY/BLK Driver's door speaker (-) Left tweeter (- ) RED Dash lights brightness controller Ground (G502) BLK '98-00 models

B

2. Measure resistance between the No.1 and No.2 terminals in each switch position according to the table. Position OFF AUDIO/CH (SEEK)

Resistance AJ!QI"ox. 3.6 k Q Approx. 780 Q

.&

Approx. 360 Q

(VOL. UP)

,.

Approx. 100 Q

(VOL. DOWN)

3. If the resistance is not as specified, replace the radio remote switch.

22-42

BACK

~

Homelink Remote Control System Circuit Diagram

I.!!!!:..I

Test Turn on the spotlight.

BATIERY

~

• If the spotlight comes on, the Homelink's power and ground circuits are OK. If the Homelink will not open the customer's garage door, check that the Homelink is programmed properly (see the owner's manual) or call Homelink at 800-355-3515. On the Internet, go to www.homelink.jci.com • If the spotlight does not come on, check for these problems: - A blown No. 11 (7.5 A) fuse in the passenger's under-dash fuse/relay box. - An open in the WHT/BLU wire between the passenger's under-dash fuse/relay box and spotlight. - An open in the BLK wire between the spotlight and G581.

SlK

No.4! (100.)

UNDER·HOOD FUSE/RElAY

sox

NO.54 (4OA)

VEL

PASSENGER"S UNDER·CASH FUSEIRELAY

BOX

WHTJBLU

SPOTLIGHTS

J Gsal

BACK

22-43

Power Seat Component Location Index Passenger's Power Seat (4-way Adiustable): NOTE: Refer to the '98-02 Accord Service Manual, PIN 61S8400, for the driver's power seat.

RECLINE MOTOR Test, page 22-46

SLIDE MOTOR Test, page 22-46

ADJUSTMENT SWITCH Test/Replacement, page 22-47

22-44

BACK

~

I..!!:.I Circuit Diagram - 4-way Adjustable UNDER·HOOD FUSE/RELAY BOX BATTERY

~

No.55 (40Al

No.41 (l00Al &- BlK -fo-..... a--..J>---o""-'>-+---,

YEUGRN

No.3 (20Al

RED

~

1 0

B4

BLK

I

~t

WARD

A2

A4

BlUtYEL

BLU

2

PASSENGER'S UNDER· DASH FUSE/RELAY BOX

WHT/RED

BI

B3

FOR.' WARD

No.5 (20Al


-,)

WARD

FOR· \ WARD

B5

YEl

I B6

YEUGRN

B2

BlK

2

RECLINE MOTOR

SLIDE MOTOR

G581

GS81

BACK

22-45

Power Seat Motor Test Passenger's Power Seat (4-way Adjustable):

4. Test the motor. When the motor stops running, disconnect battery power immediately.

1. Remove the passenger's seat (see page 20-2). Recline motor:

2. Remove the adjustment switch cover (A) from the passenger's seat by removing the 2 screws (B).

1\

Terminal

B5

B6

Forward

e

<±>

Backward

<±>

e

A2

A4

Forward

e

<±>

Backward

<±>

e

Position

\

Slide motor:

1\

Terminal

Position

5. If the motor does not run or fails to run smoothly, check for an open in the power seat wire harness between the 6P connector and the 2P connectors. If the harness is OK, replace the motor (see page 202).

B

3. Disconnect the 6P connectors (A) from the adjustment switch (B).

~ ~

Wire side of female terminals A

B


22-46

\

BACK

~ ~ Switch Test/Replacement Passenger's Power Seat (4-way Adjustable): 1. Remove the adjustment switch cover (A) from the passenger's seat by removing the 2 screws (8), and pulling off the adjustment switch knobs (C).


f\

Terminal

Position

\

FOR WARD SLIDE SWITCH BACK WARD FOR RECLINE WARD SWITCH BACK WARD

A2

,....

A4

B1

B2

B3

B4

B5

B6

'-'

~

~

;)

~

~

0 v

'-' ~

0

-0

.....

B

2. Disconnect the 6P connectors (D) from the adjustment switch (E), then remove the switch from the cover by removing its 2 mounting screws. 3. Reinstall the adjustment switch knobs.

61 I==! 62 63 64 65 66 1


r BACK

22-47

Seat Heaters - Canada Component Location Index

SEAT HEATER RELAY ('98-00 models) Test, page 22-52 in the '98-02 Accord Service Manual.

D

FRONT PASSENGER'S SEAT CUSHION HEATER Test, page 22-201 in the '98-02 Accord Service Manual. FRONT PASSENGER'S SEAT-BACK HEATER Test, page 22-201 in the '98-02 Accord Service Manual.

DRIVER'S SEAT-BACK HEATER Test,page 22-201 in the '98-02 Accord Service Manual.

DRIVER'S SEAT CUSHION HEATER Test, page 22-201 in the '98-02 Accord Service Manual.

SEAT HEATER RELAY (,01-02 models) Test, page 22-52 in the '98-02 Accord Service Manual. FRONT PASSENGER'S SEAT HEATER SWITCH Test/Replacement, page 22-201 in the '98-02 Accord Service Manual.

22-48

DRIVER'S SEAT HEATER SWITCH Test/Replacement, page 22-201 in the '98-02 Accord Service Manual.

BACK

~ ~ Circuit Diagram UNDER-HOOD FUSEIRELAY BOX BATTERY

No.4l (100A)

IGNITION SWITCH

~""'--YEl ---,

No.42 (SOA)

(±)-BlK

-+-~

WHT

I

No.S9 (20A) "V


TH : THERMOSTAT [ ON. Below 93°F (34°C) ) OFF: Above 109°F (43°C) BR:BREAKER [ ON : Below B6°F (30°C) ) OFF: Above 122°F (50°C) HI :High lO : low

RED/GRN

"(

DRIVER'S SEAT HEATER SWITCH

r-~----------------~~----------~

I

,

I

LOd

HI

• COMBINATION LIGHT SWITCH (OX, LX) • TAIlLiGHi RELAY (EX)

j'~

, . . . . - - - WHTlBlK

6

BlKlYEl

SEAT HEATER RELAY

• COMBINATION LIGHT SWITCH (OX, LX) • tAilLIGHT RELAY (EX)

RED/BlK 2

No.3 (7.SA) ~

FRONT PASSENGER'S SEAT HEATER SWITCH

,

I

HI

lO

"(

WHTlBlK 6

REDlBlK

,

I

LOd

HI

, HI

liGHT (O.S6W)

LIGHT (O.S6W) INDICATORS (O.56Wx2)

RED

BlK

WHTlBlU

V


3

4

S

GRN/BlU

BlK

RED

WHT/RED 2

CUSHION

V

GRN/RED

2

DRIVER'S SEAT HEATER

4

BACK

--=;l

3

CUSHION

3


BACK

FRONT PASSENGER'S SEAT HEATER

(Wrthout side airbag)

BlK

BlK

BlK

1

1

BlK

1

1

GSSI

GSOI

GS81

BACK

G2021'98-00 modelsl 0002 '01-02 models

22-49

BACK

Restraints SRS (Supplemental Restraint System) SRS Unit Identification ................................................. 23-2 DTC Troubleshooting Index ........................................ 23-3 Symptom Troubleshooting Index ............................... 23-4

NOTE: Refer to the '98-02 Accord Service Manual, PIN 6158400, for the items not shown in this section.

SRS SRS Unit Identification '98 Model

I

23-2

MAKER

IDENTIFICATION MARK

KEIHIN

M2

BACK

DTC Troubleshooting Index '98 Model KEIHIN (M2) SRS unit DTC 1-1 1-2 1-3 1-4 1-5 2-1 2-2 2-3 2-4 2-5 5-1 5-2 5-3 5-4 6-1 6-2 6-3 6-4 7-1 7-2 7-3 8-1 8-2 8-5 8-6 9-1

*

Detection Item Open in driver's airbag inflator Increased resistance in driver's airbag inflator Short to another wire or decreased resistance in driver's airbag inflator Short to power in driver's airbag inflator Short to ground in driver's airbag inflator Open in passenger's airba~ inflator Increased resistance in passenger's airbag inflator Short to another wire or decreased resistance in passenger's airbag inflator Short to power in passenger's airbag inflator Short to ground in passenger's airbag inflator Internal failure of SRS unit

Internal failure of the SRS unit. If intermittent, could mean internal failure ofthe unit or a faulty indicator light circuit. Refer to Troubleshooting Intermittent Failures (see page 23-45)*' 9-2 Internal failure of the SRS unit. If intermittent, could mean internal failure of the power supply (VB line). Refer to Troubleshooting Intermittent Failures (see page 23-45)*' 10-1 SRS airbag dej)loyed (SRS unit must be replaced) 1: Refer to the '98-02 Accord Service Manual, PIN 61S8400.

BACK

Notes (see page 23-74)*' (see page 23-74)*' (see page 23-76)*'


page page page page page

23-78)*' 23-80)*' 23-82)*' 23-82)*' 23-83)*'

(see page 23-85)*' (see page 23-86)*' (see page 23-88)*'

(see page 23-88)*'

(see page 23-88)*'

23-3

SRS Symptom Troubleshooting Index '98 Model Symptom


SRS indicator light doesn't come on.

SRS Indicator Light Troubleshooting, refer to '98-02 Accord Service Manual, PIN 61S8400 (see page 23242). SRS Indicator Light Troubleshooting, refer to '98-02 Accord Service Manual, PIN 61S8400 (see page 23242).

The SRS indicator light stays on when in "SCS" menu method.

23-4

BACK

Also check for

Inability to retrieve DTCs with the PGM Tester. Retrieve the flash codes with the SCS mode, refer to '98-02 Accord Service Manual, PIN 61S8400 (see paQe 23-42).

Service Manual Index

NOTE: Refer to the following list to look up DTCs, symptoms, fuses, connectors, wire harnesses, specifications, maintenance schedules, and general service information: DTC Troubleshooting Indexes ABS/TCS Components .......................... 19-9 Automatic Climate Control ................. 21-29 AutomaticTransaxle ............................. 14-7 Fuel and Emissions ................................ 11-3 SRS .......................................................... 23-3 Symptom Troubleshooting Indexes

NC ........................................................... 21-7 ABS/TCS Components .................. 19-10,31 Automatic Climate Control ................. 21-30 Automatic Transaxle ............................. 14-8 Cruise Control System .......................... 4-43 Fan Controls ......................................... 10-15 Fuel and Emissions ................................ 11-6 SRS .......................................................... 23-4 Steering ................................................... 17-4

AIC Condenser Fan Assembly Component Location Index ................... 10-2 Test .......................................................... 10-8 Replacement ......................................... 10-13

ABSfTCS Components Component Location Index ............. 19-8,24 Circuit Diagram .............................. 19-12,46 Description ........................................... 19-32

AIC Condenser Fan Circuit Troubleshooting ................................... 21-10

ABS·TCS Control Unit How-to Information ............................. 19-25 Replacement ......................................... 19·82

AIC Pressure Switch Circuit Troubleshooting ................................... 21-59 AIT Assembly Removal .............................................. 14-114 Installation .......................................... 14-121

ABS·TCS Modulator Unit Removal/Installation ............................ 19-80 Accumulator Body Disassembly/Inspection/Reassembly .... 14166

AIT Clutch Pressure Control Solenoid Valves Test ...................................................... 14-108 Replacement ....................................... 14-109

Air Cleaner Element Replacement ......................................... 11·97

AfT Countershaft Assembly Disassembly/Inspection/Reassembly .... 14-

Alternator Component Location Index ................... 4·25 Replacement ........................................... 4-31 Overhaul ................................................. 4·35

172 Installation .......................................... 14-192

FuselRelay Indexes NC Compressor Clutch Relay ............ 22-23 NC Condenser Fan Relay ................... 22-23 Blower Motor Relay ............................. 22-23 ELD (Electrical Load Detector) ............ 22-23 Headlight Relay .................................... 22-23 Horn Relay ............................................ 22-23 Power Distribution ............................... 22-26 Radiator Fan Relay ............................... 22-23 Under-dash Fuse/Relay Box, Driver's .... 2224 Under-dash Fuse/Relay Box, Passenger's .. 22-25 Under-hood Fuse/Relay Box ............... 22-23 Connector and Wire Harness Indexes Component Connectors (to hamess) ... 22-5 Grounds (to components) ................... 22-29 In-line Connectors (to hamess) ............. 22-4

AIT Countershaft 1st Gear Replacement ....................................... 14-173 AIT Countershaft 3rd Gear Replacement ....................................... 14-173 AIT Differential Component Location Index .............. 14-201 AfT Gear Position Indicator Replacement ....................................... 14-144 AfT Gear Position Indicator System Component Location Index .............. 14-138 Circuit Diagram .................................. 14-139 Test ...................................................... 14-143

AIT Hydraulic Controls Test ...................................................... 14-104

Specifications section .................. Section 2 Maintenance section .................... Section 3 General Information section ........ Section 1

A AlC Component Location Index ................... 21-3 Circuit Diagram ...................................... 21-8 Test ......................................................... 21-15

AIC Compressor Replacement ................................... 21-18, 23 AIC Compressor Clutch Inspection ....................................... 21-20, 25 Overhaul ......................................... 21-21, 26 AIC Compressor Relief Valve Replacement ................................... 21-22, 27 AIC Condenser Replacement ......................................... 21-28

AIT Mainshaft Assembly Disassembly/lnspection/Reassembly .... 14169 Installation .......................................... 14-192 AlT Secondary Shaft Assembly Disassembly/lnspection/Reassembly .... 14176 Inspection ........................................... 14-177 Installation .......................................... 14-192 AfT Shift Cable Replacement ....................................... 14-133 Adjustment ......................................... 14-136

AIT Shift Lever Removal .............................................. 14-129 Installation .......................................... 14-130 Disassembly/Reassembly ................. 14-132

Alternator·compressor Belt Component Location Index NC Compressor ................................. 4-25 Charging System ................................ 4-25 Inspection/Replacement Charging System ................................ 4-31 Alternator·compressor Belt Auto· tensioner Inspection/Replacement ........................ 4-33 ATF Inspection ........................................... 14-112 Replacement ....................................... 14-113 ATFCooier Repair .................................................. 14-127 ATF Cooler Lines and Hoses Component Location Index ................... 10·2 Replacement ....................................... 14-128 ATFPump Inspection ........................................... 14-163 Audio Unit Replacement ......................................... 22-42 AudiolEntertainment Component Location Index ................. 22-40 Circuit Diagram .................................... 22·41 Automatic Climate Control Component Location Index ................. 21-26 Description ........................................... 21-31 Circuit Diagram .................................... 21-32 Automatic Transaxle Description ........................................... 14-18 Test ...................................................... 14-101

ABS Control Unit Replacement ......................................... 19-22 ABS Indicator Circuit Troubleshooting ............................. 19-18,76 ABS Modulator Unit Removal/lnstallation ............................ 19-21

(cont'd)

Service Manual Index (cont'd) B Battery Component Location Index Charging System ................................ 4-25 Test Wiring System .................................. 22-30 Blower Power Transistor Test ........................................................ 21-58 Brake Calipers Overhaul ................................................. 19-4 Brake Pads Inspection/Replacement ........................ 19-2 Brake Pedal Position Switch Test .......................................................... 4-50 Bumper Spoiler. Rear Replacement ........................................... 20-6

c Camshaft Inspection ............................................... 6-40 Installation .............................................. 6-50 Charging System Component Location Index ................... 4-25 Circuit Diagram ...................................... 4-26 Troubleshooting ..................................... 4-27

Connectors (See first page of this Index)

Cruise Control Actuator Cable Adjustment ............................................. 4-54

Coolant Replacement ......................................... 10-10

Cruise Control Actuator Solenoid Test .......................................................... 4-50

Coolant Reservoir Component Location Index ................... 10-2

Cruise Control Communication Circuit Troubleshooting ..................................... 4-45

Coolant Temperature Gauge Test .......................................................... 10-5 Troubleshooting ..................................... 10-5

Cruise Control Main Switch Test/Replacement .................................. 4-48

Coolant Temperature Gauge Sending Unit Component Location Index Coolant Temperature Gauge Components ........................................... 10-2 Cooling System .................................. 10-2 Test Coolant Temperature Gauge Components ........................................... 10-7 Cooling System .................................. 10-7 Cooling System Component Location Index ................... 10-2 Countershaft Bearing Hub/Bearing Replacement ....................................... 14-175

Cruise Control Set/Resume/Cancel Switch Test/Replacement .................................. 4-49 Cruise Control System Component Location Index ................... 4-41 Circuit Diagram ...................................... 4-42 Cruise Control Unit Input Test ................................................ 4-46 Cylinder Head Assembly Component Location Index ..................... 6-3 Removal .................................................. 6-31 Installation .............................................. 6-51 Cylinder Head. Bare Inspection ............................................... 6-36

Countershaft Bearing. AfT Housing Replacement ....................................... 14-156 Countershaft Bearing. Torque Converter Housing Replacement ....................................... 14-168

D Differential Carrier Bearing Outer Races, A

Countershaft Idler Gear Installation .......................................... 14-195

/T

Charging System Indicator Component Location Index ................... 4-25

Countershaft Reverse Selector Hub Replacement ....................................... 14-173

Differential Carrier Bearings. AfT Replacement ....................................... 14-202 Inspection ........................................... 14-205

CKP (Crankshaft Position) Sensor Replacement ........................................... 6-56

Countershaft Speed Sensor Replacement ....................................... 14-1 10

Climate Control Power and Ground Circuits Troubleshooting ................................... 21-57

Crankshaft Component Location Index ..................... 7-3 Inspection ........................................... 7-7.14 Removal .................................................. 7-12 Installation .............................................. 7-24

Climate Control Unit How-to Information ............................. 21-34 Removal/Installation ............................ 21-64 Disassembly/Reassembly ................... 21-65 Connecting Rod Bearing Caps Component Location Index ..................... 7-3 Connecting Rod Bearings Component Location Index ..................... 7-3 Replacement ........................................... 7-10 Connecting Rod Bolts Component Location Index ..................... 7-3 Inspection ............................................... 7-21 Connecting Rods Component Location Index ..................... 7-3 Inspection ................................................. 7-7

Crankshaft Main Bearings Component Location Index ..................... 7-3 Replacement ............................................. 7-8 Crankshaft Oil Seal. Pulley End Component Location Index ..................... 7-3 Installation .............................................. 7-29 Crankshaft Oil Seal. Transmission End Component Location Index ..................... 7-3 Installation .............................................. 7-29 Crankshaft Pulley Removal/Installation .............................. 6-17 Crankshaft Thrust Washers Component Location Index ..................... 7-3 Cruise Control Actuator Test .......................................................... 4-51 Replacement ........................................... 4-52

Replacement ....................................... 14-204

Differential Carrier, A/T Replacement ....................................... 14-202 Differential Oil Seals. AfT Replacement ....................................... 14-203 Differential Pinion Gears. A/T Inspection ........................................... 14-201 Distributor Component Location Index ................... 4-14 Replacement ........................................... 4-19 Disassembly/Reassembly ..................... 4-20 Drive Plate Component Location Index ..................... 7-3 Removal/Installation ................................ 7-6 DTCs (See first page of this Index) D41ndicator Circuit Troubleshooting ................................... 14-93

E

Front Driveshaft Assembly Resassembly .......................................... 16-3

ECTSensor Component Location Index ................... 10-2

Front Seats Component Location Index ................. 22-44 Circuit Diagram .................................... 22-45

IA (Intake Air) Bypass Control Valve Test ...................................................... 11-101

Fuel and Emissions Description .............................................. 11-7 Circuit Diagram .............................. 11-30,39

ICM (Ignition Control Module) Component Location Index ................... 4-14 Input Test ................................................ 4-21

Fuel Gauge Test ........................................................ 11-94

Idle Control System Component Location Index ................. 11-85 Adjustment ........................................... 11-86

ECT Sensor Circuit Troubleshooting ................................... 21-50 EGRValve Component Location Index ................... 10-2 Emblems Replacement ........................................... 20-8 End Cover, AfT Removal .............................................. 14-151

Fuel Injection System (PGM-FI) Component Location Index ................. 11-50 Fuel Injectors Replacement ................................... 11-80,82

Engine Assembly Removal .................................................... 5-2 Installation .............................................. 5-11

Fuel Lines and Hoses Inspection ............................................. 11-91

Engine Block Assembly Component Location Index ..................... 7-3

Fuel Pressure Regulator Replacement ................................... 11-92, 93

Engine Block End Cover Component Location Index ..................... 7-3

Fuel Supply System Component Location Index ................. 11-87 Adjustment ........................................... 11-88 Troubleshooting ................................... 11-89

Engine Block, Bare Component Location Index ..................... 7-3 Inspection ............................................... 7-15 Repair ...................................................... 7-17 Engine Mount Control Solenoid Valve Component Location Index ................... 4-55

Fuses (See first page of this Index)

Ignition Coil(s) Component Location Index ................... 4-14 Test .......................................................... 4-22 Troubleshooting ..................................... 4-23 Ignition System Component Location Index ............. 4-14,15 Circuit Diagram ................................ 4-16,17 Inspection ............................................... 4-18 Ignition Wires Component Location Index ................... 4-14 Test/Inspection ....................................... 4-22 In-car Temperature Sensor Replacement ......................................... 21-61 Test ........................................................ 21-61 Intake Air System Component Location Index ................. 11-95

Engine Mount Control System Component Location Index ................... 4-55 Circuit Diagram ...................................... 4-56 Troubleshooting ..................................... 4-57

G

Intake Manifold Removal/Installation ................................ 9-2

Gauges Circuit Diagram .................................... 22-33

Interlock System Component Location Index .............. 14-145 Circuit Diagram .................................. 14-146

EVAP Control System Component Location Index .............. 11-103

General Information (See section 1)

Exhaust Manifold Removal/Installation ................................ 9-3

H

Intermediate Shaft Assembly Disassembly ......................................... 16-14 Removal ................................................ 16-14 Resassembly ........................................ 16-16 Installation ............................................ 16-18

Heater Hoses and Pipes Component Location Index ................... 10-2

K

Exhaust Manifold Gasket Replacement ............................................. 9-3 Exhaust Pipe Replacement ............................................. 9-4

Heater Valve Component Location Index ................... 10-2

F Fan Control Module Input Test .............................................. 10-20

Heater Valve Cable Adjustment ........................................... 21-13 Homelink Remote Control System Circuit Diagram .................................... 22-43 Test ........................................................ 22-43

Fan Controls Component Location Index ................. 10-14 Circuit Diagram .................................... 10-16

Hood Replacement ........................................... 20-7

Final Driven Gear, AlT Replacement ....................................... 14-202

H02S, Primary Replacement ......................................... 11-84

Frame Repair Chart .......................................... 20-12

H02S, Secondary Replacement ......................................... 11-84

Key Interlock Solenoid Test ...................................................... 14-149 Key Interlock System Circuit Troubleshooting ................................... 14-99

L Lock-up Control Solenoid Valve Test ...................................................... 14-103 Low Fuel Indicator Replacement ......................................... 22-32 (cont'd)

Service Manual Index (cont'd) Lubrication System Component Location Index ..................... 8-3 Test ............................................................ 8-4

M Main Valve Body Removal .............................................. 14-157 Repair .................................................. 14-159 Resassembly .........................•............ 14-160 Disassembly/lnspection/Reassembly .... 14161 Installation .....................................•.... 14-190

Park Pin Switch Test ...................................................... 14-150

Radiator Fan Circuit Troubleshooting ................................... 10-17

PCM Component Location Index ..•................ 4-55

Radiator Fan Switch Component Location Index ................... 10-2 Test ........................................................ 10-21

PCVValve Test ...................................................... 11-102 Piston Pins Component Location Index ..................... 7-3 Piston Rings Component Location Index ..................... 7-3 Replacement ........................................... 7-22

Mainshaft Bearing, Torque Converter Housing Replacement ....................................... 14-167

Pistons Component Location Index ............•........ 7-3 Removal .................................................. 7-12 Replacement ........................................... 7-18

Mainshaft Sealing Rings Replacement ..•.................................... 14-171

Power Seat Linkage Disassembly/Reassembly ..................... 20-4

Mainshaft Speed Sensor Replacement ....................................... 14-110

Power Seat Motors Test ........................................................ 22-46

Maintenance (See section 3)

Power Seat Switch Test/Replacement ................................ 22-47

Multiplex Control Unit, Driver's Input Test ............................................ 14-147

Power Steering Fluid Reservoir Component Location Index ................... 17-3

o Oil Filter Replacement ............................................. 8-5 Oil Pan Component Location Index Engine Block Assembly ....................... 7-3 Lubrication System .............................. 7-3 Oil Pressure Switch Test Low Engine Oil Indicator Components . 8-4 Lubrication System .............................. 8-4 Oil Pump, Engille Component Location Index Engine Block Assembly ....................... 7-3 Lubrication System .............................. 7-3 Overhaul Lubrication System .............................. 8-7 Oil, Engine Replacement ............................................. 8-5 Outside Air Temperature Sensor Replacement ......................................... 21-62 Test ........................................................ 21-62

p Park Lever Position Stop Inspection/Adjustment .........•............ 14-153

Power Steering Lines and Hoses Replacement ......................................... 17-12 Power Steering Pump Component Location Index ................... 17-3 Test ...................................................... 17-7,8 Replacement ......................................... 17-13 Overhaul ............................................... 17-14 Power Steering Pump Belt Inspection/Adjustment ........................ 17-10

R Radiator Component Location Index ................... 10-2 Test .......................................................... 10-8 Replacement ......................................... 10-13 Radiator and Condenser Fans Common Circuit Troubleshooting ................................... 21-12 Radiator Cap Component Location Index ................... 10-2 Test .......................................................... 10-7 Radiator Fan Assembly Component Location Index ................... 10-2 Test .......................................................... 10-8 Replacement ......................................... 10-13

Radiator Fan Switch Circuit Troubleshooting ................................... 10-19 Radiator Hoses and Pipes Component Location Index ................... 10-2 Radio Remote Switch Test ........................................................ 22-42 Recirculation Control Motor Circuit Troubleshooting ................................... 21-58 Refrigerant Replacement ......................................... 21-30 Test ......................................................... 21-29 Refrigerant Oil Replacement ........................................... 21-6 Regulator Valve Body Disassembly/lnspection/Reassembly .... 14164 Rocker Arm Assembly Removal .................................................. 6-36 Disassembly/Reassembly ..................... 6-37 Rocker Arms Test .......................................................... 6-10 Inspection ............................................... 6-38

s Safety Indicator System Circuit Diagram .................................... 22-38 Seat Heaters Component Location Index ................. 22-48 Circuit Diagram .................................... 22-49 Seat Wire Harness, Driver's Installation .............................................. 20-5 Seat, Front Removal/Installation .............................. 20-2 Disassembly/Reassembly ..................... 20-3 Secondary Shaft Bearing, Torque Converter Housing Replacement ....................................... 14-168 Secondary Shaft Idler Gear Bearing Replacement ....................................... 14-179 Servo Body Disassembly/Inspection/Reassembly .... 14165 Shift Control Solenoid Valves Replacement ....................................... 14-107 Test ...................................................... 14-107 Shift Lock Solenoid Test ...................................................... 14-149 Replacement ....................................... 14-150

Shift Lock System Circuit

Throttle Body

Wire Harnesses

Troubleshooting ................................... 14-96

Test ........................................................ 11-96 Removal/Installation ............................ 11-99 Disassembly/Reassembly ................. 11-100

(See first page of this Index)

Spark Plugs Component Location Index ................... 4-14 Inspection ............................................... 4-24

Wiring System

Relay and Control Unit Locations ..... 22-2, 3 Throttle Cable

Adjustment ........................................... 11-98 Specifications

(See section 2) Starter

Test ............................................................ 4-7 Replacement ............................................. 4-8 Overhaul ................................................... 4-9 Starter Solenoid

Timing Belt Inspection ............................................... 6-18 Removal .................................................. 6-19 Installation .............................................. 6-22 Torque Converter Clutch Solenoid Valve

Replacement ....................................... 14-106 Test ...................................................... 14-106

1 1st/2nd Clutch Assembly

Disassembly ....................................... 14-180 Inspection ........................................... 14-183 Resassembly ...................................... 14-185

Test ............................................................ 4-6 Transmission Housing

Removal .............................................. 14-154 Installation .......................................... 14-192

2

Component Location Index ..................... 4-3 Circuit Diagram ........................................ 4-4 Troubleshooting ....................................... 4-5

Transmission Range Switch


Replacement ....................................... 14-111

Steering

Test ...................................................... 14-140 Replacement ....................................... 14-141

Starting System

Component Location Index ................... 17-3 Troubleshooting ..................................... 17-6 Inspection ............................................... 17-9

Troubleshooting

(See first page of this Index)

3

v

3rd Clutch Pressure Switch

Steering Column

Component Location Index ................... 17-3 Steering Gearbox

Component Location Index ................... 17-3 Overhaul ............................................... 17-20

Valve Guides

Steering Lock

Inspection ............................................... 6-44 Replacement ........................................... 6-45

3rd/4th Clutch Assembly

Component Location Index ................... 17-3 Steering Rack Guide

Valve Seals Removal .................................................. 6-43

Adjustment ........................................... 17-19 Steering Wheel

Valve Seats Repair ...................................................... 6-47

Component Location Index ................... 17-3 Valve Springs Sub-frames

Removal .................................................. 6-43

Replacement ........................................... 20-9 Valves Sunlight Sensor

Replacement ......................................... 21-63 Test ........................................................ 21-63

T

Adjustment ............................................. 6-13 Removal .................................................. 6-43 Inspection ............................................... 6-44 Installation .............................................. 6-49 VTEC Lost Motion Assemblies/Springs

Inspection ............................................... 6-39 VTEC Solenoid Valve

TCS Indicator Circuit

Test .............................................•.............. 6-9

Troubleshooting ................................... 19-78 TCSRelay

Test ........................................................ 22-31

w

TCSSwitch

Test ........................................................ 19-81 Replacement ........................................... 6-55

Water Pump Component Location Index ................... 10-2 Inspection ............................................... 10-9 Replacement ......................................... 10-10

Thermostat

Wheel Speed Sensors

Test .....•.................................................... 10-9 Replacement ......................................... 10-12

Inspection ............................................. 19-82 Replacement ......................................... 19-83

TDCSensors

Replacement ....................................... 14-111 Inspection ................................... 14-170, 183

Honda Accord 1998 - 2002 Service Manual COMPLETE

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